Page 1 NCAT Asphalt Content Furnace Service Manual LT1275X3 • 2/13/04...
Page 2: Table Of Contents
Introduction................................5 What is an NCAT Asphalt Test Furnace? ....................5 Why Test Asphalt? ............................5 Why Improve the Existing Method of Asphalt Testing? ................5 Barnstead International’s Involvement......................6 How Does the NCAT Work? ........................6 Unpacking and Installation ..........................7 Electrical Specifications ..........................7 Site Selection..............................9 Power Requirements ............................9...
Page 3 ABLE OF ONTENTS Output ................................59 Bitumen Ratio ............................59 Glossary ................................60 Errors ................................63 Red Display (Furnace)..........................63 Green Display (Balance) ..........................66 NCAT Troubleshooting with No Error Codes Displayed ................68 Aggregates..............................72 Negative Air Pressure ..........................72 Displayed Letters/Numbers ........................74 Equipment Test Procedure ..........................81 Removal of the Control Assembly (Bottom Section) in the 1087 and 1275 Series NCAT ......81 1087 Series Back Wall Insulation Removal....................88 Heating Elements ............................89 Element Part Numbers and Cold Resistance ....................95...
Page 5: Introduction
The NCAT Asphalt Content Furnace is a unitized furnace, electronic weighing system, and exhaust air filtration mechanism combined into one system. The system was developed by a team of Barnstead International engineers in conjunction with the National Center for Asphalt Technology (hence the name NCAT) at Auburn University.
Page 6: Barnstead International's Involvement
NTRODUCTION Barnstead International’s Involvement Because the NCAT researchers at Auburn University decided that their new test method would use high tem- perature to separate the asphalt from the aggregate in the asphalt mix, they needed a company that specialized benchtop high temperature laboratory furnaces.
Page 7: Unpacking And Installation
Buck/Boost low voltage isolation transformers are an electrical device that has the ability to step up a 208V power supply to 240V or step down a 240V power supply to 208V. Buck/Boost transformers are available at Barnstead International (P/N TNX122) or can be purchased at local electrical retail stores.
Page 8 NPACKING AND NSTALLATION Barnstead International “packs” a chamber to transport an NCAT from one location to another, preventing damage. Parts Shipped in Chamber: (8) JSX122 - Balance/Hearth Plate Ceramic Support Tubes Parts Shipped in Accessory Box (Located on top of unit - not pictured)
Page 9: Site Selection
NSTALLATION Site Selection • The NCAT should be mounted on a sturdy level Note surface, capable of supporting the weight of the This manual does not include all fully assembled furnace (Approximately 300 information necessary to properly pounds). install an NCAT. Please refer to owner/operator manual.
Page 10 NSTALLATION Available from Barnstead International, P/N TU859X1. • Install rock-wall cloth rated to handle tempera- tures up to 270°C to insulate the exhaust tubing passing through ceiling ducts. • Do not use exhaust tubing less than 3 inches in diameter.
Page 11: Installation Drawings
NSTALLATION...
Page 12 NSTALLATION...
Page 13: Balance
Balance The original NCAT (Series 859 & 945) were all manufac- tured with an OHAUS balance, model GT8000. Design changes still found OHAUS balances being used in the 1087 series until February 1998, in which a manufacturing change from OHAUS to SETRA was completed. OHAUS vs.
Page 14: Ohaus Fuse Location
ALANCE OHAUS Fuse Location The OHAUS balances have a fuse installed on the back of the load cell. The black, rectangular fuse holder/cap is located as part of the power entry module. The cap also has voltage markings on each side. The side facing towards the top of the balance is how the holder/cap should be posi- tioned for the corresponding supply voltage.
Page 15: Ohaus Balance
240Vac (full potential line voltage). The balance is config- ured for supply voltage that corresponds with the NCAT upon production at Barnstead International. OHAUS balances were used in production from 1995 to 1998 and are currently sold as replacements only.
Page 16 OHAUS B ALANCE of the balance. Plug the nine-pin ribbon cable female socket from the controller into the corre- sponding socket on the back of the balance. Plug the 13 pin socket on the display cable (the cable from the front of the balance running beneath the balance) into the 13 pin connector located on the lower right-hand edge (as you face the unit) of the balance display board...
