Ncat 1087 Manual

BARNSTEAD|THERMOLYNE CORPORATION
NCAT Asphalt Content Tester

OPERATION MANUAL
AND PARTS LIST
Series 1087
Model No.
Phase
Voltage
Watts
Amps
F85930
220-240
4879/6379
20/27
F585938
208
5757
28
F85930-33
220-240
4879/6379
20/27
45-3790/01
220-240
4879/6379
20/27
45-3790/07
208
5757
28
Rev. G Software
LT1087X2 8/23/00
Table of Contents
Safety Information .............................................................................................................................................. 4
Alert Signals ....................................................................................................................................................... 4
Warnings ............................................................................................................................................................ 4
Introduction ........................................................................................................................................................ 6
Intended Use ...................................................................................................................................................... 6
General Usage ................................................................................................................................................... 6
Software Updates............................................................................................................................................... 6
Theory of Operation ........................................................................................................................................... 7
General Specifications ....................................................................................................................................... 8
Environmental Conditions .................................................................................................................................. 9
Declaration of Conformity .................................................................................................................................. 9
Unpacking ........................................................................................................................................................ 10
Contents of Carton ........................................................................................................................................... 11
Installation ........................................................................................................................................................ 12
Site Selection ................................................................................................................................................... 12
Electrical Connections ...................................................................................................................................... 13
Exhaust Installation Tips .................................................................................................................................. 14
Balance Installation .......................................................................................................................................... 15
Balance Assembly ............................................................................................................................................ 15
Setra Balance Operating Instructions When Used in Type F85900 NCAT Furnaces ...................................... 18
Balance Control Ports ...................................................................................................................................... 18
The Balance Default Settings When Used in the Type F85900 NCAT Furnace .............................................. 18
To Set the Time and Date Settings ................................................................................................................... 18
To Set the Time ................................................................................................................................................ 19
To set the Date ................................................................................................................................................. 19
To Span Calibrate the Balance ........................................................................................................................ 20
To Set Factory Defaults .................................................................................................................................... 21
To Escape Configuration Menu ........................................................................................................................ 22
Lift Test Procedures ......................................................................................................................................... 22
Printer Operation .............................................................................................................................................. 23
Printer Access .................................................................................................................................................. 24
Paper Advance Button ..................................................................................................................................... 24
Paper Tape Rolls .............................................................................................................................................. 24
Conserving Paper ............................................................................................................................................ 24
Paper Tape Roll Installation ............................................................................................................................. 25
Printer Record Storage .................................................................................................................................... 26
Operation ......................................................................................................................................................... 27
Displays ........................................................................................................................................................... 27
Controls ............................................................................................................................................................ 27
To Change the Setpoint Temperature .............................................................................................................. 28
To Change The Initial Sample Weight .............................................................................................................. 28
To Change the Calibration Factor .................................................................................................................... 28
To Tare the Balance ......................................................................................................................................... 29
Outline of Operational Procedures ................................................................................................................... 29
Timer Mode ...................................................................................................................................................... 31
Programmable Timer ....................................................................................................................................... 31
Programming the Timer .................................................................................................................................... 31
2
Inactivity Mode ................................................................................................................................................. 31

Interrupting the Timer Mode ............................................................................................................................. 32
Methodology and Test Tips .............................................................................................................................. 33
Software Features ............................................................................................................................................ 35
Equations Used to Determine Bitumen Ratio ................................................................................................... 35
Test Interrupt/Power Interrupt ........................................................................................................................... 35
Auto Shutdown Mode ....................................................................................................................................... 36
Positive Calibration Factor ............................................................................................................................... 36
Stability Threshold ............................................................................................................................................ 36
Serial Port Output/Operation ............................................................................................................................ 37
Sample Data Output ......................................................................................................................................... 37
Description of Sample Data ............................................................................................................................. 38
Explanation of Error Codes .............................................................................................................................. 39
Furnace Error Codes ........................................................................................................................................ 39
Setra Balance Error Codes .............................................................................................................................. 40
Hidden Key Routines ....................................................................................................................................... 41
Preventative Maintenance and Servicing ......................................................................................................... 49
Element Plate Construction Use & Care .......................................................................................................... 49
To Replace a Chamber Heating Element ......................................................................................................... 50
To Replace a Filter Heating Element ................................................................................................................ 51
To Replace a Type K Chamber Thermocouple ................................................................................................ 52
To Replace a Solid State Relay ........................................................................................................................ 53
To Replace a Fuse ........................................................................................................................................... 55
To Realign Door Switch (Microswitch) .............................................................................................................. 56
To Realign Door Lock ....................................................................................................................................... 56
Replacement Parts ........................................................................................................................................... 57
Exploded View (Insulation and Filter) ............................................................................................................... 59
Exploded View (Elements) ............................................................................................................................... 60
Ordering Procedures ........................................................................................................................................ 61
Decontamination Statement ............................................................................................................................. 61
Wiring Diagram ................................................................................................................................................ 62
Wiring Diagram Component List ...................................................................................................................... 63
Amperage Configurations ................................................................................................................................ 64
Glossary ........................................................................................................................................................... 65
One Year Limited Warranty .............................................................................................................................. 68
This manual contains important operating and safety

information. You must carefully read and understand the
contents of this manual prior to using this equipment.
Alert Signals
Warning
Warnings alert you to a possibility of
personal injury.
Your NCAT Asphalt Content Tester has been designed with

function, reliability and safety in mind. It is your responsibility
to install it in conformance with local electrical codes. For safe
operation, please pay attention to the alert signals throughout
the manual.
Warnings
To avoid electrical shock:
Caution
Cautions alert you to a possibility of
damage to the equipment.
Note
Notes alert you to pertinent facts and
conditions.
Hot Surface
Hot surfaces alert you to a possibility
of personal injury if you come in
contact with a surface during use or
for a period of time after use.
1.
This furnace must be installed by a competent,

qualified electrician who ensures compatibility
among furnace specifications, power source and
servicing.
2.
Disconnect from power supply before servicing.
3.
Ensure that the furnace is not connected to the

power supply prior to installing or removing the
balance.
4.
Ensure that the door switch is operating properly.
To avoid burns:
1. Do not touch the exterior or interior surfaces of the
chamber or exhaust area when chamber is hot.
Hot Surface. Avoid Contact with Chamber Area.
To avoid personal injury:
Warning
Barnstead/Thermolyne does not
condone the use of this product for the
purpose of cleaning glassware, such as
rolling thin film oven bottles. Prior to
ignition, the asphalt in these bottles will
liquify and may flow into the lower
control section of this product, causing
severe damage or fire.
1.
Do not use in the presence of flammable or

combustible materials, including cutback asphalts;
fire or explosion may result. This device contains
components which may ignite such material.
2.
Refer servicing to qualified personnel.
3.
Allow the furnace to cool to room temperature

before performing any maintenance or servicing.
4.
Failure to connect the exhaust port to an

appropriate exhaust system will result in smoke
and gases entering the work area. Without the
connection, gases and smoke will escape from the
furnace.
SAFETY INFORMATION
5.
This furnace contains refractory ceramic

insulation which can produce respirable fibers
and dust when handled. These fibers can cause
irritation and can aggravate preexisting
respiratory disease. The International Agency for
Research on Cancer (IARC) has classified
refractory ceramic fiber as possibly carcinogenic.
After service refractory ceramic fiber dust may
contain crystalline silica, which may cause lung
damage (silicosis) and which has been classified
by IARC as a carcinogen.
Warning
Warning
This warning is presented for compliance with California

Proposition 65 and other regulatory agencies and only
applies to the insulation in this product. This product
contains refractory ceramic, refractory ceramic fiber or
fiberglass insulation, which can produce respirable dust or
fibers during disassembly. Dust or fibers can cause irritation
and can aggravate preexisting respiratory diseases.
Refractory ceramic and refractory ceramic fibers (after
reaching 1000C) contain crystalline silica, which can cause
lung damage (silicosis). The International Agency for
Research on Cancer (IARC) has classified refractory
ceramic fiber and fiberglass as possibly carcinogenic
(Group 2B), and crystalline silica as carcinogenic to humans
(Group 1).
The insulating materials can be located in the door, the
hearth collar, in the chamber of the product or under the hot
plate top. Tests performed by the manufacturer indicate that
there is no risk of exposure to dust or respirable fibers
resulting from operation of this product under normal
conditions. However, there may be a risk of exposure to
respirable dust or fibers when repairing or maintaining the
insulating materials, or when otherwise disturbing them in a
manner which causes release of dust or fibers. By using
proper handling procedures and protective equipment you
can work safely with these insulating materials and
minimize any exposure. Refer to the appropriate Material
Safety Data Sheets (MSDS) for information regarding
proper handling and recommended protective equipment.
For additional MSDS copies, or additional information
concerning the handling of refractory ceramic products,
please contact the Customer Service Department at
Barnstead|Thermolyne Corporation at 1-800-553-0039.
5
Introduction
Congratulations on your purchase of a
Barnstead|Thermolyne NCAT Asphalt Content Tester.
Introduction
The unit is designed to perform a specific test within your
laboratory. Please read the instructions carefully to ensure
that you receive maximum benefit from it. Also, be sure to
fill out and return the enclosed warranty registration card.
We would like to receive the information requested, and it
will help us assure you of proper warranty coverage.
Intended Use
The NCAT Asphalt Content Tester is an analyzer which
determines the asphalt content of a sample by loss on
ignition per standard methods. The asphalt sample is
bathed in oxygenated air and weighed continuously
throughout the ignition procedure. The NCAT Asphalt
Content Testers software identifies the endpoint of ignition
and indicates the completion of the test. Results are
documented by a printer.
General Usage
Do not use this product for anything other than its intended
usage.
Software Updates
Software improvements are initiated based on market
feedback. Currently your tester contains Revision G
software. You will be notified by your sales representative,
distributor or Barnstead|Thermolyne as a software
improvement becomes available. A software packet
includes installation instructions, operational data and an
EPROM. The EPROM is easy to install and can be installed
within a few minutes.
INTRODUCTION
Theory of Operation
The furnace is heated to a setpoint temperature within
the range of 450 - 550C.
The hot mix asphalt sample is weighed, equally divided
and placed in two screened baskets which are mounted
on a tray assembly. This complete assembly is placed on
the furnace hearth tray. The hearth tray is mounted on
four ceramic support tubes, which are in turn mounted on
a digital balance platform. A blower draws ambient air
through the four ceramic tube support openings located
on the chamber floor. This oxygenated air saturates the
spread asphalt sample to promote ignition and ashing.
The released volatiles are further oxidized while passing
through a ceramic filter heated to 750C in a chamber
above the main chamber. Five air exit ports direct the
exhausted air to a louvered plenum. The exhaust is then
cooled by mixing with ambient air. The blower then
directs the exhaust through the plenum exhaust port.
Standard seamless exhaust tubing directs the exhaust to
an outside exhaust system.
General Specifications
Model
F85930-33, F85940-33,
45-3790/07, F85948,
45-3790/01, F85930 (240 V) F85938 (208V)

Overall Dimensions
IN. (CM)
Width
Height
Depth
Chamber Dimensions
Width
IN. (CM)
Height
Depth
Weight
Lbs. (KG)
Electrical Ratings
Volts
Amps
Watts
Freq.
Phase
Chamber Temperature Ratings*
Max. Sample Cap.
Max. Operating
Temp.
Maximum Program
Run Time
Allowable Values for
Selected Functions
Default Values for

