CONTENTS
Section page
Operating & Maintenance
Instructions
Asphalt Binder Analyser - Model ABA 7/35B
This manual is for the guidance of operators of the above
Carbolite product and must be read before the equipment is
connected to the electricity supply.
This manual should supply all the information required for safe and trouble-free
operation. If, however, any questions remain unanswered please contact our Service
Department at the address at the end of this manual.
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Contents
1 Symbols & Warnings 3
2 Supplied Item List 4
3 ABA Installation 7
3.7.3 Fig - Connecting the 11
4 Safety Features 15
5 ABA Operation 17
6 System Configuration Menu 21
7 Running a Test 22
8 Tray Lift Calculation 31
9 Access Levels 32
10 Temperature Control 35
11 Setting Date and Time 37
12 Printer Settings 38
13 Recipe Library Functions 40
14 Recipe Editor 42
15 Test Log Viewer 45
16 USB Memory Stick Data Transfer 47
17 Internal Balance Commands 49
18 Language Selection 52
19 Reconfigure Voltage Settings For Alternative Electrical Supply 53
20 Temperature Calibration 54
21 Maintenance and Repairs 56
22 Event Log Messages 62
23 Software Versions 64
24 Diagnostics 65
25 Fault Finding 66
26 Circuit Diagram and Fuses 69
27 Specifications 71
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DANGER of electrical shock– read any warning printed by this symbol.
DANGER – hot surface. Read any warning printed by this symbol.
WARNING: all surfaces of a furnace may be hot.
DANGER – read any warning printed by this symbol.
Heat Light: the adjacent light glows or flashes to indicate that power is
being supplied to the elements
Instrument switch: when the instrument switch is operated the
temperature control circuit is energised.
1 Symbols & Warnings
1.1 Switches and Lights
1.2 Warning Symbols
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Quantity
Item
1 Asphalt Binder Analyser: ABA 7/35B
1
Chimney
(1)
Optional Floor Stand (only if ordered)
(Part number 00372-3-4000)
1
Adam Equipment Internal Balance Mechanism
1
Balance Pan Extension
Fig - 2.2.1
4
Sample Baskets
(Part number 00336-3-2039 – set of 2)
Fig - 2.2.2
2
Sample Basket Lids
Fig - 2.2.2
2
Sets of Sample Basket Clips (1 large, 1 small per set)
(Part number 35-090-044-0010)
Fig - 2.2.2
2
Sample Catch Trays
(Part number 00336-3-2038)
Fig - 2.2.2
1
Sample Basket Loading Handle
(Part number 00336-3-2041)
Fig - 2.2.3
1
Hot Sample Safety Guard
(Part number 00336-3-2042 including handles & fixing kit)
Fig - 2.2.4
1
Hot Sample Guard Handle Fixing Kit
Figs - 2.2.5 & 2.2.6
2
Door Lock Keys
1 Front Brick Cover
Fig - 2.2.7
1
Calibration Plate
Fig - 2.2.8
2
Printer Paper Rolls (including 1 installed in printer)
(Part number 22-222-356-0010)
Fig - 3.8.2
2
Touch Screen Protector Films
(Part number 31-019-200-0010)
1
Operating Instruction Manual (MF60)
2 Supplied Item List
2.1 Parts Supplied
The following items should be present. These should all be checked and identified as soon as
possible after receipt of the equipment. The next page shows pictures of many of the parts for
identification purposes.
2.1.1 Table – Supplied item list
In addition, any spare parts ordered should be separately identified and put aside in safe
storage.
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2.2.1 Fig – Balance pan extension
2.2.2 Fig - Sample baskets on catch tray
with lids & clips
2.2.3 Fig - Sample basket loading handle
2.2.4 Fig – Hot sample safety guard
(assembled)
2.2.5 Fig – Hot sample safety guard handle
fixing kit
2.2.6 Fig – Safety warning label for hot
sample safety guard
2.2.7 Fig – Front brick cover
2.2.8 Fig – Calibration plate
2.2 Identifying the Parts
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2.2.9 Fig – Functional parts of the ABA
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3 ABA Installation
3.1 Tools Required
10mm spanner, 12mm spanner, cross point screwdriver, flat blade screwdriver, allen key
(supplied), 5kg calibration mass (not supplied).
