NCAT

Asphalt Content Furnace

Service Manual

LT1275X3 2/13/04

Table of Contents
Introduction..........................................................................................................................................................5
What is an NCAT Asphalt Test Furnace? ....................................................................................................5
Why Test Asphalt? ........................................................................................................................................5
Why Improve the Existing Method of Asphalt Testing? ................................................................................5
Barnstead Internationals Involvement..........................................................................................................6
How Does the NCAT Work? ........................................................................................................................6
Unpacking and Installation ..................................................................................................................................7
Electrical Specifications ................................................................................................................................7
Site Selection................................................................................................................................................9
Power Requirements ....................................................................................................................................9
Exhaust Installation Tips ..............................................................................................................................9
Installation Drawings ..................................................................................................................................11
Balance ............................................................................................................................................................13
OHAUS vs. SETRA ....................................................................................................................................13
SETRA Balance Replacement....................................................................................................................13
OHAUS Fuse Location ..............................................................................................................................14
OHAUS Display Board................................................................................................................................14
OHAUS and SETRA Ribbon Cables ..........................................................................................................14
Replacement Parts ....................................................................................................................................14
OHAUS Balance................................................................................................................................................15
Installation ..................................................................................................................................................15
Balance Control Port Hole Location ..........................................................................................................17
OHAUS Time and Date Set Procedure ......................................................................................................18
Resetting the User Variables of an OHAUS Balance ................................................................................20
OHAUS Balance Calibration ......................................................................................................................25
SETRA Balance ................................................................................................................................................27
SETRA Balance Installation........................................................................................................................27
Balance Control Port Hole Location ..........................................................................................................29
SETRA Time and Date Set Procedure ......................................................................................................30
Resetting Variables of a SETRA Balance to Factory Default ................................................................32
SETRA Balance Calibration........................................................................................................................33
Error Conditions ................................................................................................................................................35
OHAUS Balance ........................................................................................................................................35
SETRA Balance ..........................................................................................................................................36
Printer ..............................................................................................................................................................37
Thermal Paper Storage ..............................................................................................................................37
RS232 Connection Information ..................................................................................................................37
Printer Change (Production) ......................................................................................................................38
Troubleshooting ..........................................................................................................................................39
Software ............................................................................................................................................................41
History ........................................................................................................................................................41
SC859X1 Rev. 1 Software EPROM............................................................................................................43
Installation ..................................................................................................................................................45
Ordering Information ..................................................................................................................................47
Procedures ........................................................................................................................................................48
Amendment ................................................................................................................................................48
Definition ....................................................................................................................................................48
2

TABLE

OF

CONTENTS

Output ..............................................................................................................................................................59
Bitumen Ratio ............................................................................................................................................59
Glossary ............................................................................................................................................................60
Errors ..............................................................................................................................................................63
Red Display (Furnace)................................................................................................................................63
Green Display (Balance) ............................................................................................................................66
NCAT Troubleshooting with No Error Codes Displayed ............................................................................68
Aggregates..................................................................................................................................................72
Negative Air Pressure ................................................................................................................................72
Displayed Letters/Numbers ........................................................................................................................74
Equipment Test Procedure ................................................................................................................................81
Removal of the Control Assembly (Bottom Section) in the 1087 and 1275 Series NCAT ........................81
1087 Series Back Wall Insulation Removal................................................................................................88
Heating Elements ......................................................................................................................................89
Element Part Numbers and Cold Resistance ............................................................................................95
Thermocouples ..........................................................................................................................................98
Solid State Relays ....................................................................................................................................101
Keypad......................................................................................................................................................104
Maintenance ....................................................................................................................................................110
Lift Test Procedure ....................................................................................................................................110
Cleaning Procedure for NCAT ..................................................................................................................111
Chamber Temperature Verification/Calibration ........................................................................................112
Balance Calibration ..................................................................................................................................115
Drawings..........................................................................................................................................................116

Introduction
What is an NCAT Asphalt Test
Furnace?
The NCAT Asphalt Content Furnace is a unitized furnace,
electronic weighing system, and exhaust air filtration
mechanism combined into one system. The system was
developed by a team of Barnstead International engineers
in conjunction with the National Center for Asphalt
Technology (hence the name NCAT) at Auburn University.
The NCAT furnace was designed as an improvement over
the existing solvent method of determining the binder content in asphalt paving materials.

Why Test Asphalt?

Hot mix asphalt used for roads and highways has to be
incredibly durable, withstanding not only the rigors of
heavy truck and car traffic, but also the temperature
extremes of tropical summers and arctic winters.

Why Improve the Existing

Method of Asphalt Testing?
Existing testing methods are extremely time consuming
and difficult to perform properly.

INTRODUCTION

Barnstead Internationals
Involvement
Because the NCAT researchers at Auburn University
decided that their new test method would use high temperature to separate the asphalt from the aggregate in the
asphalt mix, they needed a company that specialized
benchtop high temperature laboratory furnaces.

How Does the Asphalt Content

Furnace Work?
A known weight of asphalt mix is placed in the NCAT furnace chamber. The furnace then burns away the binder
until only the stones remain. The automatic weighing
system incorporated into the unit monitors the reduction in
weight of the sample as the binder burns off until the
weight change stops (meaning all the binder has been
burnt away and only stones remain). The software within
the unit then calculates the percent of binder within the
asphalt mix. All of this is included on a paper printout by
a small built-in strip recorder so that the lab technician
can confirm that the tested sample of asphalt did meet
accepted quality standards. All of this may sound simple,
but it isnt. An especially difficult technological problem
was how to eliminate the black soot that would normally
billow out of the furnace exhaust as the asphalt binder
burned away. Our engineers developed a special ceramic filtration/burner system so effective that the outside
exhaust is essentially invisible and meets all guidelines
for emissions set by the Environmental Protection
Agency. This solution was so innovative that the U.S.
Patent Department has granted several patent claims to
Barnstead International.

Unpacking and Installation

Electrical Specifications
Model #
F85930
F85930
F85938
F85930-33

Voltage
240Vac
220Vac
208Vac
240Vac

Amperage
27 Amps
20 Amps*
28 Amps
27 Amps

Watts
6379
4879
5757
6379

Phase
50/60Hz, Single
50/60Hz, Single
50/60Hz, Single
50/60 Hz, Single

*Model # F85930 units are configured for a 27 Amp supply when shipped from the factory. You have the
option of re-configuring the wiring at the back of the furnace for 20 amps. Please refer to the owner/operator
manual for instructions on how to re-wire the unit for the lower amperage configuration. Typically, a 20-amp
configuration is used for mobile laboratory installations where the power supplies may be limited. Units configured for 20 amps will heat and process samples at a slower rate.

NCAT furnaces are not supplied with a power cord or plug and must be wired either directly
through a conduit system or by a customer supplied power cord and plug. Electrical wiring should
conform to local electrical code requirements. Please consult with a certified electrician for electrical
connection.

NCATs sold in the 208V version should not be connected to 240V power supply. Damage to electrical components in the furnace will occur.

NCATs sold in the 240V version should not be connected to 208V power supply. Damage to electrical components in the furnace will occur.

Buck/Boost low voltage isolation transformers are an electrical device that has the ability to step up
a 208V power supply to 240V or step down a 240V power supply to 208V. Buck/Boost transformers
are available at Barnstead International (P/N TNX122) or can be purchased at local electrical retail
stores.

Recommended buck/boost transformer ratings (TNX122):

MFR:
MFR Model:
Ratings:

Jefferson Electric
216-1241-000
.75 kVA
Single Phase (50/60Hz)
120/240 Volts
16/32 Volts

UNPACKING AND INSTALLATION

Barnstead International packs a chamber to transport an NCAT from one location to another, preventing damage.

Parts Shipped in Chamber:

(8) JSX122 - Balance/Hearth Plate Ceramic Support Tubes
Parts Shipped in Accessory Box (Located on top of unit - not pictured)
PHX4 - Hearth Plate
(2) FZX47 - Fuses
(2) FZX53 - Fuses
(2) FZX61 - Fuses
ME859X1 - Balance
LT1275X1 - Manual

INSTALLATION

Site Selection
Note
This manual does not include all
information necessary to properly
install an NCAT. Please refer to
owner/operator manual.

The NCAT should be mounted on a sturdy level

surface, capable of supporting the weight of the
fully assembled furnace (Approximately 300
pounds).

Allow a minimum space of 6 inches between the

NCAT outer casing and any vertical surfaces
such as the walls of the building for airflow
requirements and heat escape. The chamber
door must be permitted to swing freely to allow
loading and unloading of the chamber.

Locate the furnace so that you can direct the

furnace emissions through ducting to a fume
hood or other appropriate ventilation systems.
We recommend an exhaust length of not more
than 10 feet.

Power Requirements
The NCAT units are not supplied with a power cord due to
the large amperage draw. Please consult with a certified
electrician to have the NCAT hardwired or an appropriate
power cord and receptacle installed in your facility.
Electricians will ensure compatibility among furnace specifications, power source and ground code requirements.

Exhaust Installation Tips

See Installation tips in the Owner/Operator manuals for more information and/or refer to installation drawings for additional information on installation.

Minimize bends in exhaust tubing as much as

possible. (Rule of thumb: Only one 90 bend
allowed in exhaust tubing 10 feet in total length.)

Exhaust exiting the furnace port may reach temperatures as high as 270C. Keep all flammable
material a safe distance from the furnace.

3-inch outside diameter, flexible stainless steel

tubing works best for exhaust duct-work.
9

INSTALLATION

Available from Barnstead International, P/N

TU859X1.