Selected Functions
Chamber
Filter
Chamber Set point

Filter Set point
Sample Weight
Correction Factor
Wake up Time
Wake up Date
Inactivity Check
Auto Shut down
Beeper
Serial Port Output
Chamber Calibration
Offset
Test Stability
Threshold
Intermediate Printing
(Internal Printer)
Chamber Set point
Filter Set point
Sample Weight
Correction Factor
Wake up Time
Wake up Date
Inactivity Check
Auto Shut down
Beeper
Serial Port Output
Chamber Calibration
21.375 (54.29)
40.500 (102.87)
25.625 (65.09)
14.000 (35.56)
14.000 (35.56)
14.000 (35.56)
302 (137)
220-240
20/27
4879/6379
50/60
1
100C-650C
5 kilograms of
asphalt sample.
650C
900C
21.375 (54.29)
40.500 (102.87)
25.625 (65.09)
14.000 (35.56)
14.000 (35.56)
14.000 (35.56)
302 (137)
208
28
5757
50/60
1
100C-650C
255 minutes
100C-650C
0C-900C
100g-5000g
0.00-99.99
0:00-24:00
0.00 - 12.31
On/Off
On/Off
On/Off
Continuous/Test Only
255 minutes
100C-650C
0C-900C
100g-5000g
0.00-99.99
0:00-24.00
0.00 - 12.31
On/Off
On/Off
On/Off
Continuous/Test Only
+50 to -50
+50 to -50
0.01-0.5%
0.01-0.5%
On/Off
538C
750C
1200g
0.00
5:00
0.00
On
On
On
Continuous
On/Off
538C
750C
1200g
0.00
5:00
0.00
On
On
On
Continuous
650C
900C
GENERAL SPECIFICATIONS
Offset
Test Stability
Threshold
Intermediate Printing
(Internal Printer)
0C
0C
0.01%
0.01%
On
On
* Maximum temperature can be achieved at the maximum line voltage specified on the Specification Plate.
Environmental Conditions
Operating: 17C - 27C; 20% - 80% relative humidity, non-condensing. Installation Category II (overvoltage) in
accordance with IEC 664. Pollution Degree 2 in accordance with IEC 664.
Altitude limit: 2,000 meters.
Storage: -25C - 65C; 10% - 85% relative humidity.
Declaration of Conformity(-33 models only)

Barnstead/Thermolyne hereby declares under its sole responsibility that the model 45-3790/01 (F85940-33)
conforms with the technical requirements of the following standards:
EMC:
EN 50081-1
EN 50082-1
EN 61326
Generic Emission Standard

Generic Immunity Standard
Electrical equipment for measurement, control and laboratory use EMC requirements - Part I: General Requirements.
Safety:
EN 61010-1-92
Safety requirements for electrical equipment for measurement, control

and laboratory use; Part I: General Requirements
EN 61010-2-010
Part II: Particular requirements for laboratory equipment for

the heating of materials
per the provisions of the Electromagnetic Compatibility Directive 89/336/EEC, as amended by 93/68/EEC, and
per the provisions of the Low Voltage Directive 73/23/EEC, as amended by 93/68/EEC.
The authorized representative located within the European Community is:
Electrothermal Engineering, Inc.
419 Sutton Road
Southend On Sea
Essex SS2 5PH
United Kingdom
Copies of the Declaration of Conformity are available upon request.
Unpacking
Unpacking
1.
Visually check for any physical damage to the

shipping container. Remove the furnace from the
shipping container. Inspect the equipment
surfaces that are adjacent to any damaged area
of the shipping container. Retain damaged
packing material. File claim with the delivery
carrier if damage is incurred.
2.
Open the furnace door and carefully remove

packing material from inside the furnace
chamber. Remove the screws (4) securing the
front display panel. Open the front display panel.
Vacuum the chamber and the balance support
plate (beneath the chamber) prior to use to
remove the insulation dust which may have
accumulated during shipment. Wear a dust mask
and gloves while cleaning.
3.
Remove the balance, ceramic posts, fuses,

manual and hearth tray from the shipping
container.
4.
Retain the original packaging material if

reshipment is foreseen or required for mobile lab
use.
Note
The NCAT Asphalt Content Tester
does not come with a power cord. The
furnace has the capability of being
hard wired or having a power cord
attached depending on your local
electrical code requirements.
Allow adequate work area and bench space for loading and
unloading. Locate the cooling plate alongside the furnace to
allow for convenient transport of hot loads.
10
Contents of Carton
Each palletized furnace carton contains:
1
Asphalt Content Tester
1
Electronic Balance
Hearth tray, gray silicon carbide
Ceramic tube supports, Inside Furnace Chamber
Instruction Manual, Inside Furnace Chamber
Replacement Fuses
Accessory Kit Contents

Part # AY1087X1
Two basket assemblies consisting of:
2
Basket Retainer Brackets
Transport and Catch Trays
Top Baskets
Bottom Baskets
Covers for Top Baskets
Transport Handle
Aluminum Cooldown Plate
Cooldown Safety Cage with HOT Sign
Face Shield with Head gear
Pair High Temperature Gloves
Can of Fan Motor Lubricant
Stainless Steel Basket Brush
Rolls of Thermal Printer Paper
Optional purchase:
1
Length of exhaust tubing (3" I.D. x 10', shipped

in a separate carton), part # TU859X1
11
Installation
Site Selection
Caution
Be sure ambient temperature does not
exceed 40C (104F). Ambients above
this level may result in damage to or
malfunction of the controller.
Allow at least 6 inches of space
between the furnace and any vertical
surface. This permits the heat from
furnace case to escape so as not to
create a possible fire hazard.
Hot Surface
Do not install above or near
flammables.
12
Place the furnace on a sturdy level surface about 26-28

inches high and capable of supporting the weight of the fully
assembled furnace. Furnace must be placed on a level
surface to permit door to safely swing and remain open for
loading and unloading. Allow space for air flow around the
furnace (6" minimum). Locate the furnace so you can direct
the furnaces emissions through ducting to a fume hood or
other appropriate ventilation system. We recommend an
exhaust length of not more than 10 feet, if possible.
Leveling feet are adjustable. The furnace should be leveled
so the door will remain open.
INSTALLATION
Electrical Connections
Warning
To avoid electrical shock, this furnace
must be installed by a competent,
qualified electrician who ensures
compatibility among furnace
specifications, power source and
ground code requirements.
Caution
For supply connections, use 10 AWG
or larger wires suitable for at least
90C. Failure to observe this caution
could result in damage to furnace and/
or work area.
Note
Do not operate the 220-240 volt NCAT
Asphalt Content Tester on 208 volts.
Your test results will be negatively
affected by the lower voltage. Consult
with your supplier if this is the case.
The electrical specifications are:

Volts
220-240
208
Amps
20/27
28
Watts
4879/6379
5757
Hertz
50/60
50/60
Your furnace is factory configured for a 27 amp supply. You

have the option of re-configuring the wiring at the back of
the furnace for 20 amps. Please see page 64. Typically, a
20 amp configuration is used for mobile laboratory
installations or if your supply is only rated for 20 amps.
Prior to connecting your asphalt testing furnace to your
electrical supply, be sure the front power switch and rear
circuit breaker are in the OFF position.
The power supply entry is located at the right rear of the
lower case (as you face the rear of the unit). A terminal
block is located behind an access plate. Remove the six
screws retaining the plate covering the terminal connection
block. The line and ground connections to the terminal
block are depicted in Figure 2.
Your NCAT Asphalt Content Tester may be wired either
directly through a conduit system or by using a power cord
and plug. Electrical wiring should conform to your local
electrical code requirements.
Figure 2 Terminal Block Connections

13
INSTALLATION
Exhaust Installation Tips

Warning
Failure to connect the exhaust port to
an appropriate exhaust system will
result in smoke and gases entering the
work area. Without the connection,
gases and smoke will escape from the
furnace.
Caution
Do not connect the exhaust port to
tubing less than 3 in diameter or
otherwise restrict the exhaust flow from
the furnace. Also, do not connect the
tubing directly to an external fan or
otherwise increase the velocity of the
exhaust flow from the furnace. Either
restricting or increasing the exhaust
flow from the furnace may damage the
furnace or reduce its efficiency.
Note
Appropriate exhaust must be provided
to remove smoke and gases produced
in a testing procedure. Seamless
flexible exhaust tubing with an inside
diameter of 3 is recommended.
Seamless flexible 3 steel tubing is
available. (See Replacement Parts
list.)
The exhaust exiting the furnace
exhaust port may reach 270C. Do not
use flammable materials or materials
with a low melting point for exhaust
tubing.
14
1.
Select a location to minimize exhaust length.

We recommend an exhaust length of not more
than 10 feet.
2.
Flexible 3 I.D. seamless steel tubing or

electrogalvanized steel tubing is
recommended for venting. Lightly seal
connections at blower exit at the top of the
tester with clear silicon such as DOW >32 or
GE RTV or equivalent. Use sparingly so the
exhaust tube can be detached for servicing.
Do not use galvanized tin dryer pipe or
double-wall galvanized tin as the seams will
leak fumes into the lab. Do not use vent pipe
that is reduced to less than 3 I.D.
3.
Minimize 90 bends in your exhaust system if

possible. Bends restrict the exhaust air flow
and tend to accumulate particulates which can
also restrict air flow.
4.
Termination of your exhaust system may be in

open air or to a larger exhaust duct. Open air
termination is the most efficient. Duct
termination should not be in the vicinity of
fresh air intakes. Also, the duct cap must not
restrict the air flow.
Exhausting into a larger duct requires an
airtight connection. The larger duct must not
create a positive air pressure internally which
can diminish the testers blower efficiency.
Perform the lift test to ensure a -3.2 to -8.2
gram lift. (See page 22). Increasing the
velocity of the exhaust flow above the lift of
INSTALLATION
-8.2 grams may blow fines from the basket

resulting in an exaggerated asphalt cement
content.
5.
Turn on fume hood blowers and conduct lift test

to ensure the -3.5 to -10 gram lift is maintained.
Perform the test with room doors open and
closed to ensure proper makeup air for the room.
Balance Installation
Note
The balance is shipped separately to
ensure that the balance is not
damaged during shipment.
The NCAT Asphalt Content Tester is supplied with an

electronic balance, for use in the NCAT Asphalt Content
Tester. The balance operates on voltage supplied by the
tester.
The balance is shipped in a separate carton containing
specialized packaging material. It is recommended that the
specialized carton and packaging be retained for safe
balance storage or reshipment.
The balance carton will contain the following:
1
Balance
1
Support plate
1
Catch pan
4
Screws
Balance Assembly
Install support plate onto balance load cell with the screws
provided as shown.
To install the balance:
1.
Balance Assembly
Ensure that the furnace is disconnected from the

power supply. Remove the four screws along the
top of the front control panel securing the control
panel to the lower case of the furnace. Move
furnace forward about 2 inches beyond counter
15
INSTALLATION
edge or adjust all feet up about 1/4 inch. This

will allow the hinged control panel to open
without obstruction.
2.
Open the lower case by carefully pulling the

control panel forward and downward. The
control panel is hinged on the bottom edge to
the lower furnace case. Do not allow the panel
to fall completely open as this may
excessively strain cables attached to the
panel.
3.
Inside the lower furnace case, observe the

suspended table (balance support plate)
supported by four aluminum rods. The
balance will be supported by this table.
Vacuum the table if dust, etc., appears on it.
4.
Mount the support plate and the catch pan on

the balance. Note the four pins on the
catchpan. These will retain the ceramic
support tubes, which will project into the
furnace chamber after mounting.
5.
Place the Setra balance on the balance