Page 17: Balance Control Port Hole Location
OHAUS B ALANCE Balance Control Port Hole Location There are 4 holes strategically placed on the front of the control panel, between the green display and the red displays. These holes are used to access and adjust the balance variables. Use an appropriate sized tool or paper clip to access balance keys through the port holes in the control panel.
Page 18: Ohaus Time And Date Set Procedure
OHAUS B ALANCE OHAUS Time and Date Set Procedure The balance supplies the time & date to the microproces- sor of the NCAT. For ease of record keeping and to allow the microprocessor to function properly, please ensure the time and date are set appropriately. The balance is shipped with the time &...
Page 19 OHAUS B ALANCE 10. Press the MODE button. “Set” will be displayed. 11. Press the ON button. The display will indicate time with the first two digits (hours) flashing. 12. Repeatedly press (or press and hold to scroll) the MODE button until the current hour (24 hour clock) is displayed.
Page 20: Resetting The User Variables Of An Ohaus Balance
OHAUS B ALANCE 26. Repeatedly press (or press and hold to scroll) the MODE button until the current date is dis- played. 27. Press the ON button. The last two digits (year) will flash. 28. Repeatedly press (or press and hold to scroll) the MODE button until the current year is dis- played.
Page 21 OHAUS B ALANCE To reset balance Power down the NCAT furnace using the green power switch. Press and the hold the number “4” key on the keypad. While holding down the “4” key, power up the NCAT using the green power switch.
Page 22 OHAUS B ALANCE 11. Press the ON button. “Yes” will be displayed. Pressing the ON button again will reset the Setup menu to the OHAUS defaults. You will know when this has been done when you hear a short train of beeps. 12.
Page 23 OHAUS B ALANCE incorrect. Pressing the ON button will display the date. The date may be changed by pressing the MODE button to first change the month, day and year respectively, as was done with chang- ing the time. After pressing the ON button when selecting the date, the menu option “Set”...
Page 24 OHAUS B ALANCE 36. Press the MODE button until “Data” is dis- played. Press the ON button to display the cur- rent parameter setting. Change setting to read “8 Data” by pressing the MODE button. Press the ON button to approve the setting, which will display “Data”.
Page 25: Ohaus Balance Calibration
OHAUS B ALANCE 43. Power down the NCAT with the green power switch and power back on again to exit balance adjustment mode. OHAUS Balance Calibration OHAUS balance calibration should be performed to ensure accurate weighing. Calibration is performed with the calibration plate (provided by B/I) and a set of certified weights (8000 grams).
Page 26 OHAUS B ALANCE Press the ON button again. “Span” is displayed followed by “C 0g”. Press the ON button again to start the Span cal- ibration. “-C-“ is displayed followed by the value of mass which must be placed on the platform such as “C 2000g”.
Page 27: Setra Balance
SETRA Balance SETRA Balance Installation *Steps 1-5 also refer to replacing an existing balance. Lower the front control panel by removing the screws. Locate the balance display board mounted on the back of the front control panel. This is the board that illuminates with green numbers when the unit is powered up.
Page 28 SETRA B ALANCE 11. Install the 4 ceramic support posts down through the holes in the chamber so they straddle the support plate of the balance. Physically maneuver the bal- ance (load cell) in such a manner to ensure each of the 4 ceramic support posts are not in contact with any part of the NCAT chamber section.
Page 29: Balance Control Port Hole Location
SETRA B ALANCE Balance Control Port Hole Location There are 4 holes strategically placed on the front of the control panel, between the green display and the red displays. These holes are used to access and adjust the balance variables. Use an appropriate sized tool or paper clip to access balance keys through the port holes in the control panel.
Page 30: Setra Time And Date Set Procedure
SETRA B ALANCE Setra Time and Date Set Procedure The balance supplies the time & date to the microprocessor of the NCAT. For ease of record keeping and to allow the microprocessor to function properly, please ensure the time and date are set appropriately. The balance is shipped with the time &...
