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Summary of Contents for Troxler 5850v2
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Model 5850v2 Gyratory Compactor NOTE Before using the Model 5850v2 Gyratory Compactor, carefully read this manual. It is especially important to understand the Safety Warnings on page 1–1. Keep this manual in a safe place that is always easily accessible during the use of the Model 5850v2.
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Troxler products are protected by U.S. and foreign patents. Copyright 2009 – 2015 Troxler Electronic Laboratories, Inc. All Rights Reserved No part of this manual may be reproduced or transmitted in any form or by any means, electronic or mechanical, including...
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Phone: ++ 49.8141.71063 TroxTechSupport@troxlerlabs.com Fax: ++49.8141.80731 troxler@t-online.de TROXLER ELECTRONIC TECHNOLOGIES (ZHANGJIAGANG) 1F, Building G, No. 1 Guotai North Road ZJG, China, 215600 Phone: 0086.512.56793702 Fax: 0086.512.56793701 kjin@troxlerlabs.cn NOTE To locate an independent, Troxler-authorized service partner near you, call 1.877.TROXLER (1.877.876.9537). Model 5850v2...
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ABOUT THIS MANUAL The Model 5850v2 Manual of Operation and Instruction provides detailed information about the compactor. The manual includes product safety information, as well as instructions for the proper installation and use of the compactor. This manual is organized as follows: Chapter 1, Introduction to the Model 5850v2 –...
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Do not attempt to operate the Model 5850v2 before reading this manual and the safety warnings posted on the unit. Troxler stresses that the user is solely responsible for ensuring the safe use of the Model 5850v2.
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CONVENTIONS USED IN THIS MANUAL Throughout this manual, symbols and special formatting are used to reveal the purpose of the text as follows: WARNING Warnings indicate conditions or procedures that, if not followed correctly, may cause personal injury. CAUTION Cautions indicate conditions or procedures that, if not followed correctly, may cause equipment damage.
Calibration .................. 3–14 Special..................3–14 CHAPTER 4 ................4–1 Calibration Schedule ..............4–2 Angle Verification ................ 4–3 Calibration ..................4–5 CHAPTER 5 ................5–1 Special Menu ................5–2 Clock/Calendar ................5–3 Erase Records ................5–6 Reset Software ................5–7 Model 5850v2...
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APPENDIX A ................A–1 Troubleshooting................A–2 General Maintenance Schedule ............ A–4 Replacing the Batteries ..............A–7 Cleaning the Cooling Fan ............. A–8 Replacement Parts ................ A–8 Returning Parts for Service ............A–9 APPENDIX B ................B–1 Menu Map Description ..............B–2 APPENDIX C ................
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Figure 1–3. Proper Reservoir Fill Level ........1–13 Figure 1–4. Place a Funnel in Reservoir Fill Tube ..... 1–13 Figure 2–1. Model 5850v2 Control Panel Layout ......2–3 Figure 2–2. Compaction Chamber ..........2–9 Figure 2–3. Loading the Mold ............ 2–12 Figure 3–1.
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LIST OF TABLES Table Title Page Table 2–1. Control Panel Keys and Button ........2–2...
This chapter also includes a list of parts and accessories, and instructions for unpacking and inspecting the system. SAFETY WARNINGS The Troxler Model 5850v2 is a safe, durable gyratory compactor. Troxler cannot anticipate every example of improper or unauthorized use of this unit that may lead to malfunction or accident.
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Do not wear loose clothing or jewelry when operating the compactor. Keep hands away from the gyratory compactor when the unit is in motion. With the service panels removed, the gyratory compactor poses an electrical hazard. Unplug the gyratory compactor before removing the panels.
Connection for 100 – 240 VAC, 50/60 Hz power to the compactor Upper Left Side of Compactor 9-pin RS-232C serial interface for connecting the compactor to a computer or serial device USB port for connecting the compactor to a USB printer or memory device Model 5850v2 1–3...
The durable Model 5850v2 will consistently stand up to the rigors of any asphalt lab. SAFE OPERATION For operator safety, all moving parts are covered and cannot be physically accessed during compaction.
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EASE OF OPERATION The Model 5850v2 is calibrated and ready to use upon arrival. The unit will compact asphalt samples to a specific height or a specific number of gyrations, as selected by the operator. The angle of gyration is recorded with every gyration, assuring angle stability.