support table so that the gray ribbon cable is
protruding from your left. This gray ribbon
cable will be plugged into the front panel
display board, into the connector marked P2.
On this same display board, the connector
marked P6 should have a red and white
power jack cable plugged into it, and the
connector marked P3 should have a 9-pin
ribbon cable connected to it. All three of these
connections are necessary in order for the
Setra balance to function.
6.
Position the balance so that the pins on the

platform support plate are directly beneath the
four tube ports in the bottom of the furnace
chamber.
Note
Do not close the control panel yet.
Warning
Ensure that the furnace is not
connected to the power supply prior to
installing or removing the balance.
16
INSTALLATION
7.
Open the furnace door. Insert the four ceramic

support tubes through the tube ports located in
the bottom of the furnace chamber. Adjust the
position of the balance until the four ceramic
support tubes are seated on the appropriate pins
on the balance plate. Finely adjust the position of
the balance until the tubes are centered in their
ports, but not touching the sides of the ports.
8.
Place the 10 x 11 gray silicon carbide hearth

tray on the four ceramic support tubes with the
11 dimension from front to back. Position the
front of the hearth tray about one inch back from
the lip of the bottom element plate. Center the
hearth tray on the four support tubes, equally
distant from side to side.
9.
Close the lower case by returning the control

panel to its original position. Secure the control
panel with the four screws you removed in step
1.
Caution
Do not allow the ceramic support tubes
to contact the sides of the tube ports,
as this will cause an unstable and
inaccurate balance readout.
10. Switch the main circuit breaker (located on the

lower left rear corner of the case when facing the
front of the furnace) on. Close the furnace door
and switch the power switch on. The balance
display board will read 0.0 grams after
approximately 20 seconds of initialization. Turn
power off and reposition the balance if the
display is unstable or reads anything other than
0.0 grams. Instability may be caused by one of
the support tubes rubbing.
17
INSTALLATION
Note
The balance control buttons can be
accessed through the pin holes
located on the right front furnace
control panel, below the balance
indicator, with a tool of .063 diameter
or smaller.
Setra Balance Operating

Instructions When Used In The
Type F85900 NCAT Furnaces
Balance Control Ports:
ENTER
Not used
Not used
ON/OFF
The Balance Default Settings When Used

in the Type F85900 NCAT
Furnace:
Time: 24 hour format (0 to 24 hours).

Date: US type, 2 Digit Year format, Use the 2-digit year
only.
Examples:
23:30:30
12/29/97
To Set the Time and Date Setting

The balance supplies the date and time to the furnace
controller. For ease of record keeping, you should set the
time to reflect your local time and date.
We recommend preforming a hidden weight key routine to

print the initial date and time before making any changes.
After changing the date and time, print the information again
and compare to be certain you changed it correctly.
18
INSTALLATION
To Set the Time

1.
Switch the green power switch down to OFF.
2.
While holding the 4 key down, switch the

green power switch up to ON, the red display
should indicate [BAL CAL].
3.
Press and hold the balance ON/OFF key.
4.
Press the balance ENTER key, then release

both keys. 71nE will be displayed, press the
balance ENTER key. The two hour digits will
be blinking (Note the time is in a 24 hour format).
5.
Press the balance ON/OFF key until the

correct hour is displayed.
6.
Press the balance ENTER key, the two minute

digits will be blinking.
7.

correct minute is displayed.
8.
Press the balance ENTER key, the balance will

return to the normal weight display.
To Set the Date

1.
2.

3.
4.

both keys. [71nE] will be displayed, press the
balance ON/OFF key, [dA7E] will be displayed.
19
INSTALLATION
5.
Press the balance ENTER key, [US] (United

States) or [Eur0] (European) date type will be
displayed.
6.

desired type is displayed.
7.
Press the balance ENTER key, [2d Yr]

(Two digit year) or [4d Yr] (Four digit year) will
be displayed.
8.

desired format is displayed.
9.
Press the balance ENTER key, [dAY XX] (Day)

will be displayed.
10. Press the balance ON/OFF key until the

desired day is displayed.
11. Press the balance ENTER key , [nn0 XX]
(Month) will be displayed.
desired month is displayed.
13
Press the balance ENTER key, [Yr XX] (Year)

will be displayed.

desired year is displayed.
15. Press the balance ENTER key, the balance will
To Span Calibrate the Balance
20
1.
2.
After furnace has cooled to room

temperature, open the furnace door.
3.
Remove and clean any debris from the ceramic

load plate, balance load plate, and ceramic
support posts, replace posts and plates.
INSTALLATION
Note
Furnace door should remain open
during the balance calibration.
4.

5.
6.

balance ON/OFF key twice, [CAL] will be
displayed.
7.
Press the balance ENTER key, [LOAd 8000]

will be blinking on the display.
8.
Place an 8000 gram (NIST traceable) weight

on the ceramic load plate in the furnace.
9.
Press the balance ENTER key, the balance

will display [ACAL], then return to the normal
weight display.
To Set Factory Defaults
Note
The balance must display 0.0 before
doing calibration.
Note
This function is to reset parameters
inside the balance which are not user
accessible, the TIME, DATE, and
BALANCE CALIBRATION are
unaffected.
1.
2.

3.
4.

balance ON/OFF key three times, [FACdEF]
will be displayed.
5.
Press the balance ENTER key, the balance

will display [BUSY], then return to the normal
weight display.
21
INSTALLATION
To Escape Configuration Menu

1.
Press the balance ON/OFF key until [ESCAPE]

is displayed.
2.
Press the balance ENTER key, the balance will

Lift Test Procedures

The efficiency of the blower and/or exhaust system is
indirectly monitored by a quick test procedure named the
lift test. The procedure is detailed as follows:
Caution
Perform the lift test only when the
furnace is at room temperature.
22
1.
Fully assemble tester with exhaust system

attached, hearth tray is mounted on the four
ceramic support tubes, and at room temperature
with no load. This test should always be
performed with the furnace chamber at room
temperature.
2.
Depress power switch to the on position.

Depress 0 key to tare balance display.
3.
Push program start button. Blower will turn

on. Observe balance display reading. Display
should read -3.2 to -8.2 grams. Detach the
exhaust system and repeat the test to determine
if the exhaust system is restricting the tester air
exchange, if the initial test is out of spec or is
borderline spec on the -3.5 grams low side.
Printer Operation
The printer automatically prints a record of your furnaces
operation. When you press Start/Stop, the printer will print
the current date, then the current time. The printer will then
print a space for you to record a sample identification
number, another space for you to record the mix type, and a
third space for you to record the testers name or
identification number. The printer will then print the filter
setpoint and chamber setpoint.
Caution
The printer uses thermal paper which is
sensitive to heat and light. Radiated
heat from the hot basket assembly can
blacken the test data on the tape. Store
tape in a cool, dark environment. The
test results and header can be printed
again by depressing the Enter key.
The results will not be printed if furnace
is powered down or a new test was run.
Note
A colored stripe along the edge of the
paper indicates that you are
approaching the end of the roll. When
the stripe appears, approximately 18
inches of paper remain. Replace the
roll before it is completely exhausted to
ensure a complete record of your test
procedures.
After the printer has printed all this header information, it will
print a column header line T:TEMP:WT.LOSS:%LOSS.
The first column is elapsed minutes. The second column is
the main chamber temperature in C. The third column is
direct weight loss in grams, and the fourth column is the
uncorrected percentage of sample weight lost. The printer
will print the current values of those four measurements
every minute during the test.
When you press Start/Stop to complete your test, the
printer will print the calibrated asphalt content, the Bitumen
Ratio, the calibration factor used during the test, the
temperature compensation factor used during the test, the
total uncorrected percentage of the sample weight lost, the
total weight lost in grams, the initial sample weight and the
total elapsed time for the test.
If the printer runs out of paper during the test, the test will
not halt, though the printer will not continue to print. Your
results will be safely stored and accessible, providing you
have spare rolls of paper. If possible, install a new roll while
your test is still running. The printer will resume printing at
that point.
If the test is completed before you install a new roll of paper,
press Start/Stop to conclude the test. Prn will be
displayed in the Elapsed Time window. This indicates that
the printer ran out of paper during a test and a new roll of
paper was not loaded. Provided that you do not start another
test, you can still retrieve the results of the test. After you
load a new roll of paper, press Enter. The results of the last
test will print. This feature is always available after you run a
test, and you can print multiple copies of the results of a test
simply by pressing Enter repeatedly after your test is
completed. Allow the printer to finish printing before pressing
Enter again for additional printouts.
23
PRINTER OPERATION
Printer Access
The printer is protected by a protective cover. The printer
cover pulls off the front when you squeeze the buttons on
each side and pull forward. The printer will then slide
forward when you pull gently on the metal tab provided on
the leading edge of the printed circuit board.
The printed paper tape exits the printer through a slot in the
protective cover. The serrated slot provides a clean tearing
of the taped test results. Use only printer tape specified by
Barnstead|Thermolyne or your Barnstead|Thermolyne
distributor.
Paper Advance Button

A paper advance button is located on the upper right corner
of the printer. Pressing the paper advance button while the
printer is inactive will advance the paper through the printer.
The paper advance button is useful for installing a new roll
of paper tape and for advancing a tape for tearing off at the
end of a test.
Paper Tape Rolls

The special heat sensitive paper for the printer is available
from Barnstead|Thermolyne or your Barnstead|Thermolyne
distributor (Part Number PRX2). The printer will not print on
plain paper. For paper roll installation, see next page.
Conserving Paper
If you dont require them, you can turn off the printing of
intermediate values and only print initial values and final
results. This will save a significant amount of paper per test.
To turn off the printing of intermediate values:
Depress power switch to on while simultaneously
depressing the 1 key. Depress the power switch to off to
exit procedure. See Hidden Key Procedures for more
details.
Test Results Printout

24
PRINTER OPERATION
Paper Tape Roll Installation

Note
At the end of each day, the printed
portion of the printer tape should be
removed and stored in an appropriate
way. See Printer Record Storage for
details.
The heat sensitive paper will print on only one side, and
therefore, must be installed properly to function.
1.
Switch furnace power on. Press the Paper

Advance button to feed out any paper
remaining in the printer.
2.
Remove the printer cover and pull out the

printer as described in Printer Access.
3.
Cut the lead end of the replacement paper as

shown in the illustration. Remove at least six
inches of the lead end of the paper to remove
the adhesive which secured the roll for
shipping.
4.
Insert the paper roll on the paper roll shaft as

shown.
5.
Feed the cut end of the paper into the slot at

the bottom of the printer (A). Push the feed
button on the front of the printer until about 1
of paper comes out the front of the printer.
6.
Feed the paper through the cover and reinstall

the cover.
Figure 3
Paper Roll Installation
25
PRINTER OPERATION
Printer Record Storage

In addition to being heat-sensitive, the paper tape is also
light sensitive and will darken if left exposed to light for an
extended length of time. To ensure the long-term legibility
of your records, choose one of the following methods:
1.
Photocopy each days tapes and file the

photocopy.
2.
Store the tapes in an opaque folder, file or

envelope.
Note that certain situations and substances will hasten the

degradation of the thermal paper and should be avoided:
26
1.
Exposure to heat or hot surfaces will darken the

paper and obliterate your readings.
2.
Ultraviolet light will darken the paper and

obliterate your readings. Common fluorescent
lights emit low levels of ultraviolet light; thermal
paper tapes left exposed to fluorescent light in a
lab or office will eventually darken and become
unreadable.
3.
Common cellophane tape interacts with the

thermal paper and will darken it to illegibility. Use
care if you tape your original thermal paper
tapes into a notebook.
Operation
Displays
Note
If you do not press any other keys, the
displays will revert to their standard
displays after five seconds.
The furnace has four displays, labeled Chamber Temp.,

