TROXLER 5850 User Manual

Manual of Operation and Instruction
Model 5850
Gyratory Compactor
NOTE
Before using the Model 5850 Gyratory Compactor, carefully read this manual. It is especially important to understand the Safety Warnings on page 1–2. Keep this manual in a safe place that is always easily accessible during the use of the Model 5850.
Troxler Electronic Laboratories, Inc.
3008 E. Cornwallis Road P.O. Box 12057
Research Triangle Park, NC 27709 U.S.A.
Phone: 1.877.TROXLER
Outside the U.S.A.: +1.919.549.8661
Fax: +1.919.549.0761
www.troxlerlabs.com
Troxler products are protected by U.S. and foreign patents.
Copyright 2009 – 2011
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 photocopying, recording, or information storage and retrieval systems, for any purpose without the express written permission of Troxler Electronic Laboratories, Inc.
Bindoff is a registered trademark of Chemical Solutions, Inc.
Magnalube-G is a registered trademark of Magnalube, Inc.
Superpave is a trademark of the Strategic Highway Research
Program.
PN 116901 April 2012 Edition 2.1
ii
TROXLER SERVICE CENTERS
Troxler Corporate Headquarters
3008 E. Cornwallis Road P.O. Box 12057
Research Triangle Park, NC 27709
Phone: 1.877.TROXLER (1.877.876.9537)
Outside the U.S.A.: +1.919.549.8661
Fax: +1.919.549.0761
Web: www.troxlerlabs.com
Technical Support
Phone: 1.877.TROXLER (1.877.876.9537) E-mail: TroxTechSupport@troxlerlabs.com
NORTH CAROLINA SERVICE CENTER
3008 E. Cornwallis Road Research Triangle Park, NC 27709 Phone: +1.919.549.8661 Fax: +1.919.549.0761 TroxTechSupport@troxlerlabs.com
FLORIDA BRANCH OFFICE & SERVICE CENTER
2376 Forsyth Road Orlando, FL 32807 Phone: +1.407.681.4221 Fax: +1.407.681.3188 TroxTechSupport@troxlerlabs.com
MIDWESTERN BRANCH OFFICE & SERVICE CENTER
1430 Brook Drive Downers Grove, IL 60515 Phone: +1.630.261.9304 Fax: +1.630.261.9341 TroxTechSupport@troxlerlabs.com
WESTERN BRANCH OFFICE & SERVICE CENTER
11300 Sanders Drive, Suite 7 Rancho Cordova, CA 95742 Phone: +1.916.631.0234 Fax: +1.916.631.0541 TroxTechSupport@troxlerlabs.com
SOUTHWESTERN BRANCH OFFICE & SERVICE CENTER
2016 East Randol Mill Road Suite 406 Arlington, TX 76011 Phone: +1.817.275.0571 Fax: +1.817.275.8562 TroxTechSupport@troxlerlabs.com
TROXLER EUROPE & SERVICE CENTER
Troxler Electronics GmbH Gilchinger Strasse 33 D.82239 Alling nr. Munich, Germany Phone: ++ 49.8141.71063 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
To locate an independent, Troxler-authorized service partner near you, call 1.877.TROXLER (1.877.876.9537).
Model 5850 iii
NOTE
ABOUT THIS MANUAL
The Model 5850 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 5850 – Provides
information on the safe use of the compactor; a brief overview of the compactor and its features; a list of parts and accessories; and instructions for unpacking and inspection.
Chapter 2, Setup and Operation – Describes the compactor
keypad, and provides instructions for setting up, starting, and operating the compactor.
Chapter 3, Setup Menu Provides a detailed description of the
options available from the compactor’s Setup menu.
Chapter 4, Calibration and Verification – Includes instructions
for calibrating the compactor and verifying its calibration.
Chapter 5, Special Functions Describes the functions available
from the compactor’s Special menu.
Appendix A, Troubleshooting and Service – Provides
maintenance and service information, as well as instructions on basic troubleshooting.
Appendix B, Menu Map Shows a map of the compactor’s Setup
menu.
Appendix C, Specifications – Contains the environmental,
performance, electrical, and mechanical specifications of the compactor.
iv
HOW TO USE THIS MANUAL
Congratulations on the purchase of the Model 5850 Gyratory Compactor.
The Model 5850 Manual of Operation and Instruction contains information on safely using this unit. Also included in this manual are safety warnings, basic parameter setup, system troubleshooting, and general maintenance.