Page 31 SETRA B ALANCE Press the balance ON/OFF key until the correct minute is displayed. Press ENTER. Press the balance ENTER key, the balance will return to the normal weight display. To Set the Date Power down the NCAT. (Green Power Switch). Press &...
Page 32: Resetting Variables Of A Setra Balance To Factory Default
SETRA B ALANCE 12. Press the balance ON/OFF key until the desired day is displayed. 13. Press the balance ENTER key. [nn xx] will be displayed. 14. Press the balance ON/OFF key until the desired month is displayed. 15. Press the balance ENTER key. [Yr xx] will be displayed.
Page 33: Setra Balance Calibration
SETRA B ALANCE Release both keys simultaneously. [71nE] will be displayed. Press the balance ON/OFF key three consecu- tive times. [FACdEF] will be displayed. Press the balance ENTER key. [BUSY] will be displayed. The balance display will automatically revert back to normal weight indication screen when reset is complete.
Page 34 SETRA B ALANCE Press the balance ON/OFF key two consecutive times. [CAL] will be displayed. Press the balance ENTER key. [LOAd 8000] will be blinking on display. 10. Place 8000 grams of certified weight (NIST traceable) on the ceramic hearth plate. [0.0] will be displayed.
Page 35: Error Conditions
Error Conditions OHAUS Balance (Not a complete listing of error codes, but most common.) Error Displayed Problem Solution Calibration Error – Incorrect or Recalibrate with correct weights. no calibration weight used for calibration. Make sure all debris is off the top of the balance and the posts supporting the aluminum calibration plate are centered.
Page 36: Setra Balance
RROR ONDITIONS SETRA Balance (Not a complete listing of error codes, but most common.) Error Displayed Problem Solution HHHHH Exceeds maximum specified load Reduce load to specified range. (5000 grams). LLLLLL Load does not meet minimum specified Increase load to specified range. load requirements.
Page 37: Printer
Seiko printer P/N AYX3 (859, 945, 1087 Series units ONLY) Thermal Paper Storage To store burn tickets, Barnstead International recommends making a copy of the thermal paper ticket on an 8.5 x 11 piece of white paper. Do not store the thermal paper ticket itself as it will discolor and become illegible in time.
Page 38: Printer Change (Production)
RINTER Printer Change (Production) Seiko to Martel (1087 to 1275) The Seiko printer used in production of the 859, 945 and 1087 series NCAT is obsolete. The new printer is manufactured by Martel and will be used in production starting with the 1275 series NCAT in Oct/Nov of 2001. The software is being changed.
Page 39: Troubleshooting
RINTER Troubleshooting Problem Cause Solution Printer not printing. The red LED will not illuminate Remove the paper roll from if paper is removed from the printer. the printer, turn the paper roll The unit uses thermal paper, which over and reinstall in the printer. means characters will only show if Perform a hidden key routine the paper roll is installed properly.
Page 40 RINTER Problem (cont.) Cause (cont.) Solution (cont.) Print coming out upside down, The Seiko printers are equipped with Power off the NCAT, remove the reading right to left. an internal switch located in the upper printer cover, and slide the left corner of the printer with the switch to the opposite position.
Page 41: Software
Software History The following software revisions were used in the NCAT furnaces. All software versions are interchangeable and if in doubt it is always best to update. The software chip is located on the Main Logic PC Board (PC859X1) next to the balance.
Page 42 OFTWARE Maximum test time was extended to 255 min- utes. Maximum load size increased to 4000 grams. Asphalt content expressed in percent loss on burn ticket. Bitumen Ratio calculated and added to print out test results. Version G: Several new operating features were added. They include: Programmable time/date function.
Page 43: Sc859X1 Rev. 1 Software Eprom
OFTWARE the endpoint of a test, place an asterisk next to the endpoint, but continue to run the test, beep- ing once every 10 seconds to alert the operator the test is complete. Operator must press the START/STOP key to end test. Stability threshold factor expressed in a percent- age (0.01% - 0.5%) Version H: Revision H does not contain any operational...