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The Model 5850v2 also provides storage for and allows manual printing of the last 20 compacted specimens. All output is in SI units as described in American Society of Testing and Materials (ASTM) SI10, Standard for Use of the International System of Units (SI): The Modern Metric System.
The height standard assembly (not shown) is used to calibrate the specimen height. (Part number 106989) The Model 5850v2 Manual of Operation and Instruction (not shown) provides the operating instructions for the compactor. The printer (not shown) allows the operator to print data. (Part number 116220) ...
INSPECTION Upon receiving the Model 5850v2 Gyratory Compactor from the factory, perform a complete inspection and inventory as described below. Check to see that the following are included: Model 5850v2 Gyratory Compactor Mold Power cord Height standard assembly ...
UNPACKING WARNING The Model 5850v2 Gyratory Compactor weighs approximately 227 kg (500 lb). To prevent personal injury or equipment damage, exercise care while unpacking and lifting the unit. NOTE Troxler recommends that all packaging material be saved. It may be reused to pack the compactor for shipping.
The power switch is located on the left side panel, as shown in Figure 1–1. Ensure that the placement of the compactor provides easy access to the power switch. Model 5850v2 1–11...
Remove the rear service panel from the compactor. Locate the fill level sight glass as shown in Figure 1–2. NOTE Use only a light grade (ISO VG 32, SAE 10, Troxler part number 018203) hydraulic oil to fill the hydraulic reservoir.
ENSURE FLUID LEVEL IS AT 30-DEGREE MARK Figure 1–3. Proper Reservoir Fill Level FUNNEL Figure 1–4. Place a Funnel in Reservoir Fill Tube Model 5850v2 1–13...
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A list of USB memory devices and printers that are compatible with the Model 5850v2 Gyratory Compactor is available on the 5850v2 product page of the Troxler website (www.troxlerlabs.com). . If using the compactor with a computer, use a serial cable to connect the computer to the serial port located on the upper left side of the compactor (see Figure 1–1 on page 1–7).
CHAPTER 2 SETUP AND OPERATION This chapter describes how to get started using the Model 5850v2 Gyratory Compactor. This information includes a brief description of the control panel and instructions for turning the compactor on, setting it up, and compacting an asphalt specimen.
CONTROL PANEL Figure 2–1 shows the layout of the Model 5850v2 Gyratory Compactor control panel. Table 2–1 lists the functions for each key and button on the panel. Table 2–1. Control Panel Keys and Button FUNCTION Stops all machine movement. To release EMERGENCY...
Operator-selected internal angle of gyration Operator-selected compaction pressure FIRST TIME SETUP The Model 5850v2 is shipped with the current date and time (Eastern Standard Time) stored in its memory. By default, the date is displayed in mm/dd/yyyy format and the time in AM/PM format.
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Refer to Chapter 3 for instructions on changing any of these selections. The Model 5850v2 also provides numerous options for automatically outputting or printing data following a compaction cycle. The compactor can send the data to a computer or serial printer via the serial (RS-232) port, or to a USB printer or memory device (thumb drive) via the USB port.
Compactor, become familiar with the safety warnings on page 1–1. The following is a checklist for compacting an asphalt specimen with the Model 5850v2 Gyratory Compactor. Each step is discussed in detail in the following sections. . Set up the gyratory compactor.
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. Place the mold in the compactor chamber, and compact the specimen. . Remove the mold containing the compacted specimen from the compactor chamber and extrude the asphalt specimen using the built-in extruder provided with the compactor. . Cool specimen on the cooling table. Model 5850v2 2–7...
CLEANING AND LUBRICATING CAUTION Failure to properly clean and lubricate the Model 5850v2 before each use may result in compaction errors, premature equipment wear, and other problems. Before operating the compactor: . Vacuum the mold tray and compaction chamber. . Clean the mold tray, lower carriage plate, and ram head (see Figure 2–2, View A), as well as the upper carriage assembly and...
To maintain the specimen temperature and prevent segregation of the specimen, the asphalt mixture must be loaded into the mold in one continuous motion. The paper thickness will affect compactor results; it is recommended that you use Troxler specimen papers 2–10...
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(part numbers 106952 or 106953). Model 5850v2 2–11...