3.2 Unpacking Handling and Siting
When unpacking and moving the ABA always lift it by its base; never lift it by the door or any
other protruding part. The ABA weighs approximately120 kg please ensure
that suitable equipment and an adequate number of personnel are available to
safely lift the device into position. Remove any packing material from the
chamber before use. The ABA is fitted with a safety door lock; when
there is no power connected to the equipment the door has to be opened
using the key supplied. The keyhole is located on the right hand side of the case.
Lock the door again after checking and clearing the interior. See section 4.2.
Install the ABA 7/35B in a well-ventilated room, ideally away from sources of dust. The surface
on which the equipment is mounted should be resistant to accidental spillage of hot materials
and must not be inflammable. The surface should be stable and not subject to movement or
vibration. If the optional metal stand (part number 00372-3-4000) is supplied, this is best placed
on a solid (concrete) floor.
If sited in a prefabricated or mobile laboratory additional stiffening of the floor may be required
to ensure stability of the internal weighing system.
The height of the mounting surface is important to avoid operator strain when loading and
unloading samples. A surface height of about 600mm is recommended to give a sample loading
height of about 960mm.
Ensure that there is free space around the ABA. Do not obstruct any of the vents in the case:
they are needed to keep the controls and the case exterior cool.
Ensure that the ABA is placed in such a way that it can be quickly switched off or disconnected
from the electrical supply - see below.
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3.3.1 Fig - Fastening the
Chimney
3.3.2 Fig - Replacing the panel
3.3.3 Fig – Chimney screws
3.3 Fitting the Chimney
Remove the chimney panel, (see Fig 3.3.2)
Fasten the chimney to the top of the ABA using the screws provided,( see Fig 3.3.3)
Replace the chimney panel, (see Fig - 3.3.2)
3.4 Ducting
The chimney must either be placed under a powered exhaust hood, or connected directly to a
76mm duct (not supplied) to the outside of the building; any such duct must NOT have powered
extraction.
The fumes should be ducted by either of the above methods to at least 1m above the level of
the building.
Rules for ducting:
Ducting diameter must be 76mm or more.
Ducting must be 76mm diameter where it connects to the chimney.
Ducting length must not exceed 3m for 76mm diameter; for longer lengths consult a ducting
engineer.
Flexible ducting, if used, must be suitable for exhaust gas extraction.
If an extraction fan is fitted an extraction hood is required with free flow of air around the
chimney.
Do not connect more than one unit to a single duct. (Exception: where a fanned duct with
hoods are used)
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3.4.1 Fig - Ducting schematic
3.5 Hot Sample Guard Assembly
The hot sample safety guard is supplied as a kit comprising the guard, the handles and fixing
screws and a warning label and fixing screws. See Fig - 2.2.4 to Fig - 2.2.6. to assemble the
handles and the warning label to the guard.
3.6 Electrical Connections
Connection by a qualified electrician is recommended.
Model ABA 7/35B is designed for connection to a range of power
supplies with the minimum of circuit modifications. It is initially supplied to
suit the voltage for which it was ordered; or for 240V 1-phase for a
‘multivoltage’ order.
Look at the rating label before connection to check the supply voltage and
frequency for which the unit is configured. If there is a difference between the actual supply and
the rating label, reconnect the wires between the terminal bock and the EMC filters according to
the appropriate diagram below.
If there is a need to connect the ABA to a voltage other than that shown on the label
when it is delivered, then it is essential to first ensure that wiring configuration shown in
table 3.6:1 is configured correctly for the intended new mains supply.
The supply should be fused at the next standard size equal to or higher than the rated
amperage. A table of fuse ratings (Table 26.2:1) is given in section 26.
Either wire directly to an isolator or fit with a line plug. An isolating switch should operate on
both conductors (single phase) or on all live conductors (three phase); it should be within reach
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Failure to wire to the
appropriate diagram may
damage the ABA
of the operator. A line plug should be easily removable and should be within reach of the
operator.
The supply MUST incorporate an earth (ground).
3.6.1 Schematic for Mains Electrical Connections
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3.7.3 Fig - Connecting the
cable to the balance
3.7.4 Fig – Balance earth
cable position
3.7.5 Fig – Close up of
balance earth cable attachment
3.7.1 Fig - Positioning the Front
Brick Cover
3.7.2 Fig – Partly insert the balance through
the left hand opening then connect the
cable and earth lead
3.7 Balance Installation
Remove the balance from its packing and isolate the ABA from the electrical supply.