Page 44 OFTWARE Auto Program switching to idle at test endpoint •Increases the number tests run per day •Frees operator’s time •Asterisk documents endpoint on printout (see enclosed sample printout on page 45) Maximum test time extended to 255 minutes and load size to 4,000 grams •Meets ASTM and AASHTO maximum load size requirements...
Page 45: Installation
OFTWARE Installation Open hinged front control panel by removing four screws. The SC859X1 EPROM is mounted in a 16-pin socket on the edge of the PC859X1A board on the right side of the furnace. A label on top of EPROM indicates the part number and revision level.
Page 46 OFTWARE...
Page 47: Ordering Information
OFTWARE Ordering Information Revision “I” Software Kit AY1087X3 1 ea. SC859X1 EPROM Labeled Rev. I Software 1 ea. Installation Instructions 1 ea. Set of Operation Manual Amendments...
Page 48: Procedures
Procedures Amendment TIMER PROGRAMMING & HIDDEN KEY PROCEDURES FOR REVISION “I” SOFTWARE Definition Hidden Keys provide multiple use of the keypad. Hidden Key Procedures typically are used to access infrequently changed user variables and infrequently used diagnostic procedures. The access, procedure and exit are detailed under each key procedure.
Page 49 ROCEDURES month and then the day. Example: May 16th would be entered 5/16. Then press ENTER. Note The “wake-up” date is now set. The timer format is European or Military time so to enter a wake-up You may now proceed to enter the “wake-up” time of 5:00 a.m.
Page 50 ROCEDURES restored the blower will start up again to maintain air flow through the chamber. This will also prevent the user from prematurely opening the door. The power interrupt feature also applies to the program- mable timer. Should the power go off during the night while the unit is asleep and then come back on prior to the programmed “wake-up”...
Page 51 ROCEDURES Exit: Depress Power Switch to “OFF” and then “ON” to return to normal operation. 1 Key-Print Out Paper Saver: Access: Depress Power Switch to “ON” while depressing the 1 key simultaneously. Procedure: Chamber temperature display will display PRN and the Percent Loss display will toggle “ON”...
Page 52 ROCEDURES Setup: Calibration consists of inserting a sensor penetrating through the covered stainless steel tube located adjacently to the con- trol thermocouple. Entry is at the center rear of furnace chamber. The penetrating probe is needed to penetrate through the soft insulation.
Page 53 ROCEDURES 4 Key-Provides Entry to Balance Menus Access: Depress 4 key while simultaneously depressing Power Switch to “ON”. Procedure: BAL will display in Chamber Temperature window. CAL will display in Percent Loss window. Entry allows you to change time and date settings, review and adjust bal- ance variables, and calibrate balance.
Page 54 ROCEDURES Temperature window. “OFF” will be dis- played in the Percent Loss window. The furnace will automatically return to normal operation within five seconds with the error codes deactivated. Error codes are defeated to perform diag- nostic procedures as to temporarily ensure continued furnace operation in the event of an error code.
Page 55 ROCEDURES Exit: Automatically returns to normal operation within three seconds. 9 Key-Disables Beep Access: Depress the 9 Key while simultaneously depressing the Power Switch to “ON”. Procedure: The Chamber Temperature will display BEEP. The Percent Loss window will dis- play “ON” or “OFF”. The mode condition will display for three seconds.
Page 56 ROCEDURES Enter Key-Prints Out User Variables Access: Depress the ENTER Key while simultane- ously depressing the Power Switch to “ON”. Procedure: PRN will display in the Percent Loss win- dow. User will display in the Elapsed Time window. The printout will generate automatically upon activating hidden key sequence.
Page 57 ROCEDURES User Variable Printout. See Hidden Key ENTER. An example of the printout is depicted on page 58. Exit: Depress Power Switch to “OFF” and then “ON” to return furnace to normal opera- tion. Temp Key - Toggles from Auto Program Switching to Idle or Manual Program Switching to Idle at End- point...
Page 58 ROCEDURES will display “ON” or “OFF.” The Mode Condition will display for three seconds. Accessing toggles the mode between “ON” and “OFF.” The displayed mode is the active mode. Active Keys These keys activate a function when depressed. The fur- nace must be in the idle (non-programmable) mode.