Percent Loss, Elapsed Time and Balance Indicator.
Chamber Temp. displays the current temperature of the
main chamber in C. If you press the Temp. button on the
keypad, the Chamber Temp. display indicates the current
setpoint for the furnace chamber. The Setpoint LED will
illuminate when the setpoint is displayed.
Percent Loss displays the percentage of the total sample
weight currently consumed by combustion. When you press
the Weight button on the keypad, Percent Loss displays
the last sample weight you entered. When you press the
Calib. Factor button on the keypad, Percent Loss
displays the last calibration factor you entered.
Elapsed Time displays the elapsed time since you started

the test. Pressing the Start/Stop button starts a test.
Pressing the Start/Stop button stops a test and also stops
the timer and freezes the Elapsed Time display until the
next test is started.
Balance Indicator displays the weight change of the
sample, in grams (only during a test).
Balance Stability Indicator is a flashing LED located
within the balance indicator window. The indicator normally
flashes throughout the test period as the sample loses
mass during the ignition process. The indicator will
typically remain full on when the mass becomes stable.
Note
Other parameters can be adjusted
through the Hidden Key Routines,
explained on page 41 of this manual.
Controls
To View the Current Settings of the Controller:
Press the Temp. button to view the current chamber
setpoint on the Chamber Temp. display. Press the
Weight button to view the initial weight of the last sample
on the Percent Loss display. Press the Calib. Factor
button to view the current calibration factor on the Percent
Loss display.
27
OPERATION
To Change the Setpoint Temperature:

1.
Press the Temp. button. The Chamber Temp.

display will show the furnaces current setpoint.
2.
Enter your new setpoint. Press the Enter button

to accept your new setpoint. This must be done
before the Chamber Setpoint light goes out.
3.
Press the Temp. button again to verify your new

setpoint.
To Change the Initial Sample Weight:

1. Press the Weight button. The Percent Loss
display will show the current initial sample
weight.
2.
Enter your new initial sample weight (in grams).

Your initial sample weight should be a four digit
number, in whole grams. Press the Enter button
to accept your new initial sample weight. This
must be done before the Sample Weight light
goes out.
3.
Press the Weight button again to verify your

sample weight.
To Change the Calibration Factor:

1.
28
Press the Calib. Factor key once to enter a

negative weight loss value and twice to enter a
positive value. The Percent Loss display will
show the current calibration value. For a
calibration factor of 0.21%, enter 21.
OPERATION
2.
Enter your new calibration factor. Press the

Enter key to accept your new calibration factor.
This must be done before the calibration factor
light goes out.
3.
Press the Calib. Factor button again to verify

your new calibration factor.
To Tare Balance:
1.
Press the 0 key.
Outline of Operational
Procedures
Note
Once the test is started, the setpoints
cannot be changed.
Warning
Do not open door while program is in
process. Flame and noxious fumes
may be released into the laboratory.
Operator will be exposed to the risk of
burns. Always allow test program to
reach endpoint before opening door.
Warning
Do not load cutback asphalt samples
containing naphtha, gasoline, fuel oil or
explosive volatiles. Explosive ignition
can occur resulting in a fire or a threat
of burns to the operator.
1.
Weigh your sample on an external balance

accurate 1 gram.
2.
Enter sample weight into controller. Using the

instructions under To Change the Initial Sample
Weight, enter the initial weight of your sample.
3.
Check and, if necessary, adjust your temperature

setpoint and correction factor. See the
instructions under Controls on pages 27-29.
4.
Load the basket assembly into the furnace

chamber by inserting it directly above the hearth
tray and setting gently on the hearth tray. The
carrier tines of the transport handle will extend
past the rear of the transport tray when locked in
place. As you insert the load into the furnace
chamber, allow the carrier tines of the transport
handle to touch the rear wall of the of the furnace
chamber, then gently set the load on the hearth
tray. This will ensure proper placement of the
load from front to back. Check the load for proper
clearance on each side.
Keep objects away from the thermocouple. Do
not slide basket assembly against the
thermocouple. This will affect temperature
reading and weight indication.
29
OPERATION
Use insulated gloves and a fire retardant apron

when loading and unloading furnace. Always
wear safety glasses or a safety face shield and
high temperature gloves when loading or
unloading furnace. Long sleeve, fire retardant
attire is recommended. Always keep your gloves
and glasses clean. Allow clearance for the
basket tray so it will not touch the door
insulation. See furnace loading tips.
Hot Surface
To avoid burns, this furnace must not
be touched on the exterior or interior
furnace surfaces of the chamber area
(except door handle and front control
panel) during use or for a period of
time after use. Hot Surface. Avoid
Contact.
Warning
Do not use in the presence of
flammable or combustible chemicals;
fire or explosion may result. This
device contains components which
may ignite such materials.
Caution
Do not exceed the 5000 gram capacity.
Failure to observe this caution could
result in damage to furnace
components and/or balance.
HHHHHH will be displayed on the
balance display if the weight limit is
exceeded.
If your load touches either side, the
front or the back of the furnace
chamber during a test, the test is
invalid. Balance instability will result.
This is typically evidenced by a weight
gain on the one-minute printed test
result readout.
30
5.
Close the door. The furnace will not operate with

the door open.
6.
Press the Start/Stop button.
When you press Start/Stop, the automatic locking

mechanism will lock the door. After approximately five to
fifteen minutes of heating (depending on sample size and
sample volatility), the asphalt will ignite. You will see a
sudden increase in the actual chamber temperature
(Chamber Temp. display). The main chamber temperature
may remain significantly higher than your setpoint
temperature for some time (again, depending on sample
size and volatility). When the main chamber temperature
begins to decline, you will also see both the Percent Loss
and Balance Indicator displays begin to stabilize. After the
sample weight has stabilized, an audible alarm and stable
light will illuminate to signal test completion and the printer
will stop. Note: The printer will only stop if the Auto Program
Switching Mode is on. The furnace will continue to heat at
setpoint temperature.
7.
Press the Start/Stop button. The automatic

locking mechanism will unlock the door. Use
appropriate safety apparel and tools when
unloading the hot furnace. Note: The door will
automatically unlock, if the Auto Program
Switching Mode is on.
Timer Mode
Programmable Timer
Heating the furnace to operational levels may require two
or more hours of preheating but leaving the furnace on
constantly may not be efficient, consuming both electricity
and heating elements. To optimize your working hours, we
have designed an automatic preheat timer into your asphalt
testing furnace. This feature allows you to begin work
immediately each day, but only run your furnace as much
as necessary to complete your days work.
Note
If you dont want to enter a wake-up
date you can bypass this feature by
simply pressing ENTER after you have
pressed the timer button in step 1.
Bypassing the date automatically
converts the timer from a
programmable 364 day timer to a 24hour timer. This means that when the
programmed Time is reached, the
unit will begin heating, ignoring the
wake-up date. The date needs to be
set at 0.00 for this to happen.
Note
The timer format is European or
Military time so to enter a wake-up
time of 5:00 a.m. you would input 500
and then press ENTER. A wake-up
time of 5:00 p.m. would be entered as
1700; then press ENTER. The start up
time and date are now entered.
Programming the Timer

The following directions will explain how to program the
wake up date and time into your asphalt furnace. This will
determine exactly when the furnace will begin preheating to
your setpoint temperature. We recommend that you set the
time for at least 2-21/2 hours before you want to begin
work.
1. Press the timer button on the key pad. The
heating elements will shut down at this time. The
wake up time will be displayed in the Elapsed
Time display and the wake-up date will be
displayed in the Percent Loss display.
2.
Enter the wake-up date by inputting the month

and then the day. Example: May 16th would be
entered as 516. Then press ENTER. The wakeup date is now set.
3.
You may now proceed to enter the wake-up

time.
If at any time you wish to disable the timer, press the

START/STOP button.
Inactivity Mode
By using the hidden key feature with the Timer key, you
can select the Inactivity Mode. This mode allows the
furnace to wake-up at the programmed time and date, but
if the user does not press any keys for a period of 4 hours,
the unit will shut down and In Ac will be displayed in the
31
TIMER MODE
chamber temp display. The unit will remain shut down until
the user presses the START/STOP key. Pressing the
START/STOP key will set the unit into its normal idle mode.
The Inactivity Mode is a valuable feature should the unit be
placed in a remote location and the operator is not able to
return due to unexpected circumstances such as inclement
weather. The unit will remain shut down until the user
presses the START/STOP key.
Interrupting the Timer Mode

Should you need to interrupt the Timer mode for any
reason, simply press Start/Stop. The heating elements will
reenergize. Depending on how long the furnace has been in
Timer mode, some preheating time may be necessary
before your furnace is ready for use. To return the furnace
to Timer mode again, press the Timer button on the keypad.
32
Methodology and Tester Tips

1.
Sample aggregate and sample asphalt cement

are preheated to a constant weight in preparation
for the standard ignition method. Failure to
preheat samples will introduce inconsistent
asphalt content values.
2.
Cutback asphalts or slurry seals containing

potentially explosive naphtha, gasoline,
Kerosene or other explosive solvents must not be
placed in the tester. Explosion can occur. The
solvents must be reduced to a safe level prior to
preheating in an oven and igniting in the tester.
3.
Your tester has a rated load capacity of 5,000

grams. Splitting large samples may save time
and produce improved results particularly if your
test stability threshold is set at a lower value.
4.
Back to back testing: Proposed AASHTO and

ASTM drafts specify Samples can be placed in
the furnace at significantly lower temperature
since the furnace will quickly heat to the desired
temperature once the sample begins to burn.
For example, this means the furnace temperature
does not need to recover to 538C. The heat
from ignition will typically cause the chamber
temperature to recover rapidly. This allows you to
increase your daily test capacity significantly.
5.
Your tester automatically compensates for the

initial weight change of the load, caused by
heating the load from a low temperature to a
higher chamber temperature. Note that the load
has not lost any mass at this point; it changes
weight because its temperature has increased.
Temperature compensation typically ranges from
0.1% to 0.25%. A warm HMA sample will be
assigned a value of 0.1% or higher. A cold
Note
For complete Ignition Method
Procedure, contact your Provincial or
State D.O.T. or see the A.S. T. M. or
AASHTO procedures.
33
METHODOLOGY AND TESTER TIPS
sample will be assigned a value near .25%. Test time will be reduced if an HMA sample is warm or hot.
Problem
Possible Cause
Diagnostic
Remedy
AC results too high
Sample not dried to a
Review standard method
Re-dry
constant weight
HMA sample preparation
Calibration factor for the
Review Calibration Factor
aggregate not entered or
Display
Correct or reenter
is incorrect
AC results too low
Calibration factor is
incorrect.
Review Calibration Factor

Display
Correct calibration factor
Entered sample weight
Review Sample Weight
Correct weight entry
incorrectly
Display
Chamber temperature
too high, causing aggregate
to deteriorate, causing
excessive weight loss
Review standard method

calibrating factor procedure
for sample preparation
Rerun calibration
factor test per
standard method
Insufficient air
Perform lift test to
Oil and clean blower
exchange in chamber
ensure a -3.2 to -8.2 gram lift.
assembly. Replace
resulting in incomplete
blower. Clean exhaust
combustion of sample
system. Repeat lift test.
Sample weight and/or
Check test tape
Correct Calibration Factor
calibration factor readout

entered incorrectly
Basket assembly lodged
Correct position of basket
against chamber or door
assembly
resulting in low weight value
34
Software Features
Note
If you use Bitumen Ratio for your end
results, you must use this factor durng
your mix calibration procedure. Ignore
the calibrated asphalt content number.
Equations Used to Determine