UPPER PUCK SPECIMEN ASPHALT PAPERS MOLD (WITH LOWER PUCK INSTALLED) MOLD PULL Figure 2–3. Loading the Mold Place another specimen paper on top of the asphalt mix. Place the upper puck, with its large side down, into the mold. Keep the upper puck oriented horizontally while inserting it to prevent it from becoming wedged in the mold.
In Automatic mode, the operator begins the compaction cycle using a single keystroke. The Model 5850v2 compacts the specimen based on the number of gyrations or the target specimen height specified by the operator. In Automatic mode, the compactor can also automatically print or download compaction data upon completion of the compaction cycle.
3. Using the Extruder Positioning Buttons, raise the extruder until the sample releases from the mold. 4. Using the Extruder Positioning buttons, lower the extruder to the lowest position. 5. Remove mold from extruder. Model 5850v2 2–15...
2. Power-up the Cooling Table Fan. SHEAR OPTIONS & PERFORMANCE TESTS The Model 5850v2 can compact samples as tall as 185mm for use with AMPT (Asphalt Mix Performance Tester). The compactor also offers a shear option, either before or after purchase. This optional feature includes transducers that measure the shear forces acting on the specimen during gyration.
CHAPTER 3 SETUP MENU The compactor’s Setup menu enables the operator to select and define the operating parameters of the Model 5850v2 Gyratory Compactor. This chapter describes the many menu options. Model 5850v2 3–1...
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SETUP MENU The compactor’s Setup menu enables the operator to select and define the operating parameters of an automatic compaction cycle, to determine the destination and format for outputting or downloading compaction data, to calibrate the compactor, and to perform other special functions. To access the Setup menu, press SETUP...
CHANGE SETTINGS The Change Settings selection from the Setup menu allows you to: Select whether the compactor will run for a specified number of gyrations or until the specimen has been compacted to a specified height Specify the number of gyrations (from 1 to 999) the compactor will run when compacting a specimen ...
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OPERATION MODE The Model 5850v2 provides two modes of gyration. Based on operator selection, the unit may either compact the specimen for a set number of gyrations or until the specimen reaches a specified target height. The default mode of gyration is the number of gyrations.
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Change Settings menu. GYRATION ANGLE The Model 5850v2 can be set to an internal gyration angle of 0.00 to 1.50 degrees. To set the angle, press 4 from the Change Settings menu shown on page 3–4. The compactor displays:...
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Chapter 4 after changing the ram pressure. The Model 5850v2 ram pressure can be set between 200 and 1000 kPa. To set the ram pressure, press 5 from the Change Settings menu shown on page 3–4. The compactor displays:...
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Change Settings menu shown on page 3–4. POST GYRATE DELAY The Model 5850v2 provides the option for a five-minute delay upon completing the compaction of a specimen. This delay maintains a minimum pressure on the sample and allows low gyration specimens to cool before the ram lowers.
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The time counts down until it has elapsed or pressing ESC to Abort early. Once the time has expired, the process is completed as usual; ram is lowered, pump is turned off and data is output (enabled). Model 5850v2 3–9...
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NOTE A list of USB memory devices and printers that are compatible with the Model 5850v2 Gyratory Compactor is available on the 5850v2 product page on the Troxler website (www.troxlerlabs.com). The output data can be presented in either a height-versus-gyration or full table format.
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(see page 3–12), then returns to the Data Output menu. AUTO OUTPUT Upon completion of a compaction cycle, the Model 5850v2 can automatically download or print gyration data via the serial or USB port.
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The GyroImport software is used to convert the data on the USB memory device to a Microsoft Excel workbook. The software may be downloaded from the 5850v2 product page on the Troxler website (www.troxlerlabs.com) or it can be requested from Customer Service at 1-877-TROXLER.
If Thumb Drive is the selected output device, the result will be the following files: Ax.hdr (header file); Ax.txt (formatted data format); AxGP.txt (GyroPave data format); AxTABLE.txt (table data format). (Where “x” represents the file index number of the data stored in the compactor’s memory.) Model 5850v2 3–13...
HOME POSITION The Model 5850v2 contains hydraulic actuators that control specimen compaction. One actuator applies ram pressure; another actuator clamps the mold; and two actuators inside the compaction chamber set and control the gyration angle. The Home Position function returns all the hydraulic actuators to their home position.