Remove both lower side covers.
Open the chamber door and make sure that
there are no obstructions, such as loose
packing or insulation material, in the four
holes in the chamber hearth that the legs of
the balance pan extension pass through.
Position the front brick cover over the front
(see Fig 3.7.1).
In the base compartment, slacken the four
screws holding the balance location plate.
Partly insert the balance into the left side
opening of the furnace with the ‘front’ sloping
portion of the balance facing towards the rear of the furnace. Connect the combined
balance data and power supply lead marked ‘internal’ to the balance body, lightly
tightening the plug’s retaining screws, then connect the balance’s earth lead to the
spade connector in the upper rear part of the
recess (see Figs 3.7.4 and 3.7.5)
With the balance and furnace in their intended
final locations, adjust the threaded balance
legs using a spanner until the bubble in the
bubble arm assembly is central and the
balance is level.
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3.7.6 Fig – Insert the balance through the
left side of the furnace with the rear of the
balance towards the front of the furnace
3.7.7 Fig -Using a spanner adjust the legs on
the balance until the indicator on the bubble
arm shows that it is level
3.7.8 Fig – Inserting the balance pan
extension
3.7.9 Fig – Balance pan extension in place
3.7.10 Fig - Fastening the balance pan
extension
3.7.11 Fig - Allen key and screws
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3.7.12 Fig – Checking that the balance pan
legs are central
Open the door lock with the key provided.
Insert the balance pan extension into the
main chamber with the extension legs fitting
through the four holes in the chamber hearth
(Fig- 3.7.8 to 3.7.9). Note that the front edge
of the extension is folded down.
Fasten the balance pan extension to the
balance using the four screws and Allen key
supplied (see Fig- 0 to 3.7.11).
Adjust the balance position so that the balance pan extension legs pass centrally through the
holes in the chamber floor (see Fig 3.7.12); this can be seen from the balance side access
panel (see Fig - 3.7.6).First Loosen the four screws that hold the balance location plate position
balance as described above, once in position re-tighten then tighten the four screws (see Fig
3.7.6).
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3.8.1 Fig - Release clip & swing open the printer
3.8.2 Fig - Squeeze the spindle pins to release
printer roll
3.8.3 Fig - Feed paper through the path shown using the paper feed button
3.8 Installing Printer Paper
The printer is located on the right hand side of the control panel.
Access to the printer for changing the paper is provided by a hinged front panel. Depress the
spring catch on the left hand side of the printer to release the front panel. The paper roll carrier
is mounted on the rear of the printer front panel and will swing out from the main body for ease
of printer paper roll changing (Fig 3.8.2) squeeze the spindle pins to release the roll and its
retaining disc. Replace the printer roll using the paper path shown in
Insert the straight edge of the paper into the slot at the bottom of the front panel and press the
paper feed button at the same time, which will draw the paper through the printer. Close the
printer to continue.
3.9 Calibrating the Internal Balance
After installation or if the ABA has been moved the internal balance must be calibrated (see
section 17.3)
3.10 Connecting an External Balance
As a more accurate alternative to manually entering sample weights the ABA 7-35B can directly
import sample weight values from external balances from Ohaus Explorer models pre 2011
(with monochrome LCD display) and post 2011 with colour interface as well as Adam
Equipment Balances (see section 7.9) for connection details.
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4 Safety Features
In this section the word ‘user’ is to be interpreted as any person with access to or responsibility
for the ABA 7/35B and its ancillary equipment.
4.1 Electric Shock Risk Lamps
Opening the chamber door causes power to the heating elements to be
disconnected at both ends of the circuit.
Any failure of the relays involved in this switching causes one or two red
Electric Shock Risk lamps to illuminate; see section 5.1 and section 5.2.
The user is thereby warned that if, when the door is open, either or both of the electric shock
risk lamps are illuminated, then there is risk of electric shock from the exposed heating
elements. The user should disconnect the equipment from the power supply and correct the
fault (see section 25).
A switch is provided to test that the warning lamps are themselves working; see section 5.1.
The user is responsible for regular checking using the test switch.
4.2 Power Failure Safety Feature
A power failure could occur during a test, leaving an incompletely burnt
sample and a chamber containing explosive or volatile matter. An interruption
of power is normally signalled by the display of the Carbolite logo on the
balance display screen.