10

Install rock-wall cloth rated to handle temperatures up to 270C to insulate the exhaust tubing
passing through ceiling ducts.

Do not use exhaust tubing less than 3 inches in

diameter.

Do not use galvanized tin tubing or double wall

tin tubing.

Do not connect the NCAT exhaust port directly

to an external fan with a rating of more than 60
CFM. This will create a negative airflow in the
exhaust system. The blower motor in the
NCAT is rated at 65CFM and will provide
enough power for emission up to approximately
10 feet.

INSTALLATION

11

INSTALLATION

12

Balance
The original NCAT (Series 859 & 945) were all manufactured with an OHAUS balance, model GT8000. Design
changes still found OHAUS balances being used in the
1087 series until February 1998, in which a manufacturing
change from OHAUS to SETRA was completed.

OHAUS vs. SETRA

OHAUS balance and display board

The physical appearance between both scales

is different, with the housing of the OHAUS balance being brown or tan in color and housing of
the SETRA being gray or silver.

OHAUS balances are a 240 VAC powered scale

and the SETRA are a 15 VDC powered scale.

The display board for the SETRA is mated with

a load cell or silver colored base. Whereas the
OHAUS load cells and display boards can be
interchanged. (A 6 digit number can be found on
the SETRA load cell and on the mated display
board.)

The SETRA balance does not contain the

numerous user variables found in the OHAUS,
making functions, such as resetting the time or
date and calibrating the SETRA much easier.

The SETRA does not require a special calibration plate, as does the OHAUS. (The hearth
plate can be left in the chamber, when calibrating the SETRA.)

SETRA Balance Replacement

SETRA balance and display board

When replacing SETRA balances, the balance (load cell)

and display board MUST be changed out as a matched
pair. Locate the decal on the back of the balance (load
cell) with a 6 digit number. Locate the decal on the display board with the 6-digit number. Ensure the numbers
on both parts match. If they do not match, the balance
will not function properly. When customers return
SETRA balances, they MUST return the matching display board for warranty coverage.
13

BALANCE

OHAUS Fuse Location

The OHAUS balances have a fuse installed on
the back of the load cell. The black, rectangular
fuse holder/cap is located as part of the power
entry module. The cap also has voltage markings
on each side. The side facing towards the top of
the balance is how the holder/cap should be positioned for the corresponding supply voltage. The
fuse is rated at 250V, 160ma. Barnstead
International replacement fuse is P/N FZX60. If
the fuse opens the red display will indicated ERR
8.

OHAUS Display Board

Part number PCX22 was set up as a replacement
part number for display boards for OHAUS balances ONLY. The part is obsolete and can no
longer be ordered.

OHAUS and SETRA

Ribbon Cables
Replacement Parts

The ribbon cables that directly attached to the

OHAUS and Setra balances are part of the balance and do not have replacement part numbers.

Part Number
ME859X1

Description
SETRA upgrade kit. For customers wanting to update their NCAT from the OHAUS
to the SETRA balance. This kit includes all the necessary wire harnesses needed to
connect a new SETRA balance and installation instructions.

ME1087X1/C

New SETRA balance for warranty situations. (This part number was set up for
customers with SETRA balances that fail within warranty.)

14

OHAUS Balance
Installation
The OHAUS Balance (GT8000) operates on 208Vac or
240Vac (full potential line voltage). The balance is configured for supply voltage that corresponds with the NCAT
upon production at Barnstead International.
OHAUS balances were used in production from 1995 to
1998 and are currently sold as replacements only.
1.

Ensure that both the balance and the furnace

are 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.

2.

Open the lower control panel by carefully swinging the control panel down (hinged).

3.

Inside the lower control assembly, observe the

suspended table supported by four aluminum
rods. The balance will be supported by this
table. Vacuum the table if dust, etc., appear on
it.

4.

Mount the platform support plate on the balance. Note the four pins on the support plate.
These will retain the ceramic support tubes,
which will project into the furnace chamber after
mounting.

5.

Orient the balance so that the front of the balance faces the back of the furnace. Run the
cable attached to the front of the balance under
the balance, so that the unattached end of the
cable emerges from beneath the back of the
balance.

6.

Slide the balance front-first onto the suspended

table beneath the furnace chamber.

7.

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.

8.

Plug the balances power cord (the black, threepronged female plug) into the socket on the rear
15

OHAUS BALANCE

of the balance. Plug the nine-pin ribbon cable

female socket from the controller into the corresponding socket on the back of the balance.
Plug the 13 pin socket on the display cable (the
cable from the front of the balance running
beneath the balance) into the 13 pin connector
located on the lower right-hand edge (as you
face the unit) of the balance display board
(mounted on the right-hand side of the front control panel).
9.

Open the furnace door. Mount 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,

10. Mount the hearth tray on the four ceramic support tubes. Place the smooth side of the hearth
tray down, with the ridges on the top of the
hearth tray running from the front to the back of
the furnace chamber.
11. 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.

16

OHAUS BALANCE

Balance Control Port Hole Location

There are 4 holes strategically placed on the front of the control panel, between the green display and the red
displays. These holes are used to access and adjust the balance variables. Use an appropriate sized tool or
paper clip to access balance keys through the port holes in the control panel. Reference the sketch of the
control panel for location/identification of balance control port holes which will need to be accessed to perform
balance time/date setting, balance resetting, and balance calibration procedures.

Balance Display

PRINT Button

Chamber Temp

OFF Button

MODE Button

Percent Loss

ON Button

Elapsed Time

Control Panel Sketch

17

OHAUS BALANCE

OHAUS Time and Date Set

Procedure
The balance supplies the time & date to the microprocessor of the NCAT. For ease of record keeping and to allow
the microprocessor to function properly, please ensure
the time and date are set appropriately.
The balance is shipped with the time & date set to Central
Daylight Time or Central Standard Time, depending on
the time of the year the balance is purchased. If you wish
to adjust these settings for local time, please follow the
outlined procedure.
Note: The OHAUS balance must be set up for US date
settings and EURO time (24 hour format) settings or it will
not communicate with microprocessor in the NCAT correctly.
1. Power down the NCAT furnace using the green
power switch. Press and the hold the number
4 key on the keypad. While holding down the
4 key, power up the NCAT using the green
power switch. Hold the 4 key until you hear
the NCAT beep. Release the 4 key.

18

2.

Press and hold the balance ON button. Release

when Menu appears on the balance display.

3.

Menu will automatically change to Cal. When

Cal is displayed, repeatedly press the MODE
button until Setup is displayed.

4.

Press the ON button. Reset will be displayed.

5.

Repeatedly press the MODE button until Time

is displayed.

6.

Press the ON button. Type will be displayed.

7.

Press the ON button. US will be displayed.

8.

Press the MODE button. Euro will be displayed.

9.

Press the ON button. Type will be displayed

again.

OHAUS BALANCE

10. Press the MODE button. Set will be displayed.

11. Press the ON button. The display will indicate
time with the first two digits (hours) flashing.
12. Repeatedly press (or press and hold to scroll)
the MODE button until the current hour (24 hour
clock) is displayed.
13. Press the ON button. The last two digits (minutes) will flash.
14. Repeatedly press (or press and hold to scroll)
the MODE button until the current minute is displayed.
15. Press the ON button. Set is displayed.
16. Press the MODE button. End, Time will be displayed.
17. Press the ON button. Time will be displayed
again.
18. Press the MODE button. Date will be displayed.
19. Press the ON button. Type will be displayed.
20. Press the ON button. US will be displayed.
21. Press the ON button. Type will be displayed
again.
22. Press the MODE button. Set will be displayed.
23. Press the ON button. The display will not indicate the date with the first two digits (month)
flashing.
24. Repeatedly press (or press and hold to scroll)
the MODE button until the current month is displayed.
25. Press the ON button. The second two digits
(date) will flash.

19

OHAUS BALANCE

26. Repeatedly press (or press and hold to scroll)

the MODE button until the current date is displayed.
27. Press the ON button. The last two digits (year)
will flash.
28. Repeatedly press (or press and hold to scroll)
the MODE button until the current year is displayed.
29. Press the ON button. Set will be displayed.
30. Press the MODE button. End, Date will be displayed.
31. Press the ON button. Date will be displayed.
32. Repeatedly press the MODE button until End,
Setup is displayed.
33. Press the ON button. Setup will be displayed.
34. Press the MODE button until End, Menu is displayed.
35. Press the ON button. The display will revert to
displaying the current sample weight.
36. Power down the NCAT and power back up using
the green power switch to exit the balance
adjustment mode.

Resetting the User Variables of

an OHAUS Balance
In the event that your furnace ceases to operate and displays error code E008, check that the balance is properly
connected to furnace as described in Balance Installation.
If the balance is properly connected but the furnace is still
failing to operate and is still displaying E008, you need to
reset the balances parameters. (Reference the sketch,
depicting the balance control port holes.)

20

OHAUS BALANCE

To reset balance
1.

Power down the NCAT furnace using the green

power switch. Press and the hold the number
4 key on the keypad. While holding down the
4 key, power up the NCAT using the green
power switch. Hold the 4 key until you hear
the NCAT beep. Release the 4 key.

2.

Press and hold the ON button. Release when

Menu appears on the balance display. Menu
will automatically change to Cal.

3.

Press the MODE button. User will be displayed.

4.

Press the ON button. Reset will be displayed.

5.

Press the ON button. Yes will be displayed.

6.

Press the ON button to reset the user menu to

the OHAUS default values. You will know this
when this has been done when you hear a short
train of beeps.

7.