Do not attempt to operate the Model 5850 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 5850. The manufacturer, its subsidiary, representatives, and distributors cannot assume responsibility for any mishaps, damage, or personal injury that may occur from failure to observe the safety warnings in this manual and posted on the unit.
Model 5850 v
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.
NOTE
Notes indicate important information that must be read to ensure proper operation.
KEY Angle brackets and a different typestyle indicate a
key or character (number or letter) to press on the
compactor keypad. For example, “Press START
means to press the key labeled START.
DISPLAY A different typestyle is used in text to indicate
information or messages displayed on the compactor.
DISPLAY- Typestyle and shading used to simulate the control panel display
Numbers indicate a procedure with multiple steps.
11..
Diamonds indicate a list of things needed (such as
equipment) or things to know.
Triangles indicate that more than one option is
available. Carefully select the option that applies.
vi
TABLE OF CONTENTS
CHAPTER 1. INTRODUCTION TO THE MODEL 5850
Safety Warnings ............................................................................ 1–2
Cautions and Warnings ................................................................. 1–3
Introduction ................................................................................... 1–4
Parts and Accessories.................................................................... 1–8
Inspection ...................................................................................... 1–9
Unpacking ................................................................................... 1–10
Site Selection .............................................................................. 1–11
Assembly .................................................................................... 1–12
CHAPTER 2. SETUP AND OPERATION
Control Panel ................................................................................ 2–2
Turning the System On ................................................................. 2–4
Compacting a Specimen ............................................................... 2–7
Cleaning and Lubricating.............................................................. 2–8
Preparing a Specimen ................................................................. 2–10
Compacting the Specimen .......................................................... 2–12
Shear Options & Performance Tests ........................................... 2–13
CHAPTER 3. SETUP MENU
Setup Menu ................................................................................... 3–2
View Settings ................................................................................ 3–3
Change Settings ............................................................................ 3–4
Home Position ............................................................................ 3–13
Calibration .................................................................................. 3–13
Special......................................................................................... 3–13
CHAPTER 4. CALIBRATION
Angle Verification ........................................................................ 4–3
Calibration .................................................................................... 4–5
Model 5850 vii
CHAPTER 5. SPECIAL FUNCTIONS
Special Menu ................................................................................. 5–2
Clock/Calendar .............................................................................. 5–3
Erase Records ................................................................................ 5–6
Reset Software ............................................................................... 5–7
APPENDIX A. TROUBLESHOOTIGN AND SERVICE
Troubleshooting.............................................................................A-2
General Maintenance Schedule .....................................................A-4
Replacing the Batteries ..................................................................A-7
Replacement Parts .........................................................................A-8
Returning Parts for Service ...........................................................A-9
APPENDIX B. MENU MAP
Menu Map Description .................................................................. B-2
APPENDIX C. SPECIFICATIONS
Environmental Conditions ............................................................. C-2
Electrical Specifications ................................................................ C-3
Mechanical Specifications ............................................................. C-4
INDEX
WARRANTY
viii
LIST OF FIGURES
Figure Title Page
Figure 1–1. Model 5850 Gyratory Compactor ............................. 1–7
Figure 1–2. Hydraulic Reservoir ................................................ 1–12
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 5850 Control Panel Layout ............................ 2–3
Figure 2–2. Compaction Chamber ................................................ 2–9
Figure 2–3. Loading the Mold .................................................... 2–11
Figure 3–1. Sample Height Versus Gyration Table .................... 3–12
Figure 4–1. Aligning the Internal Angle Device Probes ............... 4–3
Figure 4–2. Puck Centered on Lower Carriage Plate ................... 4–7
Figure 4–3. Routing Load Cell Cables ......................................... 4–8
Figure A–1. Hydraulic Filter Bypass Indicator............................. A-6
Figure B–1. Model 5850 Menu Map ............................................ B-3
Model 5850 ix
LIST OF TABLES
Table Title Page
2–1 Control Panel Keys and Button ................................. 2–2
x
1. INTRODUCTION
CHAPTER 1
INTRODUCTION TO THE MODEL 5850
The Model 5850 is Troxler’s newest Superpave™ Gyratory Compactor and the most advanced, easiest to use gyratory compactor on the market today. This chapter introduces the Model 5850 and provides information on operating the compactor safely. This chapter also includes a list of parts and accessories, and instructions for unpacking and inspecting the system.