Bitumen Ratio
The Bitumen Ratio has been added to the Rev. G software.
This test result is used in the United States, Canada and
Europe. The Bitumen Ratio equation is detailed as follows:
Bitumen Ratio = (Weight Loss/Sample Weight after ignition)
x 100 minus temperature compensation,
minus correction factor.
The Bitumen Ratio test results are printed in the header
above the calibrated asphalt content for each test.
Calibrated Asphalt = (Weight Loss/Sample Weight
Content
x 100 minus
temperature compensation,
minus correction factor.
Test Interrupt/Power Interrupt

If the power to the furnace is interrupted during an ignition
test, and then restoredthe furnace will continue the test
but will print the following information on the ticket.
{Results Invalid}
Test Interrupted
Time: XX:XX:XX
The elapsed time will restart at 1 and continue to count up.
The software will continue to monitor the weight loss and
recognize the endpoint to end the test.
This feature will prevent smoke from entering the lab should
a power interrupt occur. Once power has been 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.
35
SOFTWARE FEATURES
The power interrupt feature also applies to the

programmable 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 time, the software will
recognize the present time and wake-up at the correct
programmed time.
Auto Shutdown Mode
Note
If your test procedure calls for
aggregate calibrations to determine
the calibration factor, you will need to
run the tester in the Manual Mode.
The software can be toggled between Auto Mode and

Manual Mode by performing a Hidden Temp Key Routine.
In the Auto Mode, the unit will recognize the endpoint, stop
the blower, print the results and then BEEP once every 60
seconds until the operator presses the START/STOP key.
This will unlock the door and disable the beep.
In the Manual Mode the unit will recognize the endpoint
and place an asterisk by the endpoint. It will continue to run
the test and beep until the operator presses the START/
STOP button.
Positive Calibration Factor

Software has the ability to accept a positive calibration
factor. By pressing the calibration factor key twice
simultaneously, then entering your number and pressing
ENTER, a (-) sign will appear in the percent loss display.
The software will now subtract a negative number (same
as adding) from the percent loss. This is necessary when
testing HMA that contains hydrated lime that has been
added with the oil as an antistrip.
Stability Threshold
Endpoint detection can be adjusted from .01% - .5% of the
sample weight. A higher stability threshold can sometimes
be advantageous when burning off samples containing
very soft aggregates. The stability threshold can be
changed by performing a hidden key function using the
calibration factor key, then entering the new number. (See
Hidden Key Routines.)
36
Serial Port Output/Operation

Serial Port Output/Operation
The furnace has a serial output port on the rear of the unit.
The port outputs a data string to any computer able to
receive RS232 serial communications. A one-way cable to
connect the computer with the furnace is needed, along
with software on the computer to collect the data. graphAct
Data Logging and Graphing Software will automatically
collect and graph data from the computer for you. If you are
interested in the graphACT Data Logging Software, contact
KG Systems at (201) 429-9300 or fax them at (201) 4292298. Order computer cable from Barnstead|Thermolyne or
your Barnstead| Thermolyne distributor. Other software,
such as Terminal in Microsoft Windows, can be used to
collect and manipulate the raw data from the furnace. Raw
data collected in this manner can be graphed and
manipulated in a spreadsheet program such as Lotus
123.
Sample Data Serial Port Output

On the next page are two lines of sample data output. Each
line contains the data output of a single second of the test
cycle, sampled once every minute. The data output can be
either continuous or just output during a test. To change,
see Hidden Key Routines, page 41.
37
SERIAL PORT OUTPUT /OPERATION
Description of Sample Data
Key
1
ON,
OFF,
2
34
34
3
552
552
Sample Data Output

38
4
166.9
167.0
5
5.49
5.50
6
784
784
7
538
538
8
750
750
Key
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Test Status (ON/OFF)

Elapsed Time (minutes)
Actual Chamber Temperature (C)
Actual Weight Loss (g)
Actual Weight Loss (%)
Actual Filter Temperature (C)
Chamber Setpoint (C)
Filter Setpoint (C)
Sample Weight (g)
Time (24 hour format)
Date (M/D/Y) or (D/M/Y)
Temperature Compensation (%)
Calibration Factor (%)
Calibrated Asphalt Content (%)
Test Stability Threshold (g)
Stability Indication (+/-)
Bitumen Ratio
9
3036
3036
10
11
12:03:54 6-11-97
12:03:55 6-11-97
12
0.09
0.09
13
-2.56
-2.56
14
7.96
7.97
15
0.01
0.01
16
+
17
8.28
8.29
Explanation of Error Codes

Furnace Error Codes
All errors (unless explicitly noted) will cause the test
procedure to stop. Furnace error codes are displayed in red
LED windows located on control panel.
E001
Chamber thermocouple circuit is open. Tip may be

cracked at weld. The chamber heat may open the
crack by thermal expansion. Replace thermocouple.
Resistance of a normal thermocouple is </= 1 ohm.
Also, look for loose connection at terminal
connection at rear of furnace. Thermocouple leads
are red (-) and yellow (+).
E002
Filter thermocouple open. Follow above procedure

for filter thermocouple.
E003
Chamber temperature limit of 675C is exceeded.

This error is disabled while in the test program
mode. Exceeding the 675C limit can be caused by:
1. Thermocouple has deteriorated. Remedy:
Check for 1 ohm resistance or less. Replace if
indicated.
2. HMA sample size and oil BTU content cause
the chamber temperature to exceed limit
setpoint. Remedy: Split sample or reduce
sample size.
E004
Filter temperature limit of 975C is exceeded (See

E003 explanation).
E005
Door interlock not functioning. This may be caused

by:
1. Plunger rod off center of lock port due to door
out of adjustment, mechanical linkage
jamming or plunger location shifted. Remedy:
Adjust as needed.
2. Check for a bend or ding in the outer case
where the Door Lock Linkage is attached. This
can happen during shipping or handling.
Straighten case and adjust linkage.
3. Microswitch failure.
E007
Analog to Digital Converter is not functioning

properly. This may be caused by a component
failure or faulty cable connection.
E008
The DTR signal from the balance is indicating the

balance is either not ready or not connected.
39
EXPLANATION OF ERROR CODES
E009
Setpoint is out of range. This is a temporary error to

alert you that you have crossed the allowable
boundary for the function you are setting. The
furnace will beep for 3 seconds while displaying
the error, and then return to normal operation. The
setpoint will revert to its previous value.
E010
Chamber thermocouple leads reversed.

Thermocouple is type K. Polarity is coded as red
(-) and yellow (+). Polarity must be consistent
throughout the circuit.
E011
Filter thermocouple leads reversed. Thermocouple

is type K. Polarity is coded as red (-) and yellow
(+). Polarity must be consistent throughout the
circuit.
E012
Balance not communicating; weight,

time and date not received. This may be
caused by the balance not being
configured correctly. Follow the
procedure on pages 18-21.
Setra Balance Error Codes

Displayed in green Balance indicator window.
HHHHHH
Exceeds maximum specified load. Remedy:
Reduce loads to specified range.
LLLLLL
Load does not meet minimum specified
load requirements. Remedy: Increase load
to specified range.
NOCAL
Unable to do span calibration (load not
within 1% of cal weight, or weight
unstable).
UnABLE
Unable to process command (usually due
to being in improper mode).
ProtEc
Calibration protect switch not in the
PROTECT position during operation.
REPlug
System not calibrated.
40
OFLO
Internal arithmetic overflow.
S Err
Processor stack overflow.
In Err
Memory indexing error.
Hidden Key Routines

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. The furnace must be in the
(non-programmable) mode to access the Hidden Keys.
0 Key-Diagnostics
Access:
Depress the Power Switch to ON while `
simultaneously depressing the 0 key.
Procedure: Enters the diagnostic procedure for
factory testing. The printout is typically filed
with the Operation Manual.
Exit:
Depress Power Switch to OFF and

then ON to return to normal operation.
1 Key-Printout Paper Saver:

Access:
Depress Power Switch to ON while

depressing the 1 key simultaneously.
Procedure: Chamber temperature display PRN and the

Percent Loss display will toggle ON or
OFF as the access procedure is
repeated. The new mode will be displayed
for three seconds and then the furnace will
return to normal operation.
Exit:
Automatic
2 Key-Default
Access:
Depress the 2 key while simultaneously

depressing Power Switch to ON.
Procedure: DEF will be displayed for three seconds to

indicate variables have been reset to
factory values. The furnace will return to
normal operation. Defaulting to factory
values is a useful diagnostic tool as a
comparison of current values vs. factory
values can be made within minutes. Values
can be printed by depressing ENTER
while simultaneously depressing the Power
41
HIDDEN KEY ROUTINES
Switch to the ON position.

Exit:
Automatic
3 Key-Chamber Calibration Procedure

Equipment
Needed:
1 ea. Digital Pyrometer with Penetration

Probe, Sensor NIST Traceable. (PM20700
Pyrometer with TC405X4 Penetration
Probe).
Setup:
Calibration consists of inserting a sensor

penetrating through the covered stainless
steel tube located adjacently to the control
thermocouple. Entry is at the top center
rear of furnace. The penetrating probe is
needed to penetrate through the soft
insulation. Probe insertion is at the same
depth of the chamber control thermocouple.
Cover probe entry tube after the calibration
procedure has been completed. Do not
place pyrometer on top of hot furnace. After
inserting the test thermocouple penetration
probe, set furnace chamber and filter at 538
C or standard method specified temperature.
Allow furnace to stabilize at setpoint in the idle
mode. The maximum offset allowed before
calibration is required is 50C.
Access:
Depress 3 key while simultaneously

depressing power switch to ON.
Procedure: CHBR CAL will be displayed in the Percent

Loss and Elapsed Time windows respectively.
The Chamber Temperature window will display
the actual chamber temperature which should
be at or near setpoint temperature. Allow the
furnace to stabilize at setpoint.
Enter the temperature displayed in C by the
digital pyrometer by using the keypad. Press
ENTER. The new offset value will be used
and the entered temperature will be displayed.
The entered temperature is the temporary
setpoint.
42
HIDDEN KEY ROUTINES
The original setpoint will return upon exiting.