Press the MODE button. AL (Averaging Level)

will be displayed. Select this by pressing ON.
This will display AL-1. The correct value is
AL3. In order to change the averaging level,
continue pressing MODE until AL3 is displayed.
Press the ON to accept the new value. The
menu option AL will be displayed again.

8.

Press and release the MODE button until the

menu option Auto-O is displayed. Press the
ON button to select. Repeatedly press the
MODE button until Off is displayed. Press the
ON button to accept this option.

9.

Press and release the MODE button until the

menu option End User is displayed. Press the
ON button to select. This will take you back to
the User Menu.

10. Press the MODE button. Setup will be displayed. Press the ON button to accept the
choice. Display will read, Reset.
21

OHAUS BALANCE

11. Press the ON button. Yes will be displayed.

Pressing the ON button again will reset the
Setup menu to the OHAUS defaults. You will
know when this has been done when you hear a
short train of beeps.
12. Repeatedly press the MODE button until the
Time menu option is displayed.
13. Press the ON button to select. Type will be displayed.
14. Press the ON button. US will be displayed.
15. Press the MODE button. EURO will be displayed.
16. Press the ON button to select EURO (Military
time).
17. Repeatedly press the MODE button until the
word Set is displayed.
18. Pressing the ON button will display the time that
is entered into the balance. If the time is incorrect, it may be changed by pressing the MODE
button to cycle through the hours. Once the
correct hour is displayed, press the ON button to
accept the new hour setting and move to the
minutes setting. Press the MODE button to
cycle through the minutes. Once the correct
minutes are displayed, press the ON button to
accept the new minute setting at which time the
display will change to read Set.
19. Press the MODE button. End is displayed.
20. Press the ON button. Time is displayed.
21. Press the MODE button. Date will be displayed.
22. Press the ON button to select. Type will be displayed.
23. Press the MODE button. Set will be displayed.
This menu will allow the date to be changed if
22

OHAUS BALANCE

incorrect. Pressing the ON button will display

the date. The date may be changed by pressing
the MODE button to first change the month, day
and year respectively, as was done with changing the time. After pressing the ON button when
selecting the date, the menu option Set is displayed.
24. Press the MODE button. End is displayed.
25. Press the ON button to select. Date is displayed.
26. Repeatedly press the MODE button unit End is
displayed.
27. Press the ON button to select. This will take
you back to the setup mode.
28. Press the MODE button. Print will be displayed.
29. Press the ON button to select. Reset will be
displayed.
30. Press the ON button. Yes will be displayed.
31. Press the ON button again will reset the Print
menu to OHAUS default values. You will know
when this has been done when you hear a short
train of beeps.
32. Press the MODE button. Com will be displayed. (Communication parameters of the balance).
33. Press the ON button. Baud will be displayed.
34. Press the ON button. Baud Rate will be displayed.
35. Repeatedly press the MODE button until
BR9600 appears. When it does, press the ON
button to approve the selection. Baud will be
displayed.

23

OHAUS BALANCE

36. Press the MODE button until Data is displayed. Press the ON button to display the current parameter setting. Change setting to read
8 Data by pressing the MODE button. Press
the ON button to approve the setting, which will
display Data.
37. Press the MODE button until Stop is displayed.
Press the ON button to display the current
parameter. Change setting to read 1 Stop by
pressing the MODE button. Press the ON button to approve the setting, which will display
Stop.
38. Press the MODE button until the word End is
displayed. Press the ON button. Com will be
displayed.
39. Press the MODE button until the word Options
is displayed. Press the ON button to enter the
menu. Auto will be displayed. Repeatedly
press the MODE button until the word Time is
displayed. Press the ON button to enter this
menu. Change setting to On by pressing the
MODE button. Press the ON button to approve
the setting. Time will be displayed.
40. Press the MODE button until the word Date is
displayed. Press the ON button to enter the
menu. Change the printing of the date to On
by pressing the MODE button. Press the ON
button to approve the selection. Date will be
displayed.
41. Press the MODE button until the word End is
displayed. Press the ON button until the word
Options is displayed. Repeatedly press the
MODE button until the word End appears.
Press the ON button until the word Print is displayed.
42. Press the MODE button until the word End is
displayed. Press the ON button to approve this
selection. The balance will display weight again,
and is no ready to be used with the NCAT furnace.

24

OHAUS BALANCE

43. Power down the NCAT with the green power

switch and power back on again to exit balance
adjustment mode.

OHAUS Balance Calibration

OHAUS balance calibration should be performed to
ensure accurate weighing. Calibration is performed with
the calibration plate (provided by B/I) and a set of certified
weights (8000 grams).
You need to have the calibration plate and certified
N.I.S.T. weights to perform the calibration.
NOTE: Span calibration works best at 4000 grams given
the application with the NCAT.
The OHAUS balance also has linearity and user calibration modes. However, due to the nature of the application, calibration of the balance in either of these two
modes is not necessary.
1. Power down the NCAT, allowing the unit to cool
to ambient chamber temperature.
2.

Open the furnace door and remove the hearth

plate (setting on top of the four ceramic support
posts. (Door remains open until calibration is
complete.)

3.

Place the calibration plate (P/N = PT859X7) on

top of the four ceramic support posts, ensuring
the plate is centered.

4.

Press and hold the #4 key on the keypad in.

While the #4 key is held, turn the green power
switch on as to power up the NCAT. When the
unit beeps, you may release the #4 key.

5.

Access the balance control buttons through the

pin holes located on the front of the control
panel (Reference the sketch depicting the balance control port holes.)

6.

Press the ON button. Menu is displayed followed automatically by Cal.

25

OHAUS BALANCE

7.

Press the ON button again. Span is displayed

followed by C 0g.

8.

Press the ON button again to start the Span calibration. -C- is displayed followed by the value
of mass which must be placed on the platform
such as C 2000g. NOTE: DO NOT DISTURB
THE BALANCE WHEN -C- IS DISPLAYED.

9.

Repeatedly press the MODE button to select the

percentage of the mass on the display. (25% =
2000g, 50% = 4000g, 75% = 6000g, 100% =
8000g.)

10. Place the required mass on the calibration plate.

11. Press the ON button. -C- displayed while the
balance calibrates. NOTE: DO NOT DISTURB
THE BALANCE WHEN -C- IS DISPLAYED.
12. Display will automatically indicate S followed
by the calibration weight when calibration is
complete.
13. Remove the mass from the calibration platform.
S 0.00g is displayed indicating the balance is
now in weighing mode and the SPAN calibration
is complete.
14. Power down the NCAT unit.
15. Remove the calibration platform and reinstall the
hearth plate, ensuring it is centered on the four
ceramic support posts.
16. Calibration complete.

26

SETRA Balance
SETRA Balance Installation
*Steps 1-5 also refer to replacing an existing balance.
1.

Lower the front control panel by removing the

screws. Locate the balance display board
mounted on the back of the front control panel.
This is the board that illuminates with green
numbers when the unit is powered up.

2.

Remove this board from the unit.

3.

Mount the new P.C board that comes with the

balance in this position.

4.

Open the chamber-door and remove the load

plate. Remove the (4) ceramic support collars
that extend downward into the control section of
the furnace.

5.

Remove the old balance from the control section

of the furnace. (Disconnect wire harnesses.)

6.

Secure the support plate with (4) screws on

SETRA balance.

7.

Set the SETRA balance (load cell) in the control

section of the furnace.

8.

Connect the 10-pin gray ribbon cable that protrudes from the bottom of the silver SETRA balance into P2 on the new display board.

9.

Connect the 9-pin gray ribbon cable to P3 on

the new display board. Connect the other end
of the 9-pin gray ribbon to J5 on the main control board (PC859X1A) mounted in the NCAT
control section.

10. Connect the 15Vdc power cable (red and white

wires) to P6 on the new display board. Connect
the white wire on the opposite end of the cable
to J29 on the main control board mounted in the
NCAT control section. Connect the red wire to
J30 on the main control board mounted in the
NCAT control section.

27

SETRA BALANCE

11. Install the 4 ceramic support posts down through the

holes in the chamber so they straddle the support
plate of the balance. Physically maneuver the balance (load cell) in such a manner to ensure each of
the 4 ceramic support posts are not in contact with
any part of the NCAT chamber section.
12. Set the load plate back on the (4) ceramic support
posts in the chamber. Make sure the load plate
does not come in contact with the sides of the
chamber.
13. Raise the control panel and secure with 4 screws.
Installation of the new SETRA balance is complete. The time
and date will have to be properly set and the balance should
be calibrated before usage.

28

SETRA BALANCE

Balance Control Port Hole Location

There are 4 holes strategically placed on the front of the control panel, between the green display and the red
displays. These holes are used to access and adjust the balance variables. Use an appropriate sized tool or
paper clip to access balance keys through the port holes in the control panel. Reference the sketch of the
control panel for location/identification of balance control port holes which will need to be accessed to perform
balance time/date setting, balance resetting, and balance calibration procedures.

Balance Display

ENTER Button

Chamber Temp

Not Used

Not Used

Percent Loss

ON/OFF Button

Elapsed Time

Control Panel Sketch

29

SETRA BALANCE

Setra Time and Date Set

Procedure
The balance supplies the time & date to the microprocessor
of the NCAT. For ease of record keeping and to allow the
microprocessor to function properly, please ensure the time
and date are set appropriately.
The balance is shipped with the time & date set to Central
Daylight Time or Central Standard Time, depending on the
time of the year the balance is purchased. If you wish to
adjust these settings for local time, please follow the outlined
procedure.
Note: The Setra balance must be set up for US date settings
(2-tear) and a 24 hour clock format or it will not communicate
with the microprocessor in the NCAT correctly.