Page 59: Output
Output Bitumen Ratio The Bitumen Ratio has been added to the Rev. “I” soft- ware. This test result is used in the United States and Europe. The Bitumen Ratio equation is detailed as fol- lows: Bitumen Ratio = (Weight Loss/Sample Weight after ignition) x 100% minus temperature compensation, minus cor-...
Page 60: Glossary
Glossary Balance Stability: The small “S” will flash on and off at the left side of the balance dis- play. When the “S” is shown, the balance is stable. It is normal for the “S” to flash early in the igni- tion procedure, as rapid sample weight loss occurs early in the fir- ing procedure and diminishes as...
Page 61 LOSSARY HMA: Hot Mix Asphalt. Idle Mode: This mode is entered on startup after initialization. Revision “I” software automatically transfers from the program mode to the idle mode upon completion of the test. The furnace will idle at set point temperature in preparation for the next test.
Page 62 LOSSARY Temperature This factor compensates for Compensation the loaded basket assembly Factor: weight reduction experienced when placed in the ignition furnace chamber at temperature. The Temperature Compensation Factor is automatically calculated by the furnace software. This fac- tor must be employed in the igni- tion process to achieve accept- able precision and accuracy specified by standard methods.
Page 63: Errors
Errors Red Display (Furnace) NOTE: Furnace ERROR Codes – RED display window. All error codes (unless explicitly noted) will cause the test procedure to stop. Microprocessor checks for error codes occur every second. It goes through the errors in order of importance starting at #1. If there are multiple errors occurring at the same time, the first error code will display on the unit.
Page 64 RRORS Error Code (cont.) Cause (cont.) Solution (cont.) E005 (cont.) Solenoid valve is bad and not engaging the plunger. Turn unit on and start cycle to listen for the solenoid valve to active. Watch for move- ment in the plunger. To remove the door solenoid: Disconnect the power to the unit and drop down the front control panel.
Page 65 RRORS Error Code (cont.) Cause (cont.) Solution (cont.) E009 Set point is out of range. This is a The furnace will beep for 3 seconds while dis- temporary error to alert you that you playing this error and then return to normal have crossed the allowable boundary operation.
Page 66: Green Display (Balance)
RRORS Green display (BALANCE) NOTE: Balance error codes will be displayed in the green balance display. With most error codes below, power unit down and power back up to see if the error goes away. If it continues try to recalibrate, however, if the error will not clear, the balance will need to be replaced.
Page 67 RRORS Error Code (cont.) Cause (cont.) Solution (cont.) PPPPPP Strain on the DC power supply. Disconnect printer to see if the error goes away. If it does, replace printer. ProtEc Calibration protect switch not in the Replace scale. PROTECT position during opera- tion.
Page 68: Ncat Troubleshooting With No Error Codes Displayed
RRORS NCAT Troubleshooting with No Error Codes Displayed Error Symptom Action Keypad failure The NCAT unit may beep or chirp Test keypad (See Equipment Test Procedure in a non-rhythmic fashion. section.) The red displays will indicate char- Replace keypad (Serial number of NCAT need- acters (numbers and/or letters) ed to identify correct replacement part number that do not coincide with what...
Page 69 RRORS Error (cont.) Symptom (cont.) Action (cont.) Smoke coming from In addition to control section emit- Perform a lift test with and without the exhaust control section dur- ting smoke, a complaint of longer tubing attached. (See Lift Test Section.) If ing a burn test/run times, a fowl odor, black results are out of specification, follow the clean-...
Page 70 RRORS Error (cont.) Symptom (cont.) Action (cont.) Tests never end If the sample does not lose more Perform a test in which minute by minute test (Complaint) than 15 grams at the end of the results are printed out. Examine the burn ticket 15th minute, the software is pro- &...
Page 71 Verify chamber temperature accuracy; recali- brate if necessary. REMINDER: Barnstead International has premixed samples of asphalt that can be sent to customers that have problems burning obtaining repeatable results and poor accuracy. Our samples are hand mixed at 5.0%. Our samples should be burned with a calibration factor of 0.0 at 538°C (chamber temp). Results will...