The software has calculated and saved the
new offset value which will apply to all
setpoints throughout the operating range.
Exit:
Depress Power Switch to OFF and then

ON to return furnace to normal use. Remove
sensor probe and cover entry tube.
4 Key-Provides Entry to Balance Menus

Access:

depressing Power Switch to ON.
Procedure: BAL will display in Chamber Temperature

window. CAL will display in Percent Loss
window. Entry allows user to change time and
date settings, review and adjust balance
inputs, and calibrate balance. These topics
are detailed under the Balance Calibration
instructions. (See pages 18-23.)
Exit:
Depress Power Switch OFF and then ON

to return furnace to normal use.
5 Key-Filter Temperature Adjustments

Access:

depressing the Power Switch to ON.
Procedure: Adjustment range is 0-900C. Factory setpoint
is 750C. Chamber Temperature displays
current setpoint. Percent Loss window
displays FIL. Elapsed Time window displays
SP for setpoint. Use the keypad to change the
display to the new setpoint value. Depress
ENTER promptly. This new setpoint value
will be displayed.
Exit:
Depress Power Switch to OFF and then

ON to return furnace to normal operation.
6 Key-Disables Error Codes:

Access:
Depress 6 key while simultaneously switching

the Power Switch to ON.
43
HIDDEN KEY ROUTINES
Procedure: ERR will be displayed in the Chamber

Temperature window. OFF will be displayed
in the Percent Loss window. The furnace will
automatically return to normal operation within
five seconds with the ERR codes inactivated.
ERR codes are defeated to perform diagnostic
procedures as to temporarily ensure continued
furnace operation in the event of a false error
code.
Exit:
Depress the Power Switch to OFF and then

ON to return the furnace to normal operation
with activated error codes.
7 Key-Displays Actual Filter and Chamber

Temperature:
Access:
Depress the 7 key while simultaneously

Procedure: Chamber Temperature will display actual

temperature. The Percent Loss displays actual
filter temperature. You can compare actual
chamber and filter temperatures with setpoint
to assess the need for the thermocouple or
element replacement or re-calibration.
Exit:
Depress the Power Switch to OFF and then

ON to return the furnace to normal operation.
8 Key-Serial Port Output Adjustment

Access:
Depress the 8 Key while simultaneously

Procedure: SPC or SPn will display in the Chamber

Temperature window for three seconds. SPC
prints the serial output continuously. SPn
prints the serial output only when the furnace
is in the program mode. Accessing toggles the
mode between SPC and SPn. The displayed
mode is the active mode. Default is the SPC
mode.
44
HIDDEN KEY ROUTINES
Exit:
Automatically returns to manual operation

within three seconds.
9 Key-Disables Beep
Access:
Depress the 9 Key while simultaneously

Procedure: The Chamber Temperature will display BEEP.

The Percent Loss window 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. The default mode is
BEEP ON.
The beep should only be deactivated when
the tester is used in the Manual Test Mode.
The beeper should always remain active
when the tester is in Auto Mode.
The option to inactivate the beeper is useful

for raw aggregate calibration when minute
losses may cause the endpoint beeps to
activate prematurely before the procedure has
been completed. The key press beep is not
disabled in the BEEP OFF mode.
Weight Key-Prints Out Balance Variables
Access:
Depress the weight key while simultaneously

Procedure: The Percent Loss Window will display SCAL.

The Elapsed Time window will display LIS.
The printout will generate automatically upon
entering the printout mode. See example of
factory printout for balance variables on page
24.
Exit:
The furnace will automatically return to normal

operation after the printout is generated.
45
HIDDEN KEY ROUTINES
Enter Key-Prints Out User Variables

Access:
Depress the ENTER Key while simultaneously

Procedure: PRN will display in the Percent Loss window.

USR will display in the Elapsed Time window.
The printout will generate automatically upon
entering the printout mode.
Exit:
The furnace will automatically return to normal

operation after the printout is generated.
Calibration Factor Key-Adjust or Check Test

Stability Threshold of a Test
Access:
ON/WEIGHT printout example
Depress the Calibration Factor Key while

simultaneously depressing the Power Switch
to ON.
Procedure: The stability threshold setting will be displayed

in the Percent Loss window. The Elapsed Time
window will display FLN. The value options are
0.01 - 0.5%. Enter the new value via keypad.
Observe the Percent Loss window as the new
value is entered. The new value must be
entered and the ENTRY key must be
depressed within five seconds.
ASTM Draft 6 specifies test endpoint
completion when the measured mass loss
does not exceed 0.01% over three
consecutive one minute periods. AASHTO
specifies endpoint completion when the mass
loss does not exceed 0.02% over two
consecutive one minute periods. The test
stability threshold value defines the endpoint.
The value must match the standard
specification you are applying. The test
stability value is printed on the User Variable
Printout. See Hidden Key ENTER. An example
of the printout is depicted on page 24.
Exit:
ON/ENTER printout example

46
Depress Power Switch to OFF and then ON

to return furnace to normal operation.
HIDDEN KEY ROUTINES
Temp Key - Toggles from Auto Program Switching Idle

to Manual Program Switching to Idle at Endpoint
Access:
Depress TEMP key while simultaneously

Procedure: AU appears in the Chamber Temp display. The

Percent Loss displays either ON or OFF.
Repeat ACCESS if OFF is displayed.
Repeating access changes the display to AU
ON. You are now in the Auto Program
Switching to Idle mode. Repeat ACCESS
again to return to the Manual Program
Switching to Idle mode.
Auto Program Switching to Idle can increase
the number of tests run per day. The
operators monitoring time is eliminated as the
test results automatically print out at endpoint.
The Manual Program Switching to endpoint is
still available in the event continuous running
is required after endpoint.
Exit:
AU ON or OFF is displayed for

approximately five seconds. The furnace
automatically returns to idle.
Timer Key - Disables Inactivity Check

Access:
Depress theTime key while simultaneously
depressing the Power switch to ON.
Procedure: The chamber temperature will display IN
AC. The Percent Loss window will display
ON or OFF. The mode condition will display
for three seonds. 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
furnace must be in the idle (non-programmable) mode.
47
HIDDEN KEY ROUTINES
0 Key-Tares the Balance

Access:
Depress 0 key. The balance will automatically

tare to 0 grams in the balance display.
Procedure: This mode is useful to perform the lift test, as
the balance must be tared before conducting
test. See Glossary.
The weight of the loaded basket assembly can
be rechecked if the balance is tared prior to
loading.
Exit:
Automatic at ACCESS.
Enter Key-Duplicates Header Test Results

Access:
Depress the ENTER key.
Procedure: The header test results will print out for last
test if no other key functions have been
performed since printing of the last test results.
The power switch must not be switched OFF
and ON after the original test report is
generated.
This feature provides as many header copies
of the last test results as needed by the
operator.
Exit:
48
Automatic upon completion of printout.
Preventive Maintenance and

Servicing
Warning
This furnace contains refractory
ceramic insulation which can produce
respirable fibers and dust when
handled. These fibers can cause
irritation and can aggravate preexisting
respiratory disease. The International
Agency for Research on Cancer
(IARC) has classified refractory
ceramic fiber as possibly carcinogenic.
After service refractory ceramic fiber
dust may contain crystalline silica,
which may cause lung damage
(silicosis) and which has been classed
by IARC as a probable carcinogen.
(See MSDS, p. 68.)
Hot Surface
Allow the furnace to cool to room
temperature before performing any
maintenance or servicing. Hot
Surface. Avoid Contact.
Warning
To avoid electrical shock, this furnace
must always be disconnected from the
power supply prior to maintenance and
service.
Perform only maintenance described in
this manual. Contact an authorized
dealer or our factory for parts and
assistance.
Refractory ceramic materials are located in the door, and in

the chamber of the furnace. Tests performed by the
manufacturer indicate that there is no significant risk of
exposure to dust or respirable refractory ceramic fiber
resulting from operation of the equipment under normal
conditions. However, there may be a risk of exposure to
respirable refractory ceramic dust or fiber when repairing or
maintaining the insulating materials, or when otherwise
disturbing the materials in a manner which causes release
of dust or fibers therefrom. Through the use of proper
handling procedures you can work safely with these
insulating materials and minimize any exposure.
Accordingly, before you repair or replace any insulating
materials, or perform any other servicing on this product
which could disturb or cause exposure to dust from
insulating materials, you should consult the appropriate
Material Safety Data Sheets (MSDSs) for such products
with respect to proper handling and appropriate protective
equipment. For additional MSDSs, or additional information
concerning the handling of refractory ceramic products,
please contact the Customer Service
Department of Barnstead|Thermolyne or Barnstead|
Thermolyne distributor.
Element Plate Construction Use

and Care
Your tester contains five element refractory plates
containing special helical coiled element embedded in the
refractory. The proprietary element design protects the
element wire from harmful asphalt ignition fumes, arrests
coil expansion and contraction and protects the coils from
mechanical damage. The filter element heats the ceramic
filter and is controlled by a separate electronic controller.
The sides, top, and bottom elements heat the chamber.
It is normal for the refractory plates to develop hairline
cracks in the refractory plates. This does not necessitate
element plate replacement if the mechanical strength is not
compromised.
Periodically fire the chamber at 650C for two hours in the
idle mode to clean element plates. Vacuum chamber floor
as needed.
49
PREVENTIVE MAINTENANCE
AND
SERVICING
Your tester requires blower maintenance which consists of

cleaning and oiling the motor about every six months or if
the lift test results indicate a decline in blower efficiency.
This service requires detaching the exhaust duct, removing
the top cover and fume hood. The motor is fastened to the
rear of the fume hood. Place one drop of Anderol High
Temperature Lubricant (included in accessory kit), into the
small oil ports located on the blower motor. Locate the tester
where adequate space for servicing is available. Excessive
air leakage around the door insulation can also reduce lift
values. The remedy is to adjust the door fit or replace door
insulation. Door fit adjustment is performed by loosening the
top and bottom hinge screws. Adjust the door and refasten.
Door lock adjustment may also be required to ensure proper
door seal. The latch hook on the door, hooks the latch pin in
the closed position. The latch pin is adjustable. The two
Phillips screws located above the latch pin port tighten the
doors fit when turned counter clockwise. One screw should
be turned a half turn followed by turning the second screw a
half turn. This adjustment procedure will ensure proper latch
pin position and prevent binding.
The blower assembly consists of the wheel housing, cooling
fan bracket and motor. A 2 wide paint brush with a vacuum
cleaner works nicely to clean the assembly, baffle plates,
ceramic vent tubes and flame deflectors. We recommend
wearing glasses.
To Replace a Chamber Heating Element
50
1.
Disconnect furnace from power supply. (See

parts list for normal cold resistance values.)
2.
Remove the back terminal cover of the furnace.

(Note placement and connections of wires.)
3.
Loosen the screws and nuts on the terminals of

the element to be replaced.
4.
Open the door.
5.
Remove the hearth tray and the ceramic

supporting posts.
6.
Pull the defective element out.
AND
SERVICING
7.
Slide the new element into place, threading the

leads through the insulating porcelain bushing
on the back of the furnace.
8.
Cut off any excess lead wire. Reinstall terminal

connections and tighten screws and nuts
securely.
9.
Replace the ceramic supporting posts and the

hearth tray.
10. Replace the back terminal cover.

11. Reconnect furnace to power supply.
12. Test operation of furnace.
To Replace a Filter Heating Element

Caution
Make sure to align the five holes in the
insulation to the top cover plate.
1.
Disconnect the furnace from the power

supply.(See parts list for normal cold resistance
value.)
2.

(Note placement and connections of wires.)
3.
Loosen the screws and nuts on the terminals of

the filter element. Remove the filter
thermocouple.
4.
Remove exhaust tubing, remove top cover and

fume hood.
5.
Open the door of furnace, remove the (4) screws

retaining the cover above the door.
6.
Remove the fume hood retaining brackets and

remove all screws which are holding the top
cover plate onto the furnace.
7.
Remove top cover plate, blanket insulation, and

top piece of vacuum formed insulation. The
element will be exposed. Remove the filter
element. Inspect the filter.
8.
If filter is OK, then install the new element,

threading leads through the insulation, porcelain
bushings and terminals on back of furnace.
9.
Replace the insulation, top cover and front

cover.
51
AND
SERVICING
10. Tighten screws and nuts on the element

terminals, trim the excess wire from the element
leads.
11. Replace the back terminal cover, fume hood,
fume hood retaining brackets, ceramic posts,
hearth plate, top cover, and exhaust.
12. Reconnect furnace to power supply.
To Replace a Type K Chamber Thermocouple
Note
The thermocouple circuit consists of
the thermocouple and thermocouple
extension lead wires. Polarity plus to
plus and minus to minus must be
maintained in the circuit. Reversing
lead wire polarity, thermocouple lead
wires touching one another or
grounding to case will cause the
chamber temperature to exceed the
setpoint temperature and could cause
element failure. The actual displayed
temperature will read on the low side
of setpoint temperature.
1.