To Set the Time

30

1.

Turn the green power switch on the furnace control

panel to the OFF position.

2.

Press & hold the # 4 key while turning the green

power switch to the ON position. (Hidden Key 4 procedure). The red display will indicate [BAL CAL].
Release the # 4 key when the NCAT beeps once.

3.

Press and hold the balance ON/OFF key with a

small device such as straightened paper clip. (Note
balance control port holes in control panel sketch.)

4.

Press the balance ENTER key with a second small

device such as a straightened paper clip. (Note balance control port holes in control panel sketch.)

5.

Release both keys simultaneously. [71nE] will be

displayed.

6.

Press the balance ENTER key. The two-hour digits

will be blinking in 24-hour format.

7.

Press the balance ON/OFF key until the correct

hour is displayed. Press ENTER.

SETRA BALANCE

8.

Press the balance ON/OFF key until the correct

minute is displayed. Press ENTER.

9.

Press the balance ENTER key, the balance will

return to the normal weight display.

To Set the Date

1.

Power down the NCAT. (Green Power Switch).

2.

Press & hold the # 4 key while powering the

NCAT back up. (Hidden Key 4 procedure). The
red display will indicate [BAL CAL]. Release the
# 4 key when the NCAT beeps once.

3.

Press & hold the balance ON/OFF key with a

small device such as straightened paper clip.
(Note balance control port holes in control panel
sketch.).

4.

Press & hold the balance ENTER key with a

small device such as straightened paper clip.
(Note balance control port holes in control panel
sketch.).

5.

Release both keys simultaneously. [71nE] will

be displayed.

6.

Press the balance ON/OFF key. [dA7E] will be

displayed.

7.

Press the balance ENTER key. [US] or [Eur0]

date type will be displayed.

8.

Press the balance ON/OFF key until [US] is displayed.

9.

Press the balance ENTER key [2d Yr] or [4d Yr]

will be displayed.

10. Press the balance ON/OFF key until [2d Yr] is

displayed.
11. Press the balance ENTER key. [dAY xx] will be
displayed.

31

SETRA BALANCE

12. Press the balance ON/OFF key until the desired

day is displayed.
13. Press the balance ENTER key. [nn xx] will be
displayed.
14. Press the balance ON/OFF key until the desired
month is displayed.
15. Press the balance ENTER key. [Yr xx] will be
displayed.
16. Press the balance ON/OFF key until the desired
year is displayed.
17. Press the balance ENTER key. The display will
revert back to normal weight indication screen.

Resetting Variables of a Setra

Balance to Factory Default
This function is to reset the parameters inside the balance, which are not user accessible. The TIME, DATE,
and CALIBRATION are not affected.)

32

1.

Turn the green power switch on the furnace control panel to the OFF position.

2.

Press & hold the # 4 key while turning the green

power switch to the ON position. (Hidden Key 4
procedure). The red display will indicate [BAL
CAL]. Release the # 4 key when the NCAT
beeps once.

3.

Press & hold the balance ON/OFF key with a

small device such as straightened paper clip.
(Note balance control port holes in control panel
sketch.).

4.

Press & hold the balance ENTER key with a

small device such as straightened paper clip.
(Note balance control port holes in control panel
sketch.).

SETRA BALANCE

5.

Release both keys simultaneously. [71nE] will

be displayed.

6.

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

7.

Press the balance ENTER key. [BUSY] will be

displayed.

8.

The balance display will automatically revert

back to normal weight indication screen when
reset is complete.

Setra Balance Calibration

1.

Turn power to the NCAT unit OFF.

2.

Open chamber door and allow unit (Chamber) to

cool to ambient temperature. NOTE: DO NOT
attempt calibration with warm/hot chamber. The
chamber door will remain open during the entire
calibration procedure and the chamber must be
at ambient temperature.

3.

Make certain the chamber ceramic hearth plate

is centered on supports posts and free of debris.

4.

Press & hold the # 4 key while powering the

NCAT back up. (Hidden Key 4 procedure). The
red display will indicate [BAL CAL]. Release
the # 4 key when the NCAT beeps once.

5.

Press & hold the balance ON/OFF key with a

small device such as straightened paper clip.
(Note balance control port holes in control panel
sketch.).

6.

Press & hold the balance ENTER key with a

small device such as straightened paper clip.
(Note balance control port holes in control panel
sketch.).

7.

Release both keys simultaneously. [71nE] will

be displayed.

33

SETRA BALANCE

8.

Press the balance ON/OFF key two consecutive

times. [CAL] will be displayed.

9.

Press the balance ENTER key. [LOAd 8000]

will be blinking on display.

10. Place 8000 grams of certified weight (NIST

traceable) on the ceramic hearth plate. [0.0] will
be displayed. NOTE: DO NOT procedure to
step 11 until display reads [0.0].
11. Press the balance ENTER key. [BUSY] will be
displayed.
12. The balance display will automatically revert
back to normal weight indication screen when
calibration is complete. The software of balance
calculates it's own offset when the display is
reading [BUSY].

34

Error Conditions
OHAUS Balance
(Not a complete listing of error codes, but most common.)
Error Displayed

Problem

Solution

3.0

Calibration Error Incorrect or

no calibration weight used for calibration.

Recalibrate with correct weights.

Make sure all debris is off the top of
the balance and the posts supporting
the aluminum calibration plate are
centered. Only the aluminum
calibration plate should be used
during the calibration procedure. If
this error is only displayed when
calibrating the unit, the software is
bad and the unit needs to replaced.

4.4

RS232 buffer is full. There is a bad

connection in balance.

Double check all connections.

8.0

Hardware error causing an internal

weight signal, which is too low.

Check if the platform or platform

support is off. If not, balance must be
serviced.

Displayed momentarily NCAT is getting

power disconnect for a brief second and
resetting itself.

Check power source. Lower control

panel and check all wiring
connections - especially to balance.

EEEE

35

ERROR CONDITIONS

SETRA Balance
(Not a complete listing of error codes, but most common.)
Error Displayed

Problem

Solution

HHHHH

Exceeds maximum specified load

(5000 grams).

Reduce load to specified range.

LLLLLL

Load does not meet minimum specified

load requirements.

Increase load to specified range.

Make sure the ceramic posts are
centered and the plate is on top of
them.

NOCAL

Unable to do span calibration

(load not within 1% of cal weight, or
weight unstable.)

Replace scale.

PPPPPP

Strain on the DC power supply.

Disconnect printer to see if the error

goes away. If it does, replace printer.

ProtEc

Calibration protect switch not in the

PROTECT position during operation.

Check all connections. Replace scale.

REPlug

System not calibrated.

Recalibrate unit.

OFLO

Internal arithmetic overflow.

Replace scale.

S Err

Processor stack overflow.

Replace scale.

In Err

Memory indexing error.

Replace scale.

Unable to process command

(usually due to being in improper mode.)

Replace scale.

UnABLE

36

Printer
The printer is a parallel output port for the microprocessor,
with the three red digital displays. The microprocessor can be
programmed to print the Header and Footer of a test burn
(paper saver mode) or the Header, Minute-by-Minute burn
information, and finally the Footer. A hidden key one routine
will toggle between the two modes of operation.
With the 1275 Series NCATS, Barnstead began manufacturing NCATS with a thermal printer manufactured by Martel.
859, 945, and 1087 with Seiko thermal printers will not function with a Martel printer.
Seiko printer P/N AYX3
(859, 945, 1087 Series units ONLY)

Thermal Paper Storage

To store burn tickets, Barnstead International recommends
making a copy of the thermal paper ticket on an
8.5 x 11 piece of white paper. Do not store the thermal paper
ticket itself as it will discolor and become illegible in time.

RS232 Connection Information

Martel Printer P/N AYX28

(1275 Series units ONLY)

The 1087 and 1275 series NCATS are equipped with an

RS232 port on the back of the control assembly. This
enables the NCAT to be connected to an external printer or
computer terminal for recording burn information. Contact
Atser Inc. at 281-999-9961 to inquire about Burn-It software
package. B/I does not sell the software or the harness needed to connect the 25 pin female RS232 port (back of NCAT)
to a computer.
Specifications of RS232:
8 bits
1 stop bit
No parity
Stream of data every second
Computer configuration - Comm port set at 8N1 continuous
Hardwire handshake 9600 Baud

RS232 Port
37

PRINTER

Printer Change (Production)

Seiko to Martel (1087 to 1275)
The Seiko printer used in production of the 859, 945 and 1087 series NCAT is obsolete. The new printer is
manufactured by Martel and will be used in production starting with the 1275 series NCAT in Oct/Nov of 2001.
The software is being changed. The reason for the software update is the degree symbol on the front display
would not print with the Martel.
SOFTWARE UPDATE: REV H software was only used in production for a couple of months. Behind the
scene changes were made and we are now using Rev I in production.
Part Number

Description

AYX3

Thermal Printer (Seiko)

AYX28

Thermal Printer (Martel)

DL1087X8

Keypad RPO for Seiko printers

DL1275X4

Keypad RPO for Martel Printers

DL1087X8 keypad 1087 series only

(Seiko printer)

DL1275X4 keypad 1275 series only

(Martel printer)

DL859X11A keypad 859 and 945 series only

(Seiko printer)

38

PRINTER

Troubleshooting
Problem

Cause

Solution

Printer not printing.

The red LED will not illuminate

if paper is removed from the printer.
The unit uses thermal paper, which
means characters will only show if
the paper roll is installed properly.