Page 72: Aggregates
RRORS Aggregates Issues that can affect the accuracy and repeatability of the results not related to the NCAT: 1. Sample size consistency 2. Splitting errors 3. Moisture in mix 4. Type of material Limestone, granite, and sandstone are the three most common base aggregates used.
Page 73 RRORS of the NCAT provides a direct path for atmospheric air pressure to enter the room/building when exhausted directly through an outside wall or the roof. The NCAT does have a 60CFM rated blower motor to aid the ventila- tion process, but in some situations, the pressure differ- ence is too great and the blower motor can not prevent or stop the negative air pressure from occurring.
Page 74: Displayed Letters/Numbers
RRORS Displayed Letters/Numbers “IN Ac” = Inactivity Mode. This mode is part of the timer, which allows the unit to automatically turn on and heat to set point temperatures. “IN Ac” will be displayed if the user does not press any keys for a period of four hours if the timer is set.
Page 75 RRORS “SCAL” = Scale. “SCAL” will be displayed in the Chamber Temp window. Hidden Key WEIGHT will cause “SCAL” to be displayed. “FLN” = Stability Threshold. “FLN” will be displayed in the Elapsed Time window. Hidden Key CALIBRATION FAC- TOR will cause “FLN” to be displayed. “AU”...
Page 76 RRORS Elapsed Time: 30:12 Sample Weight:1093g Weight Loss: 57.7g Percent Loss: 5.27% Temp Comp: 0.00% Calib. Factor: 0.29% =================== Calibrated Asphalt Ctnt 4.98% =================== 57.7 5.27 57.6 5.26 57.5 5.26 57.3 5.24 56.9 5.16 56.4 5.15 55.7 5.09 55.0 4.94 54.1 4.85 53.1...
Page 77 RRORS Elapsed Time: 30:12 Sample Weight:1093g Weight Loss: 0.8g Percent Loss: 0.03% Temp Comp: 0.00% Calib. Factor: 0.00% Bitumen Ratio: 0.03% =================== Calibrated Asphalt Ctnt 0.03% =================== 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 An example of the time/date function of the balance not 0.02 properly set.
Page 78 RRORS Elapsed Time: 30:12 Sample Weight:1093g Weight Loss: 0.8g Percent Loss: 0.03% Temp Comp: 0.00% Calib. Factor: 0.00% Bitumen Ratio: 0.03% =================== Calibrated Asphalt Ctnt 0.03% =================== 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% An I.C.
Page 79 RRORS Elapsed Time: 30:12 Sample Weight:1093g Weight Loss: 57.7g Percent Loss: 5.27% Temp Comp: 0.13% Calib. Factor: 0.00% =================== Calibrated Asphalt Ctnt 4.98% =================== 14.7 1.99 32.2 3.14 57.5 5.26 108.6 8.81 56.9 5.16 56.4 5.15 107.2 8.80 55.0 4.94 54.1 4.85 1.14...
Page 80 RRORS Elapsed Time: 30:12 Sample Weight: 1093g Weight Loss: 57.7g Percent Loss: 5.27% Temp Comp: 0.14% Calib. Factor: 0.29% =================== Calibrated Asphalt Ctnt 4.98% =================== 57.7 5.27 57.6 5.26 57.5 5.26 57.3 5.24 56.9 5.16 56.4 5.15 55.7 5.09 55.0 4.94 54.1 4.85...
Page 81: Equipment Test Procedure
Equipment Test Procedure Removal of the Control Assembly (Bottom Section) in the 1087 & 1275 Series NCAT The control assembly is the lower section of the furnace. It houses all the P.C. boards, relays, the balance, and wire assemblies. When the front control panel (keypad) is lowered, you can look into the electronic control hous- ing.
Page 82 QUIPMENT ROCEDURE Lowering the front panel, a washer/nut assembly can be located at each corner (front right & front left, right behind the hinges the panel swings on). These nut assembles need to be loosened because they hold down the bottom plenum of the control assemble.