On a power failure, the door remains locked, and automatically opens only on restarting and
safe completion of the test.
It may be necessary in some circumstances to bypass the door lock, and a key is provided for
this purpose. Safe use of the key is the user’s responsibility.
4.3 Access to the Plenum Chamber
Soot can accumulate in the airway following the after-burner, giving rise to fire
risk.
The Plenum chamber can be cleaned by first removing the upper panel on
right side of the case. Then Loosen the 6 screws (Do not remove screws) holding the
removable panel of the plenum chamber and remove the panel by sliding it sideways off the
screws to reveal the inside of the plenum chamber. See section 21.4
The user is responsible for maintaining a clean plenum chamber, and also for regular cleaning
of the chimney and the external flue or ducting system.
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4.4 Door Lock Indication ‘Lamps’ on Touchscreen
4.4.1 Screen-view - Top status bar
A ‘door locked lamp’ is shown on the top status bar on the user interface. If the door is locked
then it is illuminated in orange, otherwise it is grey. The user should always check that the ‘door
locked lamp’ is lit when a test is started.
4.5 Maintenance or Dismantling
NOTE: This product contains Refractory Ceramic Fibre (better described as
Alumino Silicate Wool) for precautions and advice in handling this material
see the ‘Maintenance and Repairs’ section 20
The user should disconnect the equipment from the electrical supply before removing panels to
access the electrical connections and control equipment.
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furnace power
switch
printer on/off
switch
safety circuit
test switch
main chamber
heater lamps
USB data port
after burner
heater lamp
5 ABA Operation
This section describes how to heat the chamber up to temperature, and how
the automatic door locking system operates.
5.1 Switches – Control Panel
The main control switches are on the left hand side of the control panel (see Fig 5.1.1).
5.1.1 Fig - Mains switch panel
5.1.2 Fig - Electrical shock warning lights
The ‘furnace switch’ cuts off power to the
controllers, other devices (including the balance)
and heating circuit contactors.
The ‘safety circuit test switch’ is
used to check the operation of
the two red warning lamps
referred to in section 4.1 (see
The heater lamps indicate when the power control relays are on; they flash while the
Figs 5.1.1 and 5.1.2.)
chamber is heating or maintaining temperature. They are also used to diagnose faults – see
section 25.
5.2 Door Operation and Status Display
In previous models ‘door open’ and ‘door locked’ indicator lamps were positioned above the
‘Electric shock risk’ lamps on the upper right front of the furnace. These door status indicators
are now included (see Screen-views 4.4.1 and 5.5.1) in the status bar at the top of the
touchscreen display panel.
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When the door is open power to the main chamber elements are automatically cut off. If a fault
occurs then one or both of the red warning lamps above the door on the left (see Fig 5.1.2) will
light up. These warning lamps should be tested daily by pressing the test switch on the lower
mains switch panel (see Fig 5.1.1) when the door is closed and no test is running.
The door open warning indicator in the header bar of the main menu screen (Screen-View
5.2.1) will appear red if the door is open or the lock is not properly fastened.
5.2.1 Screen-view: Door open warning
The door locked indicator (Screen-view: 5.5.1) shows that the door is locked after a test has
started.
If either or both of the shock risk warning lamps (Fig 5.1.2) light up when the
door is open, do not load or remove a sample. Samples may be removed if
the power is first turned ‘Off’. Contact a Carbolite approved service
engineer immediately.
The door lock is automatically controlled but has an override key, the lock is on
the right hand side of the ABA case. Ensure that the key override has been correctly left in the
‘locked’ position after installation.
If the door lock is unlocked when a test is started the test will fail to start and a continuous
warning tone will be emitted along with a warning screen indicating that “The door has failed to
lock”. The door must be locked before the test can be started.
If the door is unlocked during a test a continuous warning tone will be emitted along with a
warning screen indicating that “The door should be closed and locked immediately”. This
warning should not be ignored; failure to do so may result in serious injury. The test will
continue when the door is once again locked.