Remove the paper roll from

the printer, turn the paper roll
over and reinstall in the printer.
Perform a hidden key routine
ENTER or WEIGHT key. (Found
in operation manual section of
this book). The printer is activated
to print the user and balance
variables immediately. If the unit
prints the variables, the printer
itself is most likely not defective
and the paper roll is installed
properly.

Not printing burn results, but will print

user variables when a hidden key is
performed. The 859 and 945 Series
units are equipped with a printer
software on/off key located below the
green power switch on the front control
panel. If this switch (SWX108) is in the
Off position or defective, the printer
will not print during a burn, yet print
user variable information during a
hidden key routine.

Check electrical connections on

backside of switch on older
models. In the 1087 and 1275
series units this switch is removed in
place of a jumper wire. Wire
harness part number WH1087X2
connects to the A/D Converter PC
Board(PC859X3A) on the J1
terminal. Check for continuity or
replace this wire harness, as the
jumper wire is located on the
terminal connector. If the unit still
does not print after verifying
WH1087X2 is good or replaced, the
A/D Converter PC Board may need
to be replaced.

If the printer does not print any

information during a burn or when a
hidden key ENTER or WEIGHT is
performed, yet the displays of the NCAT
indicate the unit is functioning properly,
then the printer is defective or the wire
harness ribbon connecting the printer to
the Main Logic PC Board (PC859X1A) is
defective. (The wire harness ribbon part
number is dependent on the series of
NCAT.)

Replace wire harness and/or printer.

39

PRINTER

Problem (cont.)

Cause (cont.)

Solution (cont.)

Print coming out upside down,

reading right to left.

The Seiko printers are equipped with

an internal switch located in the upper
left corner of the printer with the
cover removed. The small switch can
be slid from the left to the right or vise
versa.

Power off the NCAT, remove the

printer cover, and slide the
switch to the opposite position.
Replace the cover and perform
a hidden key two routine when
powering back on. Test printer
again. If still printing upside
down or right to left, replace the
printer.

Printer ticket indicating

invalid numbers for weight
loss, % loss, calibrated
asphalt content, temp comp,
and bitumen ratio.

If the time and date are not set

properly in the balance, the software
in the NCAT automatically moves the
decimal place to the left on a burn
ticket.

The time and date of the balance

(SETRA or OHAUS) needs to be
reset. This is not a malfunction
of the printer. (An example burn
be seen in the Error Code section
of this manual.)

Seiko printer switch

40

Software
History
The following software revisions were used in the NCAT
furnaces. All software versions are interchangeable and if
in doubt it is always best to update. The software chip is
located on the Main Logic PC Board (PC859X1) next to
the balance. A sticker on the chip will indicate the revision letter. Hidden Enter Key routine will also prompt the
printer to print the installed revision letter.
Series
859
945
1087
1275
1275
Main Logic Board - Software I.C.

Version
AD
DE
FG
H
I

Dates Used
Used up to 1995
Used in 1996
Used in 1997 to 2002
Used in 2002 (few months)
Used in production currently

Because the software IC chip is a plug-in style chip (no

soldering necessary to replace) and interchangeable
between every model/series, production dates (beginning
and end) are not important.
*When ordering new software, use part number
AY1087X3. The latest version in production will be
shipped. Barnstead will not provide software versions
used in the past. Only the latest revision is production.
Versions A and B were Beta site versions.
Versions C and D were the first two revisions of beta site
software to be used in production. Operation of an NCAT
was no different between the software revisions.
Changes were all behind-the-scene programming to
allow the microprocessor to execute commands faster.
Version E: A feature was added to allow operators to program a positive calibration factor.
Version F: Several new operating features were added.
They include:
1.

Auto program switching to idle mode. (Unit will

stop test automatically when the sample is stable and revert to idle mode, placing an asterisk
next to endpoint. This feature frees up operators time and increases the number of tests that
can be run in a days time.)
41

SOFTWARE

2.

Maximum test time was extended to 255 minutes.

3.

Maximum load size increased to 4000 grams.

4.

Asphalt content expressed in percent loss on

burn ticket.

5.

Bitumen Ratio calculated and added to print out

test results.

Version G: Several new operating features were added.

They include:

42

1.

Programmable time/date function. (This allows

operators to program the NCAT to begin heating
up automatically at a specific time/date.
Operators can arrive to work in the morning to
find the NCAT unit all ready up to burn temperature!) If no date is entered, software will revert to
a 24 hour time format. The unit must be in the
inactivity mode of operation in order for programmable timer to function properly.

2.

Inactivity mode. (If no keys are pressed in 4

hours of operation, the display will read In Ac
in the chamber temp window. This feature will
benefit operators with NCATs in remote locations should the operator not be able to return to
power off unit in times of non-use.) The unit
must be in the inactivity mode of operation in
order for programmable timer to function properly.

3.

Test interrupt/Power interrupt. (If power to the

NCAT is interrupted during a burn and then
restored, the furnace will continue the test, preventing smoke buildup in the lab. The burn ticket
will print Results Invalid with Test Interrupted.

4.

Auto-Shutdown Mode. Software can be toggled

by performing a hidden temperature key routine
to toggle between Auto and Manual mode of
operation. In Auto mode, the unit will recognize
the endpoint of a test, stop the blower motor
and print the results. The unit will beep once
every minute to alert operator the test is complete. In Manual mode, the unit will recognize

SOFTWARE

the endpoint of a test, place an asterisk next to

the endpoint, but continue to run the test, beeping once every 10 seconds to alert the operator
the test is complete. Operator must press the
START/STOP key to end test.
5.

Stability threshold factor expressed in a percentage (0.01% - 0.5%)

Version H: Revision H does not contain any operational

differences from Revision G. With revision H, behindthe-scene programming changes were made to accommodate the new style of printer being used in production
of the new 1275 series units. The only difference operators will see is on sample tickets where the symbol for
degrees has been removed from the ticket. Version H
was only used in production for a few months in early
2002.
Version I: Revision I is currently being used in production
(August 15, 2002) and shipped as replacement software
for NCAT units. Revision I contains behind-the-scenes
changes enabling the software to execute commands
faster than version H.

SC859X1 Rev. I Software

EPROM
Power Interrupt
If power is lost, then regained during a test, the unit will
restart the blower and continue the test until the
endpoint is reached. However, it will read Results
Invalid Test Interrupted.
Programmable Timer
New timer allows user to program a specific date and
time for the unit to begin its preheat cycle.
Inactivity Mode
Allows user to choose inactivity mode which puts unit
back to sleep as long as no other keys are pressed
after 4 hrs. from initial timer wake-up. This mode can be
toggled OFF and ON by using the hidden key Timer
routine. The displayed mode is the active mode.
43

SOFTWARE

Auto Program switching to idle at test endpoint

Increases the number tests run per day
Frees operators time
Asterisk documents endpoint on printout (see
enclosed sample printout on page 45)
Maximum test time extended to 255 minutes and load
size to 4,000 grams
Meets ASTM and AASHTO maximum load size
requirements
Saves time - no need to split sample size
Asphalt content expressed in percent loss
Meets ASTM and AASHTO test result requirements
Saves time - no need to manually adjust results from
gram loss to percent loss
Bitumen Ratio added to print out test results
Meets international and U.S. requirements
Saves time - no need to perform manual calculations

44

SOFTWARE

Installation
2.

The SC859X1 EPROM is mounted in a 16-pin

socket on the edge of the PC859X1A board on
the right side of the furnace. A label on top of
EPROM indicates the part number and revision
level.

3.

Note orientation of the EPROM notched end to

rear of the furnace. Gently pry the chip from its
socket until removed. Do not use magnetic tools
in the vicinity of the EPROM.

4.

Gently mount the new EPROM into the open

socket. Adjust pins on a flat surface if not matching socket.

5.

Refasten control panel.

6.

Turn power switch on. Review and adjust default

values.

7.

Your unit is now ready for operation.

C31

J30
J5

U12

C27
R19
R20

J7
5DISP

R3

12DIG

J6

R4
-

R1
R23

U6

J2 LEDS

J29

Q3
Q1

R24

R22

R38

SDL
U10

R21

R37

J9 DISPLAY
R25

5PTR

C26

SCALE
C23

5DIG

+
J32
R2

U13

C4

J27

Open hinged front control panel by removing four

screws.

C29

C28

C30
J31

1.

J28
+

C5

J1

SSR
Q2

Q4

J3

J4

J23

C6 C20
C21

C22

INTERCOM

CRY1

R39

R14

C64
U7

+ C13

U3

C2

C19

SC859X1
EPROM

C63
U1

RESET

U8

R10

R6
C3

C15

C1

C12

JMP1

C16
5DIG J15

C11
+C10

U4

R15

+
C9

R17

U9
+ C18

R40
R8
C7

U2

C17

C8
C14

R5

U5

PC859X1A

Printed Circuit Board Assembly

Sample printout
45

5DIG

U8

5DIG

C28

J15

C3

J4

R38

R37

J32
R2

INTERCOM

RESET

JMP1

C26

C16

C15

J3

SSR

C14

J2 LEDS

C22

C30

R14

C27

CRY1

R22

R21

R20

C29

R19

U4

R6

C9

C20

C13

C6

U6

C12

C8

J31

U5

U12

U7

R10

SCALE

R17

R3

J5

C17

R15

C2

PC859X1A

+ C18

R39

J1

J7
5DISP

U9

R23

R1

R24

U3

J9 DISPLAY

R5

R25

C4

C5

R8

R40

+
J27
U10

SDL

C7

+C10

C11

C23
U1

12DIG

Q2

Q1

J30
J6

U13
C64

U2

C19

C63

Q4

R4
Q3
5PTR

46
C1

J23

J28

J29

Location of EPROM

SOFTWARE

C21

C31

SOFTWARE

Ordering Information
Revision I Software Kit AY1087X3
1 ea.
1 ea.
1 ea.