Page 83 QUIPMENT ROCEDURE Next, unhook the wire harnesses that secures the control assembly in place. IT IS VERY IMPORTANT THAT YOU NOTE WHERE EVERY WIRE HARNESS IS CONNECTED BEFORE STARTING TO UNPLUG THEM. There are a total of TEN different wire harness- es in the front that need to be disconnected and one grounding strap.
Page 84 QUIPMENT ROCEDURE d. There is a gray grounding-wire mounted to control assembly floor and the swing down con- trol panel. One end needs to be released. The balance display board has 3 different wire har- nesses plugged into it. e. A small gray ribbon running from the balance to "P2"...
Page 85 QUIPMENT ROCEDURE There are two wire harnesses that need to be disconnected in the back of the unit. (See photo. Harness placement is indicated by white X’s.) Back of unit - Control panel slid out 2.5” 2 wire harnesses to disconnect to slide control panel out of unit. a.
Page 86 QUIPMENT ROCEDURE Proceed to slide the control section out of the back of the unit. See photo below. As soon as the control section is approximately half way out, the thermocouple wires (Red and Yellow) will come into view and prevent the control sec- tion from sliding any further.
Page 87 QUIPMENT ROCEDURE The complete control assemble will slide all the way out now. Control section pulled from unit To reinstall the control panel, perform the same steps in the reverse order. (Remember to plug your thermocouple wires back in as you slide the control section back into the unit.) The biggest cause of failure when reinstalling the control section is having wire harnesses that are not plugged in...
Page 88: 1087 Series Back Wall Insulation Removal
QUIPMENT ROCEDURE 1087 Series Back Wall Warning Insulation Removal Unit should be at ambient tempera- ture before attempting to replace the back wall insulation. Procedure to remove/replace JC1087X3 Tools needed: - Phillips screw-driver (power screw driver is available) Warning - Flat head screw-driver & Needle nose pliers Unit should be disconnected from - Refer to drawings "ZD", "ZC, &...
Page 89: Heating Elements
QUIPMENT ROCEDURE 12. Remove blanket insulation (JC1087X7) 13. Remove insulation material (JC1087X4) Note Refer to the pictures and parts list in 14. Remove afterburner element (EL1087X1) the back of this manual. 15. Remove the filter (FL859X2) 16. Remove insulation material (JC1087X4) 17.
Page 90 QUIPMENT ROCEDURE when the CYCLE FILTER and CYCLE CHAM- BER LED’s illuminate on the front control panel. Allow the NCAT to heat for 30 seconds. a) The 30 seconds begin when the CYCLE FILTER and CYCLE CHAMBER LED’s illumi- nate. Power off the NCAT unit.
Page 91 QUIPMENT ROCEDURE Open the chamber door and slide the top ele- ment straight out the front of the unit. Remove the each side element in the same fashion. Refer to photos on page 94. Remove the bottom element in the same fash- ion.
Page 94 QUIPMENT ROCEDURE Description Element terminal blocks Element terminal blocks Element terminal blocks Element terminal blocks Element terminal blocks Element terminal blocks Element terminal blocks Filter thermocoupler Chamber thermocoupler 1087 or 1275 series back view Element terminal block close up Element lead wire...
Page 95: Element Part Numbers And Cold Resistance
QUIPMENT ROCEDURE Element Part Numbers & Cold Resistance Series 1087 & 1275 Part Number Description Voltage Cold Resistance EL859X3 Right Side All Voltages 55 Ohms EL859X4 Left Side All Voltages 55 Ohms EL1087X1 Afterburner 220-240V 36 Ohms EL1087X2 Bottom 220-240V 10 Ohms EL1087X3 220-240V...
Page 98: Thermocouples
QUIPMENT ROCEDURE 1087 or 1275 series back view Thermocouples The NCAT utilizes two type K thermocouples. One thermocouple is routed into the back of the chamber. The other is routed into the top plenum (filter). A type K thermocouple generates a millivolt signal. As the temperature rises in the chamber and filter section, the millivolt signal generated by the thermocouple increases.