CONTENTS
Safety Warnings ............................................................................ 1–2
Cautions and Warnings ................................................................. 1–3
Introduction ................................................................................... 1–4
Safe Operation ........................................................................ 1–4
Ease of Operation ................................................................... 1–5
Performance Tests and Shear Options .................................. 2–13
Care and Maintenance ............................................................ 1–6
Parts and Accessories.................................................................... 1–7
Inspection ...................................................................................... 1–9
Unpacking ................................................................................... 1–10
Site Selection .............................................................................. 1–11
Assembly .................................................................................... 1–12
Model 5850 1–1
SAFETY WARNINGS
The Troxler Model 5850 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. Thus, if a particular use is not specifically mentioned in this manual as authorized, then consult Troxler about the alternate use. Otherwise, it is assumed that the use is unauthorized and improper.
To ensure minimal operator risk, Troxler recommends the following safety precautions:
Wear safety glasses when preparing an asphalt specimen. Always wear heat-resistant gloves when handling any hot
substance.
When moving the mold, grasp it firmly on either side under the
top flange.
Remove all objects, except the mold and asphalt specimen, from
the compaction chamber before pressing the START key.
Do not operate the compactor with the chamber door or any
panels removed.
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.
1–2
1. INTRODUCTION
CAUTIONS AND WARNINGS
Identification of Interconnects:
Lower Left Side of Compactor
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 5850 1–3
INTRODUCTION
The Troxler Model 5850 Superpave Gyratory Compactor provides compaction of asphalt specimens at a given pressure, angle, and number of gyrations. The Model 5850 meets or exceeds all Federal Highway Administration (FHWA) Superpave specifications.
The Model 5850 Gyratory Compactor provides safe, reliable gyratory compaction of asphalt specimens using a compaction pressure and gyration angle selected by the operator. The method of specimen compaction is crucial to creating asphalt specimens that behave similar to asphalt used in construction and in obtaining meaningful test results.
Building upon the successes of Troxler’s Model 4140 and 4141
Gyratory Compactors, the Model 5850 has been completely redesigned with improved electronics, a robust compaction system, and software-adjustable angle of gyration. The durable Model 5850 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. An interlock switch prevents the gyratory compactor from operating with the compaction chamber door open. The red EMERGENCY safety switch located at the bottom of the control panel stops all moving parts.
WARNING
Do not operate the Model 5850 Gyratory Compactor with the chamber door or any panels removed.
1–4
1. INTRODUCTION
EASE OF OPERATION
The Model 5850 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.
As selected by the operator, the Model 5850 provides a compaction pressure of 200 to 1000 kPa and an angle of gyration between 0.00 and 1.50 degrees. Angle and pressure adjustments can be performed quickly and easily using the keypad.
For ease of operation, the Model 5850 provides a fully automatic method of compaction. The Model 5850 compacts an asphalt specimen at the touch of a single key.
NOTE
Do not attempt to operate the Model 5850 before
reading this manual and the safety warnings posted on
the unit. Troxler stresses that the operator is solely
responsible for ensuring the safe use of the Model 5850.
The manufacturer, its subsidiaries, distributors, or
representatives cannot assume responsibility for any
mishaps, damage, or personal injury which may occur
from failure to observe the safety warnings in this
manual and posted on the unit.
The Model 5850 can be equipped with 150-mm, 100-mm, or 4-inch diameter molds, and can compact specimens with heights of up to 185 mm.
The Model 5850 features USB and serial ports for transferring data to USB or serial devices. The operator may choose to automatically send the compaction data to a computer, printer, or USB device upon completion of a compaction cycle.
NOTE
A list of USB memory devices and printers that are
compatible with the Model 5850 Gyratory Compactor is
available on the 5850 product page of the Troxler
website (www.troxlerlabs.com).
Model 5850 1–5
The Model 5850 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.
CARE AND MAINTENANCE
The Model 5850 requires little maintenance. To reduce the effects of gyration on moving parts, the gyratory compactor requires regular cleaning and lubrication. For a schedule of machine maintenance, refer to Appendix A.