Door Lock will operate under the following conditions:
when the ABA is disconnected from the power supply the door is locked
when the illuminated furnace power switch (Fig 5.1.1) is switched on the door normally
unlocks
If however there has been an interruption in a running test, for example by a power cut
or the ABA being switched off, the door lock remains locked when the ABA is once
again switched on. To unlock the door, the test must be cancelled using the test cancel
code (see section 7.7) .
at the start of a test the door locks automatically
at the end of a test the door unlocks automatically
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5.3 General Operating Notes
Heating element life is shortened by use at temperatures close to maximum. Do not leave the
ABA at high temperatures when not required. The maximum temperature for the main chamber
is 750°C (1380°F) and is factory set for the after burner at 900°C (1652°F)
The chimney and should always be correctly fitted and unobstructed (see Fig 3.4.1)
See section 20 for information about maintenance
5.4 Operator Safety
The ABA incorporates a safety switch which interrupts the heating element
circuit when the door is opened. This prevents the user from touching a live
heating element, but also prevents heating up if the door is left open.
When a test is started the door is automatically locked until a constant weight
loss (end-point) is achieved. This is to prevent the user from opening the door whilst volatiles
are being driven off from the test sample. If the door were to be opened during this time the
addition of air could cause the volatile materials to ignite in an explosive manner.
The red sample basket cover must be used to cover the hot sample baskets
whilst they are allowed to cool.
Before removing any hot objects from the chamber make sure that you have a
safe place to put them down. Do not place hot objects on inflammable surfaces.
Wear appropriate safety clothing; gloves, mask and safety glasses are
recommended.
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MF60 – 1.04
Main Menu Button
Reference Section
Temperature
10
System Configuration
6 & factory settings
Balance Menu
17
USB Data Transfer
16
View Test Results
15
Select Access Level
9
View Recipe Library
13
New Standard Recipe
14
New Calibration Recipe
14
Calculate Tray Lift
8
Software Versions
23
Hours of Use
0
5.5 Touchscreen - Main Menu
The main menu is accessed directly from the button in the top left corner of the home screen as
shown in Fig 7.2.1.
Table: 5.5.2 gives a reference to a section of this document where detailed information is given
for each of the buttons on the Main Menu.
5.5.1 Screen-view: Main Menu
5.5.2 Table: Main Menu references
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MF60 – 1.04
System Configuration
Menu Button
Reference Section
General Settings
7.12 & 10.2
Set Date Time
11
Print Settings
12
Diagnostics
24
PID 1 Settings
Factory Set
PID 2 Settings
Factory Set
Voltage Setting
19.1.1
Language Setting
18
Temperature Calibration
20
6 System Configuration Menu
Screen-view: 6.1.1 shows the System Configuration Menu which is accessed via:
Home Screen → Main Menu → System Configuration
Table: 6.1.2 gives a reference to a section of this document where detailed information is given
for each of the buttons on the Configuration Menu.
6.1.1 Screen-view: System Configuration Menu
6.1.2 Table: System Configuration Menu references
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MF60 – 1.04
State
Button Text
Idle
Run Test
Running a Test
Cancel Test
Test Complete
Clear Results
7 Running a Test
7.1 Setup
Before running the test for the first time, ensure the tray lift calculation has been performed as
described in section 8.
Before every test, the weights of the sample tray and sample must be determined as described
in section 7.13.
7.2 Selecting a Recipe
To start a test a recipe must first be created and then selected. Refer to section 14.1 for details
on creating a recipe. To select a recipe go to the Recipe Library by pressing the ‘View Recipe
Library’ button on the Main Menu. Select the required recipe from the displayed list and then
press the ‘Run’ button (see section 13.5). The ‘Home’ screen will then be displayed with the
selected recipe in the recipe name field, the temperature set point from the recipe, and
depending on the recipe type, either the calibration factor or binder % from the recipe will be
displayed as shown in Screen-view: table 7.2.1 . The furnace will heat the main chamber to the
temperature specified in the recipe set point. If the furnace has just been switched on from cold,
it should be allowed to soak at the set point temperature for 30 minutes. The after burner will be
heated to 900°C. Tare balance (see section 17.2), then load the sample and tray. The operator
should check that the pre-requisite test conditions are satisfied before attempting to start the
test, refer to section 7.3. If the conditions are satisfied, the test can be started by pressing the
‘Run Test’ button. Note: the text on this button will change, depending on the state of the
system, as shown in Table 7.2.2.
7.2.1 Screen-view: Home Screen Recipe Settings
7.2.2 Table: Run Test Button Text
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