SC859X1 EPROM Labeled Rev. I Software

Installation Instructions
Set of Operation Manual Amendments

47

Procedures
Amendment
TIMER PROGRAMMING & HIDDEN KEY
PROCEDURES FOR REVISION I SOFTWARE

Definition
Hidden Keys provide multiple use of the keypad. Hidden
Key Procedures typically are used to access infrequently
changed user variables and infrequently used diagnostic
procedures. The access, procedure and exit are detailed
under each key procedure. The furnace must be in the
idle (non-programmable) mode to access the Hidden
Keys.
Amendment #1 applies to Operation Manuals, Part
Numbers LT859X1, LT945X1, LT945X3 and LT945X4 for
NCAT Asphalt Content Tester.

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 presses the timer button in step
1. Bypassing the date automatically
converts the timer from a programmable 364 day timer to a 24-hour timer.
This means that when the programmed Time is reached, the unit
will begin heating, ignoring the wakeup date. The date needs to be set at
0.00 for this to happen.
48

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 temperate. We recommend that
you set the time for at least 2-1/2 hours before you want
to begin work.
1. Press the timer button on the key pad. The
heating element 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

PROCEDURES

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 inputted as
17:00 then press ENTER. The start
up time and date are now entered.

month and then the day. Example: May 16th

would be entered 5/16. Then press ENTER.
The wake-up 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.

Interrupting the Timer Mode

(Same as before.)
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 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.

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
49

PROCEDURES

restored the blower will start up again to maintain air flow

through the chamber. This will also prevent the user from
prematurely opening the door.
The power interrupt feature also applies to the 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 Shut-Down Mode
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.

O Key-Diagnostics:
Access:

Depress the Power Switch to ON while

simultaneously depressing the O key.

Procedure:

Enter the diagnostic procedure for factory

testing.
The furnace must be at room temperature
and unloaded. Run time is approximately
two hours. Upon accessing, the user
variables will default to factory set variables in order to match the variables
used in the factory test. You will need to
prompt the initial test segments by
depressing the START-STOP key to
move to the next segment. Test segments
requiring heat-up times automatically proceed to the next segment without prompting.

50

PROCEDURES

Exit:

Depress Power Switch to OFF and then

ON to return to normal operation.

1 Key-Print Out Paper Saver:

Access:

Depress Power Switch to ON while

depressing the 1 key simultaneously.

Procedure:

Chamber temperature display will display

PRN and the Percent Loss display will
toggle ON 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 Switch to the ON position.

Exit:

Automatic

3 Key-Chamber Calibration Procedure

Equipment
Needed:

1 ea. Digital Pyrometer with

Penetration Probe, Sensor NIST
Traceable. (Recommend Thermolyne
PM20700 with TC405X4 Penetration
Probe).
51

PROCEDURES

Setup:

Calibration consists of inserting a sensor

penetrating through the covered stainless
steel tube located adjacently to the control thermocouple. Entry is at the center
rear of furnace chamber. 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
at 538C or standard method specified
temperature. Allow furnace chamber to
stabilize at set point in the idle mode. The
maximum offset allowed before hardware
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
set point temperature. Allow the furnace
to stabilize at set point.
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 set point.
The original set point will return upon exiting. The software has calculated and
saved the new offset value, which will
apply to all set points throughout the
operating range.

Exit:

52

Depress Power Switch to OFF and then

ON to return furnace to normal use.
Remove sensor probe and cover entry
tube.

PROCEDURES

4 Key-Provides Entry to Balance

Menus
Access:

Depress 4 key while simultaneously

depressing Power Switch to ON.

Procedure:

BAL will display in Chamber Temperature

window. CAL will display in Percent Loss
window. Entry allows you to change time
and date settings, review and adjust balance variables, and calibrate balance.
These topics are detailed under
Resetting the Balance and Balance
Calibration instructions.

Exit:

Depress Power Switch OFF and then

ON to return furnace to normal use.

5 Key-Filter Temperature Adjustment

Access:

Depress 5 key while simultaneously

depressing the Power Switch to ON.

Procedure:

Adjustment range is 0-900C. Factory set

point is 750C. Chamber Temperature
displays current set point. Percent Loss
window displays FIL. Elapsed Time window displays SP for set point. Use the
key pad to change the display to the new
set point value. Depress ENTER
promptly. This new set point 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:

Procedure:

Depress 6 key while simultaneously

switching the Power Switch to ON.
ERR will be displayed in the Chamber
53

PROCEDURES

Temperature window. OFF will be displayed in the Percent Loss window. The
furnace will automatically return to normal
operation within five seconds with the
error codes deactivated.
Error codes are defeated to perform diagnostic procedures as to temporarily
ensure continued furnace operation in the
event of an 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 Temperatures:
Access:

Depress the 7 key while simultaneously

depressing the Power Switch to ON.

Procedure:

Chamber temperature will display actual

chamber temperature. The Percent Loss
displays actual filter temperature. Use for
diagnostic purposes only.

Exit:

Depress the Power Switch to OFF and

then ON to return the furnace to normal
operation.

8 Key-Serial Port Output Adjustment

54

Access:

Depress the 8 Key while simultaneously

depressing the Power Switch to ON.

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.

PROCEDURES

Exit:

Automatically returns to normal operation

within three seconds.

9 Key-Disables Beep
Access:

Depress the 9 Key while simultaneously

depressing the Power Switch to ON.

Procedure:

The Chamber Temperature will display

BEEP. The Percent Loss window will 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.

Setra Balance Printout

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 depressing the Power Switch to
ON.

Procedure:

The Percent Loss Window will display

SCAL. The Elapsed Time window will display L1S. The printout will generate automatically upon entering the printout
mode. See Hidden Weight Key printout at
left for balance variables. You can compare current printout with the example to
ensure correct variables are entered.

Exit:

The furnace will automatically return to

normal operation after the printout is generated.

Ohaus Balance Printout

55

PROCEDURES

Enter Key-Prints Out User Variables

Access:

Depress the ENTER Key while simultaneously depressing the Power Switch to
ON.

Procedure:

PRN will display in the Percent Loss window. User will display in the Elapsed
Time window. The printout will generate
automatically upon activating hidden key
sequence.

Exit:

The furnace will automatically return to

normal operation after the printout is generated.

Calibration Factor Key-Adjust or

Check Test Stability Threshold at Test
Endpoint
Access:

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, 0.02, 0.03,
0.04%. 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. This value must match the
standard specification you are applying.
The test stability value is printed on the

56

PROCEDURES

User Variable Printout. See Hidden Key

ENTER. An example of the printout is
depicted on page 58.
Exit:

Depress Power Switch to OFF and then

ON to return furnace to normal operation.

Temp Key - Toggles from Auto

Program Switching to Idle or Manual
Program Switching to Idle at Endpoint
Access:

Procedure:

Depress TEMP key while simultaneously

depressing the Power Switch to ON.
AU appears in the Chamber Temp display.
The Percent Loss displays either ON or
OFF. 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:

Procedure:

Depress the timer key while simultaneously depressing the power switch to
ON.
The Chamber Temp will
display InAc. The Percent Loss window
57

PROCEDURES

will display ON or OFF. The Mode

Condition will display for three seconds.
Accessing toggles the mode between
ON and OFF. The displayed mode is
the active mode.

Active Keys
These keys activate a function when depressed. The furnace must be in the idle
(non-programmable) mode.

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

Enter Key-Duplicates Header Test

Results
Access:

Depress the ENTER key.

Procedure:

The header and footer 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:
58

Automatic upon completion of printout.

Output
Bitumen Ratio
The Bitumen Ratio has been added to the Rev. I software. This test result is used in the United States 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.
NOTE: When developing aggregate calibration factors,
the desired output must be determined. If calibrated
asphalt content value is used to develop the aggregate
calibration factor, the Bitumen Ratio value should be
ignored. The opposite is true if Bitumen Ratio value is
used to develop aggregate calibration factor.

59

Glossary

60

Balance Stability:

The small S will flash on and off

at the left side of the balance display. When the S is shown, the
balance is stable. It is normal for
the S 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 S
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 S 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 keys 0
and 2.

Default Values:

These are factory values applied

to each unit for testing during
production. A printout of these
values are supplied with each
unit. Default values can be compared to your current values to
assess correct entry of each
value.

Error Codes:

Error codes are displayed to notify the operator of an out-of-specification condition or modification.
Error codes range from E001 to
E005 and E007 to E012.
Explanations are detailed in the
Operation Manual.

GLOSSARY

HMA:

Hot Mix Asphalt.

Idle Mode:

This mode is entered on startup

after initialization. Revision I
software automatically transfers
from the program mode to the
idle mode upon completion of the
test. The furnace will idle at set
point temperature in preparation
for the next test. The blower is
OFF in the idle mode.

Initialization:

This procedure sets up and configures the furnace 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 start-stop key, and
observe the balance display.
Normal lift measurements are
minus 3.5-10 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 External Digital
Thermometer.

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.

61

GLOSSARY

62

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 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 sample weight loss does
not exceed the Test Stability
Threshold Setting for three consecutive one-minute periods.
Furnaces containing Rev. I 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
Threshold:

This adjustable variable

determines the endpoint of the
HMA sample mass loss. 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.