Replacement Parts list for normal cold
resistance value).
2.

(Note placement and connection of T/C lead
wires).
3.
Remove the screws on the chamber

thermocouple terminals and disconnect the
wires.
4.
Remove the clamp retaining the thermocouple.
5.
Pull the thermocouple straight back.
6.
Insert the new thermocouple into the furnace and

connect the leads to the terminal block, matching
the wire colors with the incoming wires.
7.
Secure connections with screws removed in Step

3.
8.
Replace the back terminal cover.
9.
Reconnect the furnace to power supply.
To Replace a Type K Filter Thermocouple
52
1.

Replacement Parts list for normal cold
resistance value.)
2.

(Note placement and connection of T/C lead
wires.)
AND
SERVICING
3.
Remove the screws on the filter thermocouple

terminals and disconnect the filter thermocouple
wires.
4.
Remove the clamp retaining the thermocouple.
5.
Pull the thermocouple straight back.
6.
Insert the new thermocouple into the case.
7.
Replace the clamp securing the thermocouple.
8.
Connect the leads to the terminal block,

matching the wire colors with the incoming wires.
9.
Replace the back terminal cover on the furnace.
10. Reconnect the furnace to the power supply.

11. Test the operation of the furnace.
To Replace a Solid State Relay

Three solid state relays are located inside the lower control
section at the rear. The relays are mounted on the heat sink
inside the case. Facing the front of the furnace, the fan relay
is on the right, chamber elements relay middle and filter
relay on the left. See wiring schematic on page 62.
1.
Disconnect furnace from power supply.
2.
Remove the screws on the front dial plate. Open

the front dial plate and remove the two hex 8/32''
(11/32'' socket or wrench is required) nuts in the
lower corners behind the front dial plate. Remove
the eight screws on the lower back cover.
3.
Remove the (3) four wire modular connectors,

one on the right and two on the left, behind the
front cover. (The connectors have a locking tab
which has to be opened before removal).
4.
Remove the remaining (5) cables from the

printer, balance, and display board.
5.
Remove the nut from the short ground wire on

the front cover. Disconnect the ground wire.
6.
Slide the base toward the rear of the furnace

about 3 inches.
53
AND
SERVICING
7.
Remove the large brown modular connector from

the center rear of the control section by squeezing
the tabs on the side of the connector and pulling up.
8.
Remove the small (4 wire) modular connector on

the right side of the brown connector above the fan.
(This connector has the same locking tab as the
previous (3) connectors.
9.
Slide the base toward the rear of the furnace an

additional 3 inches.
10. Remove the two yellow cables with green

connectors from the PC board to which they are
connected. Mark the locations of the wires to
ensure that they are connected to the same
terminals when they are reinstalled.
11. Slide the base the remaining distance out of the
furnace control section being careful not to catch
and damage any of the cables.
12. Mark wiring of locations on the relay to be replaced.
Remove wiring and screws.
13. Replace relay, replace wiring and screws on the
relay.
14. Slide the base section back into the furnace, again
being careful not to damage any of the cables, to
about 6 inches from case.
15. Reinstall the two yellow cables with green
connectors to their original locations, loop wire
down toward bottom of base section.
16. Slide the base section in an additional 3 inches and
reconnect the two modular connectors.
17. Slide the base section in the remaining distance,
refasten all screws and nuts which retain the base.
18. Reconnect all cables and ground wire.
19. Close front cover and install the screws.
20. Reconnect the furnace to the power supply.
21. Test the operation of the furnace.
54
AND
SERVICING
To Replace a Fuse
Six fuse holders are located at the rear of the lower control
section. A medium flat-bladed screwdriver is needed to
remove the carriage from the barrel-style fuse holder. Both
sides of the circuits are fused. The 6.3 amp FZX61 fuse
protects the low voltage circuitry. The 1.6 amp FZX47 fuse
protects the low amperage/high voltage circuit consisting of
the control boards, front control panels display and RS232
port. The 4 amp fuse (FZX53) is tiered over all other circuits
but not the filter or chamber elements. The filter and
chamber elements are protected by the 30 amp circuit
breaker which is tiered above the 4 amp fuse circuit.
Fuse failure may be caused by:
1. Dielectric breakdown of insulators due to
cracking, moisture pickup and contamination
resulting in case to ground shorts.
2.
Excessive current due to line spikes or lightning

strikes.
The cause of fuse failure must be determined and resolved

before installing replacements. See the Replacement Parts
list on page 57 for fuse details.
To Replace a Door Switch (Microswitch)

1.
2.
Remove the four top screws on the front dial

plate.
3.
Open the front dial plate. Remove the shield

which covers the door switches.
4.
Disconnect the wires from the door switch to be

replaced. (Note connection and placement of
wires to Microswitch.)
5.
Remove the two screws from the Microswitches.
6.
Insert new Microswitch and secure with screws

removed in Step 5.
55
AND
SERVICING
7.
Reconnect wires to new door switch. Replace

wire shield.
8.
Close front dial plate and install screws.
9.
Reconnect to power supply.
10. Test operation of door switch.
To Realign Door Switch (Microswitch) Bracket

1.
2.
Loosen the screws which retain the door switch

bracket on the bottom left side of door.
3.
Move the bracket closer to furnace to make

switch engage sooner. Move bracket further
away to make switch engage later. (Lightly
tighten screws between each adjust to hold
bracket while you test the switch.)
4.
The switches should click when the door is

approximately 1" from being completely closed.
5.
Tighten screws when bracket is positioned

correctly.
6.
Reconnect to power supply.
7.
To test the operation of the door switch: turn the

power switch on, set the control to a setting high
enough to keep the control from cycling, open
and close the door; the mechanical relay should
be heard when the door is about 1 from being
closed.
To Realign Door Lock

The door lock plunger interlocks through a port at the
bottom of the door. If the plunger is missing the port,
realign the door by adjusting the position of the door hinge
pins in the door hinge brackets.
56
Replacement Parts
Models:
Series:
220-240 Volts, 208 Volts

1087
Number
Part Number
Description
Voltage
Required
1
04246
Micro Switch, Solenoid Door Lock
All Models
2
1
1
1
1
1
1
1
1
1
1
1
1
2
6
2
2
10
1
4
1
1
2
2
2
1
10
7
7
4
10
10
1
1
1
1
04246
AYX3
EL859X3
EL859X4
EL1087X1
EL1087X2
EL1087X3
EL1087X4
EL1087X5
EL1087X6
FA759X1A
FA1087X2
FL859X2
FZX47
FZX50
FZX53
FZX61
JC408X1
JC412X1
JC412X10
JC859X2
JC1087X3
JC1087X4
JC1087X5
JC1087X6
JC1087X7
JS356X1
JSX102
JSX110
JSX122
JSX124
JSX125
LT1087X1
ME1087X1
PC859X1A
PC859X3A
Switch, Door
Printer
Element, Side, Right - Cold Resistance, 55 ohms
Element, Side, Left - Cold Resistance, 55 ohms
Element Filter - Cold Resistance, 36 ohms
Element, Chamber, Bottom - Cold Resistance, 10 ohms
Element, Chamber, Top - Cold Resistance, 10 ohms
Element, filter - Cold Resistance, 30 ohms
Element, Chamber, Bottom - Cold Resistance, 8 ohms
Element, Chamber, Top - Cold Resistance, 8 ohms
Fan, cooling, control case
Fan, Blower
Filter, Ceramic, Coarse
1.6 Amp Fuse, Little Fuse #23901.6
Fuse Holder
4 Amp Fuse, Schurter #034.3123
6.3 Amp Fuse, Schurter #FSTO34.3125
Insulators, Blanket, element lead
Insulation, formed, door All Models
Insulation, blanket, door All Models
Insulation, formed, chamber bottom
Insulation, formed, chamber rear
Insulation, formed filter assembly, top or bottom
Insulation, blanket, chamber rear
Insulation, formed, chamber sides
Insulation Blanket, filter assembly top
Insulators, ceramic, element lead
Insulator, ceramic, chamber support bottom
Insulator, ceramic, chamber support bottom
Tube, Ceramic, Balance platform to hearth tray
Insulators, element lead terminals
Insulators, element lead terminals
Owners Manual
Balance
Logic, Printed Circuit Board
Analog, Printed Circuit Board
All Models
All Models
All Models
All Models
220-240
220-240
220-240
208
208
208
All Models
All Models
All Models
All Models
All Models
All Models
All Models
All Models
All Models
All Models
All Models
All Models
All Models
All Models
All Models
All Models
All Models
All Models
All Models
All Models
All Models
All Models
All Models
All Models
57
REPLACEMENT PARTS
1
1
1
1
1
3
1
1
1
1
1
1
1
1
1
1
PC859X4A
PC1087X1
PH42X1
PH412X1
PRX2
RYX34
RYX59
RYX62
SC859X1
SWX103
SWX144
TC859X1A
TC1087X1
TNX81
TRX116
TU859X1
1
1
1
WH1087X3
WH1087X4
WH1087X15
58
Power, Printed Circuit Board

Display, Printed Circuit Board
Hearth Tray
Hearth Plate, Chamber, Rear
Printer Paper Tape
Solid State Relay Chamber/Fan /Filter
Solenoid, Door Lock
Contactor, Main
EPROM Software
Circuit Breaker
Switch, Power
Thermocouple, Chamber - Cold Resistance, 1 ohm or less
Thermocouple, Filter - Cold Resistance, 1 ohm or less
Transformer, stepdown
Terminal, fan connection, back top case
Tubing, Exhaust, 3" X 10', Electrogalvanized Steel
(optional accessory, order separately)
Wire harness, Balance RS232 Cable
Wire harness, Printer Cable
Wire harness, 14 Pin Display Cable
All Models
All Models
All Models
All Models
All Models
All Models
All Models
All Models
All Models
All Models
All Models
All Models
All Models
All Models
All Models
All Models
All Models
All Models
All Models
Exploded View
(Insulation & Filter)
Element, Filter
(2) JC408X1
FL859X2
JC1087X7
JC1087X4
JC1087X4
JC1087X1
JC1087X2
JC1087X6
(2) JC1087X5
(7) JSX110
(7) JSX102
JC1087X3
JC859X2
JC1087X6
59
Exploded View (Elements)