1–6
1. INTRODUCTION
CHAMBER
DOOR
(IN OPEN
POSITION)
KEYPAD
DISPLAY
EMERGENCY
STOP SWITCH
SERIAL & USB
PORTS
AC POWER
INLET
POWER
SWITCH
MOLD
Figure 1–1. Model 5850 Gyratory Compactor
Model 5850 1–7
PARTS AND ACCESSORIES
The Model 5850 includes the electrical and mechanical parts required to continuously compact hot-mix asphalt. Use Figure 1–1 to locate and identify the following parts:
The power switch is located on the left side of the compactor. The emergency stop switch stops all machine movement. The keypad and display provide the interface. The mold with the lower puck inserted receives the asphalt for
making specimens. Troxler offers molds with inside diameters of 150 mm, 100 mm, and 4 inches. (Part numbers 116066 and
116069)
The USB and serial ports enable the operator to print or
download data to a USB or serial device.
The USB cable (not shown) connects the compactor to the
printer or other USB device. (Part number 110697)
The serial cable (not shown) connects the compactor to a serial
device, such as a computer. (Part number 106514)
The gravity extruder (not shown) is used to remove a
compacted specimen from the mold. (Part number 110665)
The height standard assembly (not shown) is used to calibrate
the specimen height. (Part number 106989)
The Model 5850 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)
The specimen papers (not shown) prevent the asphalt specimen
from sticking to the puck and ram head. (Part number 106953)
The optional Pressure Verification Kit (not shown) allows the
operator to verify the pressure calibration. The pressure is initially calibrated at the factory. (Part number 108706)
1–8
1. INTRODUCTION
INSPECTION
Upon receiving the Model 5850 Gyratory Compactor from the factory, perform a complete inspection and inventory as described below.
Check to see that the following are included:
Model 5850 Gyratory Compactor Mold Power cord Height standard assembly Specimen papers (500 per package) Printer USB cable Serial cable Manual of Operation and Instruction Gravity extruder
Inspect each part for damage that may have occurred during shipment. If any parts or accessories appear damaged, notify the carrier and your Troxler representative immediately.
Model 5850 1–9
UNPACKING
WARNING
The Model 5850 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.
To remove the shipping carton from the top of the unit, cut each
11..
side of the carton approximately 2 inches above the pallet. Lift the carton up and off the unit.
Remove the metal strap and bolts that secure the compactor
22..
to the pallet.
Remove the two brackets that secure the front casters in
33..
place. The compactor is now free to roll on the pallet.
WARNING
To prevent personal injury or equipment damage, do not tip the compactor while lifting it from the pallet.
Using a forklift, lift the compactor from the pallet.
44..
CAUTION
When using a forklift, lift the compactor from the side to prevent equipment damage.
1–10
1. INTRODUCTION
SITE SELECTION
After unpacking and inspecting the compactor as described in the previous sections, select a suitable site for installation. Apply the following criteria in selecting the installation site:
Place the compactor on a flat, level location. Locate the compactor no more than 1.2 m (4 ft) from the
required electrical power source (see Appendix C). Ensure that
the distance does not place stress on the power cord. The power
source must be wired by a qualified electrician. 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 5850 1–11
RESERVOIR
FILL CAP
FILL LEVEL
SIGHT GLASS
ASSEMBLY
The hydraulic reservoir is filled with a premium quality, light
11..
grade (ISO VG 32, SAE 10) hydraulic oil prior to shipping. Before using the compactor, check the oil level as follows:
Remove the rear service panel from the compactor.
aa..
Locate the fill level sight glass as shown in Figure 1–2.
bb..
NOTE
Use only a light grade (ISO VG 32, SAE 10, Troxler part number 018203) hydraulic oil to fill the hydraulic reservoir.
Ensure that the oil level is at the 30-degree mark on the sight
22..
glass, as shown in Figure 1–3. If oil is needed:
Remove the reservoir fill cap (see Figure 1–2) and place a
aa..
funnel into the fill tube as shown in Figure 1–4.
Add oil until the level is at the 30-degree mark.
bb..
Remove the funnel and replace the reservoir fill cap.
cc..
Re-install the rear service panel.
dd..
1–12
Figure 1–2. Hydraulic Reservoir
1. INTRODUCTION
ENSURE
FLUID LEVEL
IS AT 30-DEGREE
MARK
FUNNEL
Figure 1–3. Proper Reservoir Fill Level
Figure 1–4. Place a Funnel in Reservoir Fill Tube
Model 5850 1–13
Following the site selection guidelines in the previous section,
33..
set the compactor in place.
Lock the casters so that the unit remains in place.
44..
Plug the ac power cord into the ac power inlet on the
55..
compactor’s lower left panel (see Figure 11 on page 1–7).
Connect the ac power cord to the required ac power source
66..
(refer to Appendix C).