CHAPTER 4 CALIBRATION The Model 5850v2 allows for simple calibration of the specimen height and compaction pressure, and for offsetting the angle of gyration. This chapter provides a recommended schedule for calibration and verification of these parameters, as well as instructions for performing these procedures.
CALIBRATION SCHEDULE The Troxler Model 5850v2 Gyratory Compactor is calibrated at the factory, and requires no initial calibration upon receipt. Troxler recommends the following calibration schedule for the Model 5850v2. If calibrating the compaction pressure and specimen height, calibrate the pressure first and then calibrate the height.
Machine Idle screen as well as during gyration. This angle can be easily verified using an internal angle device, such as the Dynamic Angle Verification (DAV) device available from Troxler (part number 108706). To verify the internal angle, follow the instructions in Chapter 3 to: .
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. Follow the instructions provided with the internal angle device to measure the bottom angle. Ensure that the probes of the internal angle device are aligned along Position 1 with the edge of the mold pull as shown in Figure 4–1. .
Compactor, become familiar with the safety warnings on page 1–1. The Model 5850v2 allows for simple calibration of the compaction pressure and specimen height, and for offsetting the gyration angle. To access the Calibration menu, press 5 from the Setup menu shown on page 3–2.
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PRESSURE NOTE For optimum performance—if operating the compactor at a ram pressure other than 600 kPa—calibrate the specimen height and gyration angle after changing the ram pressure (see page 3–7). The Pressure Verification Kit includes all the equipment needed to calibrate and/or verify the compaction pressure, including a calibration load cell.
. Route the load cell cables through the notch in the upper center of the chamber opening as shown in Figure 4–3. Close the chamber door. LOAD CELL PUCK LOWER CARRIAGE PLATE Figure 4–2. Puck Centered on Lower Carriage Plate Model 5850v2 4–7...
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Upon completion, the compactor verifies the pressure calibration, and then displays the compaction pressure as measured internally by the compactor (System) and as measured by the load cell (Load Cell): Model 5850v2 4–9...
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10 kPa, or if the System pressure is not within 600 18 kPa, check all cable connections and the position of the load cell and puck. Repeat the calibration. If repeated attempts to calibrate the pressure fail, contact your Troxler representative. . Press ENTER. The compactor stores new calibration constants based on the System and Load Cell values.
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When the calibration is complete, the compactor displays the Measured height and the Standard height, as shown below. The displayed height should be within 0.10 mm of the value stamped on the height standard assembly. If not, repeat the height calibration. Model 5850v2 4–11...
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ANGLE OFFSET The Model 5850v2 can be set to a gyration angle of 0.00 to 1.50 degrees. As noted earlier, Troxler recommends verifying the angle after every 800 samples or once per year using an internal angle device, such as the Dynamic Angle Verification (DAV) device available from Troxler.
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To use this function, press 4 at the Calibration menu shown on page 4–5. The compactor sends the calibration data to the selected output device (see page 3–12), then returns to the Calibration menu. Model 5850v2 4–13...
CHAPTER 5 SPECIAL FUNCTIONS The Model 5850v2 Gyratory Compactor firmware includes a number of functions that typically are not used on a day-to-day basis. These functions are accessed from the Special menu, which is a submenu of the Setup menu.
SPECIAL MENU The Special menu provides access to a number of functions that typically are not used on a day-to-day basis. These functions enable the operator to set the date and time, to clear all project (specimen) data, and to reset the software. To access these functions, press 6...
The compactor displays: 08:45 AM Arrows toggle AM/PM Input Time and Press <ENTER> Note that in this example, the time is displayed in AM/PM format. To change the format, see the Time Format section on page 5–5. Model 5850v2 5–3...
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The top line of the display shows the current clock setting. To accept this setting, press ENTER. The compactor returns to the Clock/Calendar menu. To change the clock setting, enter the current time using the numeric keys and press ENTER. The compactor returns to the Clock/Calendar menu.
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To set the desired format, press 4 from the Clock/Calendar menu shown on page 5–3. The compactor displays: -Date Format- 1- mm/dd/yyyy 2- dd/mm/yyyy Press the numeric key that corresponds to the desired date format. The compactor returns to the Clock/Calendar menu. Model 5850v2 5–5...
ERASE RECORDS The Erase Records function erases all data records stored in the compactor’s memory. To erase data records, press 2 from the Special menu shown on page 5–2. The compactor displays: Permanently Erase all Data Records? <YES> or <NO> ...