Right Side
Element
Top Element
Left Side
Element
Bottom
Element
(10) JS356X1
(10) JSX124
(10) JSX125
(8) JC408X1
PH412X1
Note
See Replacement Parts list to
properly identify replacement
elements. Element Part Numbers will
vary with the voltage of the furnace.
The voltage of the furnace may be 208
volts or 220-240 volts. See the
electrical specification label located at
the rear of the control section of the
furnace to obtain the rated voltage.
60
Ordering Procedures
Please refer to the Specification Plate for the complete model number, serial number, and series number when
requesting service, replacement parts or in any correspondence concerning this unit.
All parts listed herein may be ordered from Barnstead|Thermolyne or your Barnstead|Thermolyne distributor
from whom you purchased this unit.
Decontamination Statement
We cannot accept any product or component sent to Barnstead Thermolyne for repair or credit that is
contaminated with or has been exposed to potentaially infectious agents or radioactive materials. No product or
component willbe accepted without a Return Goods Authorization (RGA) number.
61
Wiring Diagram
62
Wiring Diagram
Component List
Ref. No.
C1
CB1
F1
F2
F3
F4
F5
F6
FL1
FL2
HR1
HR2
HR3
HR4
HR5
J1
Description
Capacitor
Circuit Breaker
Fuse 4 amp
Fuse 4 amp
Fuse 1.6 amp
Fuse 1.6 amp
Fuse 6.3 Amp
Fuse 6.3 Amp
Filter, Low Amp Circuits
Filter, Main
Element, Right Chamber
Element, Top Chamber
Element, Left Chamber
Element, Bottom Chamber
Element, Filter
Wire Harness Assy,
RS232 Port, External
J2
J3
J4
M1
M2
PC1
PC2
PC3
PC4
PC5
PR1
RY1
RY2
RY3
RY4
S1
S2
S3
S4
S5
SC1
SO1
T1
Cordset
Wire Harness Assy, RS232 Balance
Wire Harness, 15V, Balance
Fan, Chamber Exhaust
Fan, Cooling
PC Assy, Main/Logic
PC Assy, Power
PC Assy, Display
PC Assy, Analog
PC Assy, Display Balance
Printer
Relay, Contactor
Relay, S.S., Chamber
Relay, S.S., Filter
Relay, S.S., Fan
Switch, Main (Green)
Switch, Door Switch
Switch, Door Switch
Switch, Interlock
Switch, Keypad
Meter, Balance
Relay, Solenoid
Transformer
Ref. No.
TB1
TB2
TB3
TB4
TC1
TC2
Description
Terminal Block, power entry
Terminal Block, main
Terminal Block, fan
Terminal Block, TC
Thermocouple, chamber
Thermocouple, filter
63
Amperage Configurations
Amperage Configurations
240V Unit Only
The original wiring of your furnace is configured to the 27
Amp (High Amp) configuration. The furnace is capable of
being wired to a 20 Amp (Low Amp) configuration.
1. Disconnect the furnace from power supply.
2. Remove the rear terminal cover.
3. Configure as desired.
Low Amp to High Amp

To change from Low Amp configuration to High Amp
configuration - move the wire at Terminal T4 which goes to
Terminal T6 to Terminal T1, also move one end of the short
looped wire at T4 to T3. See below.
T9
T2
T8
T1
T7
High Amp to Low Amp

To change from High Amp configuration to Low Amp
configuration - move the wire at Terminal T1 which goes to
Terminal T6 to Terminal T4, also move the T3 end of the
short wire to T4 (it will be connected on both ends to the
same terminal).
T4
T6
All other wiring will remain the same.
T3
T5
Wiring Configuration Key

- - - Low Amperage - Wire connected between T4 & T6, wire
disconnected between T3 & T4.
---- High Amperage - Wire connected between T1 & T6, wire
connected between T3 & T4.
64
4. Replace the rear terminal cover.

5. Reconnect power supply.
6. Test operation of furnace. (See Hidden Key
Routine 0 Zero).
Glossary
Balance Stability:
A green LED will flash on and off at

the lower right side of the balance
display. When the LED is shown,
the balance is stable. It is normal
for the LED to flash early in the
ignition procedure, as rapid sample
weight loss occurs early in the
firing procedure and diminishes as
ignition nears completion. The LED
will not illuminate if the furnace is
subject to vibration from other
equipment in the lab. The stabile
indicator on the control panel is not
related to the LED balance stability
indicator.
Calibration Factor: Addresses the aggregate weight loss or

gain which occurs during the ignition
process. This loss or gain is not related
to asphalt content loss and is added or
subtracted from the asphalt content.
Standard methods specify the
procedure for determination. This
calibration factor is entered by the
operator.
Default:
Resets your current values to the

factory values. See hidden key 0 and 2.
Default Values:
These are factory values assigned to

each unit for testing during production.
A printout of these values is supplied
with each unit. Default values can be
compared to your current values to
assess correct entry of each value.
EPROM:
Electronically Programmable Read

Only Memory. Part #SC859X1 is an
EPROM programmed to the current
software configuration. Software
revisions are designated alphabetically.
Current software is Revision G.
Error Codes:
Error codes are displayed to notify the

operator of out-of-specification
condition or modification. Error codes
range from E001 to E005 and E007 to
E012.
65
GLOSSARY
66
HMA:
Hot Mix Asphalt.
Idle Mode:
This mode is entered on startup after

initialization. Revision G software
automatically transfers from the
program mode to the idle mode upon
completion of the test. The furnace will
idle at setpoint temperature in
preparation for the next test. The
blower is OFF in the idle mode.
Initialization:
This procedure sets up and configures

the tester for operator use when the
Power Switch is depressed to ON.
Initialization time is approximately 5-15
seconds.
Lift Test:
This test measures the blower

efficiency when the furnace is in an
unloaded condition and is at room
temperature. The operator is required
to tare the balance, depress the startstop key, and observe the balance
display. Normal lift measurements are
minus 4-6 grams.
NCAT:
National Center for Asphalt

Technology.
Offset Value:
This value is the temperature

difference between the stabilized
chamber displayed temperature value
and the chamber temperature
verification value determined by the recalibration process.
Program Mode:
This mode is entered by depressing

the start-stop key. The program mode
is used to determine asphalt content of
a HMA sample, calibration of the HMA
sample, or raw aggregate.
Temperature
Compensation
Factor:
This factor compensates for the

loaded basket assembly weight
reduction experienced when placed in
the ignition furnace chamber at
temperature. The Temperature
GLOSSARY
Compensation Factor is
automatically calculated by the
furnace software. This factor must
be employed in the ignition process
to achieve acceptable precision and
accuracy specified by standard
methods. This factor is subtracted
from the asphalt content.
Test Endpoint:
This is the point at which the HMA

samples weight loss does not
exceed the Test Stability Threshold
Setting for three consecutive one
minute periods. Furnaces containing
Rev. G software will end the test,
asterisk the endpoint reading on the
printout, and switch from the
program mode to the idle mode at
endpoint if the Auto Program
Switching to Idle is employed.
Test Stability
This adjustable variable defines the

endpoint sensitivity by measuring
the HMA sample mass loss and
comparing it to the test threshold
setting. The test is complete when
the measured mass loss does not
exceed the stability threshold setting
for three consecutive one minute
periods. The stabile indicator on the
front control panel indicates the test
stability threshold (endpoint) has
been attained.
67
One Year Limited Warranty

Barnstead International (BARNSTEAD) warrants that if a product manufactured by Barnstead shall be free of
defects in materials and workmanship for one (1) year from the first to occur of (i) the date the product is sold
by BARNSTEAD or (ii) the date the product is purchased by the original retail customer (the Commencement
Date). Except as expressly stated above, BARNSTEAD MAKES NO OTHER WARRANTY, EXPRESSED OR
IMPLIED, WITH RESPECT TO THE PRODUCTS AND EXPRESSLY DISCLAIMS ANY AND ALL
WARRANTIES, INCLUDING BUT NOT LIMITED TO, WARRANTIES OF DESIGN, MERCHANT ABILITY AND
FITNESS FOR A PARTICULAR PURPOSE.
An authorized representative of BARNSTEAD must perform all warranty inspections. In the event of a defect
covered by BARNSTEADs warranty, BARNSTEAD shall, as its sole obligation and exclusive remedy, provide
free replacement parts to remedy the defective product. In addition, for products sold by BARNSTEAD within
the continental United States or Canada, BARNSTEAD shall provide provide free labor to repair the products
with the replacement parts, but only for a period of ninety (90) days from the Commencement Date.
BARNSTEADs warranty provided hereunder shall be null and void and without further force or effect if there is
any (i) repair made to the product by a party other than BARNSTEAD or its duly authorized service
representative, (ii) misuse (including use inconsistent with written operating instructions for the product),
mishandling, contamination, overheating, modification or alteration of the product by any customer or third
party or (iii) use of replacement parts that are obtained from a party who is not an authorized dealer of
BARNSTEAD.
Heating elements, because of their susceptibility to overheating and contamination, must be returned to the
BARNSTEAD factory and if, upon inspection, it is concluded that failure is due to factors other than excessive
high temperature or contamination, BARNSTEAD will provide warranty replacement. As a condition to the
return of any product, or any constituent part thereof, to BARNSTEADs factory, it shall be sent prepaid and a
prior written authorization from BARNSTEAD assigning a Return Goods Number to the product or part shall
be obtained.
IN NO EVENT SHALL BARNSTEAD BE LIABLE TO ANY PARTY FOR ANY DIRECT, INDIRECT, SPECIAL,
INCIDENTAL, OR CONSEQUENTIAL DAMAGES, OR FOR ANY DAMAGES RESULTING FROM LOSS OF
USE OR PROFITS, ANTICIPATED OR OTHERWISE, ARISING OUT OF OR IN CONNECTION WITH THE
SALE, USE OR PERFORMANCE OF ANY PRODUCTS, WHETHER SUCH CLAIM IS BASED ON
CONTRACT, TORT (INCLUDING NEGLIGENCE), ANY THEORY OF STRICT LIABILITY OR REGULATORY
ACTION.
The name of the authorized Barnstead International dealer nearest you may be obtained by calling 1-800-4466060 (563-556-2241) or writing to:
68
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BARNSTEAD|THERMOLYNE CORPORATION

NCAT Asphalt Content Tester

Inactivity Mode ................................................................................................................................................. 31

This manual contains important operating and safety

Your NCAT Asphalt Content Tester has been designed with

This furnace must be installed by a competent,

Disconnect from power supply before servicing.

Ensure that the furnace is not connected to the

Ensure that the door switch is operating properly.

Do not use in the presence of flammable or

Refer servicing to qualified personnel.

Allow the furnace to cool to room temperature

Failure to connect the exhaust port to an

This furnace contains refractory ceramic

This warning is presented for compliance with California

45-3790/01, F85930 (240 V) F85938 (208V)

Default Values for

Chamber Set point

Declaration of Conformity(-33 models only)

Generic Emission Standard

Safety requirements for electrical equipment for measurement, control

Part II: Particular requirements for laboratory equipment for

Visually check for any physical damage to the

Open the furnace door and carefully remove

Remove the balance, ceramic posts, fuses,

Retain the original packaging material if

Hearth tray, gray silicon carbide

Ceramic tube supports, Inside Furnace Chamber

Instruction Manual, Inside Furnace Chamber

Accessory Kit Contents

Basket Retainer Brackets

Transport and Catch Trays

Covers for Top Baskets

Aluminum Cooldown Plate

Cooldown Safety Cage with HOT Sign

Face Shield with Head gear

Pair High Temperature Gloves

Can of Fan Motor Lubricant

Stainless Steel Basket Brush

Rolls of Thermal Printer Paper

Length of exhaust tubing (3" I.D. x 10', shipped

Place the furnace on a sturdy level surface about 26-28

The electrical specifications are:

Your furnace is factory configured for a 27 amp supply. You

Figure 2 Terminal Block Connections

Exhaust Installation Tips

Select a location to minimize exhaust length.

Flexible 3 I.D. seamless steel tubing or

Minimize 90 bends in your exhaust system if

Termination of your exhaust system may be in

-8.2 grams may blow fines from the basket

Turn on fume hood blowers and conduct lift test

The NCAT Asphalt Content Tester is supplied with an

Ensure that the furnace is disconnected from the

edge or adjust all feet up about 1/4 inch. This

Open the lower case by carefully pulling the

Inside the lower furnace case, observe the

Mount the support plate and the catch pan on

Place the Setra balance on the balance

Position the balance so that the pins on the