NOTE
On 240 VAC units, a connector must be installed on the ac power cord. The connector must meet local safety and electrical code requirements. Refer to the Electrical Specifications section on page C–3 for the current and voltage ratings for the compactor.
If using the compactor with a USB printer or memory device,
77..
connect the device to the USB port located on the upper left side of the compactor (see Figure 1–1 on page 1–7).
NOTE
A list of USB memory devices and printers that are compatible with the Model 5850 Gyratory Compactor is available on the 5850 product page of the Troxler website (www.troxlerlabs.com).
If using the compactor with a computer, use a serial cable to
88..
connect the computer to the serial port located on the upper left side of the compactor (see Figure 1–1 on page 1–7).
1–14
2. SETUP & OPERATION
CHAPTER 2
SETUP AND OPERATION
This chapter describes how to get started using the Model 5850 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.
CONTENTS
Control Panel ................................................................................ 2–2
Turning the System On ................................................................. 2–4
First Time Setup ..................................................................... 2–4
Compacting a Specimen ............................................................... 2–7
Cleaning and Lubricating.............................................................. 2–8
Preparing a Specimen ................................................................. 2–10
Compacting the Specimen .......................................................... 2–12
Model 5850 2–1
KEY
FUNCTION
EMERGENCY
Stops all machine movement. To release the button, rotate it clockwise.
START
Begins automatic compaction of asphalt specimen.
SETUP
Accesses the Setup functions. These include setting or viewing the run options, setting the data output options, calibrating the compactor, verifying the calibration, and clearing project data.
ESC
Returns to the next higher-level menu without updating or storing data. In response to Yes/No questions, it has the same effect as pressing NO/CE. During gyration, it aborts the compaction cycle.
YES
Responds Yes to Yes/No questions.
NO/CE
Responds No to Yes/No questions. Also clears an incorrect entry and allows for re­entry.
 
Scrolls through menu options or views screens.
0...9
Enters numeric values.
.
Enters a decimal point.
ENTER
Enters data or views screens.
CONTROL PANEL
Figure 2–1 shows the layout of the Model 5850 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
2–2
2. SETUP & OPERATION
Figure 2–1. Model 5850 Control Panel Layout
Model 5850 2–3
TURNING THE SYSTEM ON
NOTE
Control panel screens in this manual are intended as examples only. Values on your displays may differ slightly from those shown.
The power switch is located on the left side panel of the compactor (see Figure 1–1). After the compactor is turned on, it briefly displays the model and software version number, then performs a series of brief self-tests. After self-tests are completed, the compactor displays the Machine Idle screen shown below:
-Machine Idle­04-08-2008 11:02 AM G:100 AI:1.16 P:600
Press <START>
Where:
G = Operator-selected number of gyrations (this value is
999 if the compactor is set to compact to a target specimen height)
AI = Operator-selected internal angle of gyration P = Operator-selected compaction pressure
FIRST TIME SETUP
The Model 5850 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. To change the date, time, or display format, refer to page 5–3.
The Model 5850 provides a number of operator-definable options that control its operation. From the Setup menu, the operator can:
Select whether the compactor will run for a specified number of
gyrations (from 1 to 999) or until the specimen has been compacted to a specified height (50 to 200 mm). Then define the desired ram pressure (200 to 1000 kPa)
Set the desired gyration angle (0.00 to 1.50 degrees)
2–4
2. SETUP & OPERATION
Before using the compactor for the first time, ensure that these options are set properly. Press SETUP on the keypad to access the Setup menu:
-Setup-
1- View Settings 2- Change Settings 3- Data Output
Press 1 to access the View Settings selection. The compactor displays:
Selected run count (number of gyrations) Selected mode (number of gyrations or specimen height) Specimen height Gyration angle Ram pressure Mold diameter Gyrate Delay
Refer to Chapter 3 for instructions on changing any of these selections.
The Model 5850 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.
NOTE
A list of compatible USB memory devices and printers is available on the 5850 product page on Troxler’s website at www.troxlerlabs.com.
Model 5850 2–5
The output data can be formatted either in a height-versus-gyration table format or in a full table format which includes the height, ram pressure, gyration angle, and gyration rate for each gyration.
To automatically output gyration versus height data, connect the compactor to the computer or printer and turn on the Auto Output option as described on page 3–10.
NOTE
Before outputting data to a printer or computer, ensure that the Model 5850 is properly connected to the output device.
2–6
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