To restore the default settings, press YES. The compactor restores the default settings, displays a brief confirmation message, and returns to the Special menu. To return to the Special menu without restoring the default settings, press NO/CE or ESC. Model 5850v2 5–7...
APPENDIX A TROUBLESHOOTING AND SERVICE This appendix contains information on servicing and maintaining the Model 5850v2 Gyratory Compactor. Model 5850v2 Appendix A–1...
TROUBLESHOOTING WARNING To prevent personal injury or equipment damage, become familiar with the safety warnings on page 1–1 before operating the compactor. Gyratory compactor does not turn on . Ensure that the unit is plugged in. . Check that the power switch is in the ON position. .
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. If printing or downloading data to a USB device, ensure that the device is compatible with the compactor. A list of compatible USB memory devices and printers is available on the 5850v2 product page at www.troxlerlabs.com/. General calibration problems .
GENERAL MAINTENANCE SCHEDULE The following sections provide a recommended schedule for performing regular maintenance on the Model 5850v2 Gyratory Compactor. CAUTION Do not use a degreasing cleaner or glass cleaner to clean the clear chamber door. To prevent damage to the door surface, use a mild detergent only.
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Replace if necessary. Retaining ring (inside the bottom of the mold) – Ensure that the ring is in place. If necessary, return the mold to Troxler for servicing. . Remove the rear service panel and perform the following steps: ...
. Remove the right-side service panel. Locate the hydraulic filter (see Figure A–1). Verify that the bypass indicator on the top of the filter housing is green. If the bypass indicator is red, the filter element must be changed. Contact your Troxler representative for more information. ENSURE...
. Install the control panel using the four screws removed in step 2. . Reconnect the ac power cord and turn the power switch on. . Verify that the compactor displays the current date and time. Reset, if necessary, as described on page 5–3. Model 5850v2 Appendix A–7...
2. Pull Fan Assembly removal handle and extend fan assembly REPLACEMENT PARTS The list below shows part numbers for parts that are replaced often. Other replacement parts can be ordered by calling 1-877- TROXLER or visiting our online catalog at www.troxlerlabs.com. PART # DESCRIPTION 106514...
All shipments to the factory must be accompanied by a Returned Goods Authorization (RGA) number, and a description of the instrument, and its problem. This information is used by Troxler shipping and service personnel to expedite the repair work. To obtain an RGA number, please call or fax the factory or branch office with your request.
MENU MAP DESCRIPTION Figure B–1 is a map of the compactor’s Setup menu and each of its submenus. To access the Setup menu, press Setup. Where applicable, the default (as shipped) menu settings are shown in shaded text. The menu map uses indentation to indicate submenus that result from selection of a menu item.
APPENDIX C SPECIFICATIONS This appendix provides environmental conditions and specifications for the Model 5850v2 Gyratory Compactor. CONTENTS Environmental Conditions ............C–2 Electrical Specifications ............... C–3 Mechanical Specifications ............C–4 Model 5850v2 Appendix C-1...
ENVIRONMENTAL CONDITIONS –55 to 85 C Ambient Storage (–67 to 185 F) Temperature 10 to 50 C Ambient Operating (50 to 122 F) Temperature Altitude Rating 2000 meters maximum 10% Main Supply Voltage Fluctuation Pollution Degree Installation Categories (Overvoltage Categories) Humidity 92% maximum Appendix C–2...
RS-232 null modem 9-pin female – 9 (25) pin female USB Port A list of compatible USB memory devices and printers is available on the 5850v2 product page at www.troxlerlabs.com. Modes of Operation Compact to operator-specified number of gyrations or specimen height...
MECHANICAL SPECIFICATIONS Size 162.6 H x 71.1 D x 68 W cm (64 H x 28 D x 26.75 W in.) Weight Approximately 227 kg (500 lb) Shipping Weight (est.) 328.8 kg (725 lb) Unit with Packaging Shipping Weight, (est.) 487.6 kg (1075 lb) with All Accessories Mold Weight...
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During the applicable warranty period, TROXLER’s obligation under this warranty shall be limited exclusively to the repair at a TROXLER facility at no charge, except for shipping to and from TROXLER’S plant, of any instrument which may prove defective under normal use and which TROXLER’s examination shall disclose to its satisfaction to be thus defective.
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