Page 99 QUIPMENT ROCEDURE b) This will electrically isolate the thermocouple from the rest of the circuitry. c) It is important to label or note the color of the wire at the terminal block connection for polarity purpos- Using a continuity tester, measure across the lead wires of the thermocouple.
Page 100 QUIPMENT ROCEDURE Replace the thermocouple if it has high resist- ance or no continuity. **Do not attempt to connect a voltmeter in parallel with either thermocouple, attempting to monitor the millivolt- generated signal. A meter will load the circuit, resulting in inaccurate measurements.
Page 101: Solid State Relays
QUIPMENT ROCEDURE Solid State Relays There are a total of three solid-state relays in the NCAT. All three are located in the lower control section. Refer to photo of keypads on page 38. The solid state relays, activated by a 5 - 15Vdc signal from the main micro- processor P.C.
Page 102 QUIPMENT ROCEDURE a) Each nut is physically located 1/2” to 1” directly behind the hinges. These nuts secure the control section to the front of the NCAT. The control panel will slide out from the back side of the NCAT (Approximately 2” out from the unit.) a) It is important not to pull the control section too far back with force, as several wire harness-...
Page 103 QUIPMENT ROCEDURE positive terminal. Pin “4” is the DC negative ter- minal. Refer to page 96. Power on the NCAT unit. Allow the NCAT to step through the startup countdown and go into the preheat mode. 10) Note if the CYCLE FILTER and CYCLE CHAM- BER LED’s illuminate on the front control panel.
Page 104: Keypad
QUIPMENT ROCEDURE solid-state relay is working properly. Taking voltage measurements at this point is not necessary. However, if the blower motor does not run or is run- ning while the NCAT is in the preheat mode, the solid-state relay may be defective. Take voltage measurements as described in step 11 to determine if the solid-state relay is defective.
Page 105 QUIPMENT ROCEDURE b) Matrix chart: 7 Key • • 8 Key • • 9 Key • • Temp Key • • 4 Key • • 5 Key • • 6 Key • • Weight Key • • 1 Key • •...
Page 110: Maintenance
Maintenance Lift Test Procedure The efficiency of the blower and/or exhaust system is monitored by a quick test procedure, referred to as the “lift test”. Steps to perform a lift test: Chamber must be at ambient (room tempera- ture) condition before attempting to perform a lift test.
Page 111: Cleaning Procedure For Ncat
AINTENANCE Cleaning Procedure for NCAT The NCAT unit must be kept clean in order to ensure proper operation. The lift test procedure is a tool to indi- cate when the unit needs to be cleaned. (See Lift Test Procedure) Follow the instructions below for proper cleaning.
Page 112: Chamber Temperature Verification/Calibration
AINTENANCE Reconnect power. Increase the chamber set point temperature to 650°C using the chamber set button. Increase the filter set point tempera- ture to 900°C by performing a hidden key 5 to change filter set point temperature as follows: Turn the green power switch “off”. Press and hold the #5 key in while pressing the green power switch.
Page 113 NCAT furnaces. NOTE: To verify or calibrate chamber temperature, you will need an N.I.S.T. traceable digital pyrometer (Barnstead International part number = PM20700) & an N.I.S.T. 10” Type K thermocouple probe (Barnstead International part number TC405X2). These can be cali- brated to N.I.S.T.
Page 114 AINTENANCE Connect the probe to the digital pyrometer (B/I part number = PM20700) & power up the pyrometer. Record the chamber temperature reading as indicated by the pyrometer. Power off the NCAT. Power the NCAT back up while holding the #3 key in (Hidden Key #3 routine).
Page 115: Balance Calibration
AINTENANCE - Chamber temperature should be +/- 10°C difference between unit temperature and probe temperature at 500°C. Calibration Type K Chamber Port Thermocouple 10.5” Back view of chamber section (859 & 945 series) with cover removed. A 1/4” diameter hole is predrilled through the stainless steel sheet metal but is not predrilled through the chamber insulation material.
Page 116: Drawings
Drawings...
Page 117 RAWINGS...
Page 118 RAWINGS...

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Barnstead International Thermolyne 859 Series Service Manual

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