Errors
Red Display (Furnace)
NOTE: Furnace ERROR Codes RED display window. All error codes (unless explicitly noted) will cause the
test procedure to stop. Microprocessor checks for error codes occur every second. It goes through the errors
in order of importance starting at #1. If there are multiple errors occurring at the same time, the first error
code will display on the unit.
Error Code
E001

Cause
Chamber Thermocouple is open.Tip may
be cracked at the weld and the crack
may open with thermal expansion.

Solution
Thermocouple resistance is </= 1 ohm. If it is
open, replace it. If it is good check the connections 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 will only come up when
not running a cycle. This error is disabled while in the test program mode.

Key routine #7 will display the actual temperature. If the temperature readout is erratic,
replace the analog board (bad optocoupler).
If the readout is correct and the readout is
675C, see if they recently changed any parts in
the unit especially the thermocouple. It could
be a thermocouple with the leads labeled wrong
(red wire = magnetic, yellow wire = non-magnetic) or thermocouple connected to the wrong connector. (i.e. Chamber thermocouple wiring connected to the filter thermocouple wiring.) Same
with a SSR that was replaced, verify the wiring
to make sure they were not switched.
Check for shorted heating element.
Check for shorted SSR.

E004

Filter temperature limit of 975C is

exceeded.

Follow above procedure.

E005

Door interlock not functioning.

Is the unit brand new? Plunger is misaligned

and should move freely up and down. (Plunger
is located on the lower right hand corner of the
unit.) Realign the position of the door hinge pins
in the door hinge brackets. Check for a bent linkage bracket to adjust or a dent in the side of the
unit. Straighten case if necessary.

63

ERRORS

Error Code (cont.)

Cause (cont.)

Solution (cont.)
Solenoid valve is bad and not engaging the
plunger. Turn unit on and start cycle to listen for
the solenoid valve to active. Watch for movement in the plunger.
To remove the door solenoid:
1. Disconnect the power to the unit and
drop down the front control panel.

E005 (cont.)

2.

Remove the two wires on solenoid

valve and two screws on the outside of
the case.

Microswitch on right side of the unit has failed.

This switch looks for the plunger to engage.
12VDC pulse engages the solenoid valve.
Door switch on left side of unit - make sure it is
connected.
Main Logic Board has failed (Moss FET on
board has failed.)
E007

E008

Analog to Digital Convert is not functioning properly. A component failure

or faulty cable connection may cause
this. This should only occur during a
test.

Turn the unit off and power back up. If E003

comes up then proceed with E003 information
above.

The DTR signal from the balance is

indicating the balance is either not
ready or not connected.

Reset the time and the date.

If E003 does not come up then replace the Logic

PC Board or the Main PC Board.

Recalibrate the balance.

Check the balance connection.
Replace balance and/or cable WH859X3A. If the
balance needs to be replaced, see BALANCE
section of this manual.
No display on balance display OHAUS balance - check the fuse on the balance.

64

ERRORS

Error Code (cont.)

Cause (cont.)

Solution (cont.)

E009

Set point 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 this error and then return to normal
operation. The setpoint will revert to its previous valve. Chamber temperature is to be less
than 674C; Filter temperature is to be less
than 900C.

E010

Chamber thermocouple leads

reversed. Thermocouple is a type K.
Polarity is coded as red (-) and yellow
(+).

If the thermocouple was just replaced, then

reverse the leads.
Check to see if E003 comes up while the unit
is NOT running a program.
If this error occurred during operation, perform
hidden key routine #7 to verify the temperature. If the displayed temperature is erratic,
replace the analog board.

E011

Filter thermocouple leads reversed.

See above to proceed.

E012

Balance not communicating; weight,

time and date not received.

Follow steps in E008. If the balance needs to

be replaced, see BALANCE section of this
manual.

65

ERRORS

Green display (BALANCE)

NOTE: Balance error codes will be displayed in the green balance display. With most error codes below,
power unit down and power back up to see if the error goes away. If it continues try to recalibrate, however, if
the error will not clear, the balance will need to be replaced. See the BALANCE section of this manual. Two
types of balances have been used in the NCAT furnace.

OHAUS Balance
(Most common error codes. See Ohaus manual for the full list of error codes)
Error Code

Cause

Solution

3.0

Calibration Error - Incorrect or no calibration weight used for calibration.

Recalibrate with correct weights. Make sure all

debris is off the top of the balance and the posts
supporting the aluminum calibration plate are
centered. Only the aluminum calibration plate
should be used during the calibration procedure.
If this error is only displayed when calibrating
the unit, the software is bad and the unit needs
to replaced.

4.4

RS232 buffer is full. There is a bad connection in balance.

Double check all connections.

8.0

Hardware error causing an internal

weight signal which is too low.

Check if the platform or platform support is off.

If not, balance must be serviced.

EEEE

Displayed momentarily.

NCAT is getting power disconnect for a brief

second and resetting itself.

SETRA Balance
(Error codes, unless specifically stated, refer to note at the top of the page.)
Error Code

Cause

Solution

HHHHH

Exceeds maximum specified load (5000

grams).

Reduce load to specified range.

LLLLLL

Load does not meet minimum specified

load requirements.

Increase load to specified range. Make sure the

ceramic posts are centered and the plate is on
top of them.

NOCAL

Unable to do span calibration (load not

within 1% of cal weight, or weight unstable)

Replace scale.

66

ERRORS

Error Code (cont.)

Cause (cont.)

Solution (cont.)

PPPPPP

Strain on the DC power supply.

Disconnect printer to see if the error goes away.

If it does, replace printer.

ProtEc

Calibration protect switch not in the

PROTECT position during operation.

Replace scale.

REPlug

System not calibrated.

Replace scale.

OFLO

Internal arithmetic overflow.

Replace scale.

S Err

Processor stack overflow.

Replace scale.

In Err

Memory indexing error.

Replace scale.

UnABLE

Unable to process command (usually due to being in improper

mode).

Replace scale.

67

ERRORS

NCAT Troubleshooting with No Error Codes Displayed

Error

Symptom

Action

Keypad failure

The NCAT unit may beep or chirp

in a non-rhythmic fashion.

Test keypad (See Equipment Test Procedure

section.)

The red displays will indicate characters (numbers and/or letters)

that do not coincide with what
should be displayed or what is normal.

Replace keypad (Serial number of NCAT needed to identify correct replacement part number
of keypad.)

NCAT performs a hidden key routine when initially powered on, yet
end user did not initiate a hidden
key routine.
Blower motor failure

Results from lift test will not meet

specifications.
Full potential line voltage is applied
to the blower motor in test mode
but blower will not run.
Motor may run, but makes abnormal noises.

Test blower motor by monitoring feed voltage.

Voltage will measure full potential line voltage
on 945 series and 1087 series NCATs. 859
series units will measure full potential line voltage (if upgraded) or 120Vac.
Oil blower motor (See Maintenance Section.)
Replace blower motor. (Serial number of NCAT
needed to identify correct replacement part
number of blower motor.)

Low lift-test reading

(Complaint)

A low lift-test reading is when performed by operators to signify routine maintenance needs to be performed. Lift-test readings should
range from -3.0 to -8.2. (See
Maintenance Section for proper lift
test procedure.)

Follow the cleaning procedure steps. (See

Maintenance Section)
Test/replace the blower motor. (Serial number of
NCAT needed to identify correct replacement
part number of blower motor.)
The insulation in the upper plenum may need to
be replaced. If the blanket insulation is not tightly tucked against the top sides of the NCAT, air
will not be forced through the five air baffle
holes. Instead the air escapes around the outer
edges resulting in a low lift test.

68

ERRORS

Error (cont.)

Symptom (cont.)

Action (cont.)

Smoke coming from

control section during a burn

In addition to control section emitting smoke, a complaint of longer

test/run times, a fowl odor, black
colored substance running down
the back balance support
column(s), sample not burning out
completely and inaccurate test
results.

Perform a lift test with and without the exhaust

tubing attached. (See Lift Test Section.) If
results are out of specification, follow the cleaning procedure steps. (See Maintenance
Section)
Check the door insulation for black streaks running from the edge of the insulation towards the
center. This indicates the door is too loose and
in need of tightening. (See Maintenance
Section)
Monitor the axial cooling fan located in the back
of the control section. The cooling fan should
be sucking ambient air into the control section
from the room. It should not be pulling air out of
the NCAT control section. Axial fan may need
to be remounted properly or replaced.
Test the afterburner element in the 1087 series
units or the top element in the 945 and 859
series units. (See element equipment test procedure.) If this element is not heating properly
the unit will not be able to breakdown
fumes/soot generated during the run mode. The
top plenum of the unit will clog in a very short
time and soot will build up rapidly as a result. It
this element tests okay, then test the solid state
relay. (See SSR equipment test procedure.)
In 1087 Series units, there is a 1" diameter hole
cut in the back piece of insulation. Locate the
hole in the lower left side of the back of the
chamber and use a sturdy piece of wire to
loosen any soot build up. The hole acts as a
chimney and may clog up with soot.
Replacement of this piece of insulation may be
necessary.
Ventilation system may be inadequate. (See
Maintenance Section; Air Pressure.)

69

ERRORS

Error (cont.)

Symptom (cont.)

Action (cont.)

Tests never end

(Complaint)

If the sample does not lose more

than 15 grams at the end of the
15th minute, the software is programmed not to detect an endpoint
and the test will run until stopped
by the end user. (Written into
software due to early aggregate
calibration procedures.)

Perform a test in which minute by minute test

results are printed out. Examine the burn ticket
& note the weight loss at the 15th minute. If not
greater than 15 grams, unit is performing as it
should. (See Sample Ticket Section.)
Perform a hidden key 2 routine and attempt to
burn a 1500 gram sample. Initial sample may
have been too large.
Recalibrate balance or replace balance. (See
Balance Section.)
Inaccurate temperature indication on display.
Verify chamber temperature with an external
N.I.S.T. Pyrometer and probe. Calibrate temperature.
Ensure samples are being leveled off in baskets. DO NOT MOUND SAMPLES, as the
internal portions of the sample may not burn out
Completely due to the lack of oxygen to burn.

Burn ticket indicates

the load actually
gains weight
(Complaint)

Support posts may be touching or

rubbing as may the ceramic plate
or basket in the chamber.

Ensure all are centered and try running another

sample. (See Sample Ticket Section.)

Evaluate basket. As baskets age,

they may start to warp, especially
when introduced in a hot chamber.

Warping may cause the basket to rub against

the chamber. Basket(s) may need to be
replaced.
Recalibrate balance. (See Balance Section.)
Replace the balance.

Unit will not heat up

but displays appear
normal (Complaint)

If the area ambient temperature is

below 50F, the main microprocessor will not recognize the milli-volt
signal generated by the thermocouples.

Attempt to warm the tip of the chamber thermocouple by holding it in the flame of a match for
15 seconds. Close chamber door and see if unit
starts to heat.
Use a portable space heater to warm the electronics of the unit. Allow 15 to 30 minutes for
NCAT to warm.

70

ERRORS

Error (cont.)

Symptom (cont.)

Action (cont.)

Test results inaccurate from sample

to sample of the same source

Ensure samples are the same size (weight.)

Methodology errors in sample splitting.
Recalibrate balance or replace balance.
Verify chamber temperature accuracy; recalibrate if necessary.

REMINDER: Barnstead International has premixed samples of asphalt that can be sent to customers that
have problems burning obtaining repeatable results and poor accuracy. Our samples are hand mixed at
5.0%. Our samples should be burned with a calibration factor of 0.0 at 538C (chamber temp). Results will
show 4.9% to 5.1% ac. in a fully functional NCAT.

71

ERRORS

Aggregates
Issues that can affect the accuracy and repeatability of
the results not related to the NCAT:
1. Sample size consistency
2. Splitting errors
3. Moisture in mix
4. Type of material
Limestone, granite, and sandstone are the three most
common base aggregates used. Granite is the hardest of
these three. Sandstone is the softest with limestone
being the medium. It is generally seen that harder aggregates burn more accurate than softer aggregates.
Dolomite is a base aggregate used in some parts of the
United States (Indiana, Ohio). Dolomite based samples
are difficult to burn with repeated accuracy in the NCAT.
Off gases produced during burns cause mini like explosions in the chamber of the NCAT during a burn (like popcorn being popped). Barnstead has done extensive testing with Dolomite based samples. Copies of results are
available upon request.
Hydrated Lime is sometimes added to to HMA to improve
binder adhesion to certain aggregates. Hydrated lime will
migrate to the aggregate during the burn, trapping some
of the asphalt into the aggregate. In severe situations,
the aggregate gradation may appear to actually gain
weight after a burn is complete.

Negative Air Pressure

Air temperature and altitude have an impact on air pressure, specifically the exhaust system on the NCAT.
Negative air pressure refers to an area that has less
atmospheric pressure exertion versus another. The
area referred to is the room/building the NCAT is being
installed versus the atmosphere (outside). If the atmospheric air pressure is greater than the room/building air
pressure, you have a negative air pressure condition.
The atmospheric pressure will attempt to offset the room
or building pressure and equalize. The ventilation system
72

ERRORS

of the NCAT provides a direct path for atmospheric air

pressure to enter the room/building when exhausted
directly through an outside wall or the roof. The NCAT
does have a 60CFM rated blower motor to aid the ventilation process, but in some situations, the pressure difference is too great and the blower motor can not prevent or
stop the negative air pressure from occurring. Smoke
generated for the NCAT will fill the room and/or the lift test
will be low. This is a design issue in the buildings ventilation system, not the fault of the NCAT. There are a couple of options if the NCAT is to be installed at this location.
1.

Open any doors or windows in the room. This

may be enough to offset the pressure differences, allowing the NCAT to be operated properly.

2.

Install a second blower motor in-line with the

ventilation tubing from the NCAT. The second
blower motor must be installed no closer than
10 feet from the unit. Barnstead/Thermolyne
does not offer a selection of blower motors for
this purpose and a motor would have to be purchased locally.

3.

Checking the buildings ventilation system. This

is would require consulting a HVAC technician.

73

ERRORS

Displayed Letters/Numbers
IN Ac = Inactivity Mode. This mode is part of the timer,
which allows the unit to automatically turn on and heat to
set point temperatures. IN Ac will be displayed if the
user does not press any keys for a period of four hours if
the timer is set. Customer must press the start/stop key
to return to the idle mode. Hidden Key TIME will also
cause IN Ac to be displayed.
PRN = Printer. PRN will be displayed in the Chamber
Temp window. On or Off will be displayed in the percent
loss window to indicate if the printer is to print the header
and footer of tests or minute by minute test results.
Hidden Key 1 toggles the PRN On or Off.
Hidden Key ENTER will also cause PRN to be displayed.
DEF = Default. DEF is displayed for 3 seconds in the
Chamber Temp window to indicate the variables have
been set back to factory default. Variables affected are
chamber temperature (538C), filter temperature (750C),
and stability threshold (.02%). Hidden Key 2 reset variables back to factory default.
CHBR CAL = Chamber Calibration. CHBR CAL will be
displayed in the Percent Loss window and Elapsed Time
window. Hidden Key 3 will cause CHBR CAL to be displayed.
BAL = Balance. BAL will be displayed in the Chamber
Temp window. Hidden Key 4 will cause BAL to be displayed.
FIL = Filter. FIL will be displayed in the Elapsed Time
window. Hidden Key 5 will cause FIL to be displayed.
ERR = Error. ERR will be displayed in the Chamber
Temp window. Hidden Key 6 will cause ERR to be displayed.
SPC or SPn = Serial Port Output. SPC or SPn will
be displayed in the Chamber Temp window for 3 seconds.
Hidden Key 8 will cause SPC or SPn to be displayed.

74

BEEP = Beep. BEEP will be displayed in the

Chamber Temp window. Hidden Key 9 will cause BEEP
to be displayed.

ERRORS

SCAL = Scale. SCAL will be displayed in the

Chamber Temp window. Hidden Key WEIGHT will cause
SCAL to be displayed.
FLN = Stability Threshold. FLN will be displayed in the
Elapsed Time window. Hidden Key CALIBRATION FACTOR will cause FLN to be displayed.
AU = Auto Program. AU will be displayed in the
Chamber Temp window. Hidden Key TEMP will cause
AU to be displayed.

75

ERRORS

Elapsed Time: 30:12

Sample Weight:1093g
Weight Loss: 57.7g
Percent Loss: 5.27%
Temp Comp:
0.00%
Calib. Factor: 0.29%
===================
Calibrated Asphalt Ctnt
4.98%
===================
30
533
57.7
5.27
29
534
57.6
5.26
28
534
57.5
5.26
27
535
57.3
5.24
26
536
56.9
5.16
25
537
56.4
5.15
24
538
55.7
5.09
23
539
55.0
4.94
22
541
54.1
4.85
21
542
53.1
4.75
20
542
52.0
4.63
19
543
50.7
4.51
18
544
48.1
4.40
17
544
46.7
4.27
16
544
45.1
4.12
15
543
43.3
3.96
14
542
40.7
3.83
13
540
39.7
3.72
12
536
35.5
3.65
11
534
34.7
3.45
10
512
26.9
2.46
9
511
14.1
1.29
8
492
10.3
0.32
7
481
0.0
0.0
6
477
0.0
0.0
5
472
0.0
0.0
4
469
0.0
0.0
3
465
0.0
0.0
2
455
0.0
0.0
1
451
0.0
0.0
-----:------:--------:-----------T: Temp: Wt. Loss: %Loss
---------------------------------Filter Set Pt: 750C
Chamber Set Pt: 538C
Tested by:______________
Mix Type: ______________
Sample ID:______________
Time: 10:03:32
Date: 10-13-01
76

Example of an Ohaus balance configured incorrectly:

0.0 weight loss during the first 1-7 minutes, 0.00%
for the temperature compensation factor in the header
of the test.

OHAUS balance had incorrect parameter settings

causing this type of error. AZT was set to .5
AL was set to 1.
AZT should have been set to OFF and AL should
have been set to 3.

ERRORS

Elapsed Time: 30:12

Sample Weight:1093g
Weight Loss: 0.8g
Percent Loss: 0.03%
Temp Comp:
0.00%
Calib. Factor: 0.00%
Bitumen Ratio: 0.03%
===================
Calibrated Asphalt Ctnt
0.03%
===================
30
533
0.8 0.03
29
534
0.8 0.03
28
534
0.8 0.03
27
535
0.8 0.03
26
536
0.8 0.03
25
537
0.8 0.03
24
538
0.8 0.03
23
539
0.7 0.03
22
541
0.7 0.03
21
542
0.7 0.03
20
542
0.7 0.03
19
543
0.7 0.03
18
544
0.7 0.03
17
544
0.6 0.02
16
544
0.6 0.02
15
543
0.6 0.02
14
542
0.6 0.02
13
540
0.6 0.02
12
536
0.6 0.02
11
534
0.6
0.02
10
512
0.5 0.02
9
511
0.5 0.02
8
492
0.5 0.02
7
481
0.5 0.02
6
477
0.4 0.01
5
472
0.4 0.01
4
469
0.2 0.01
3
465
0.2 0.01
2
455
0.1 0.01
1
451
0.1 0.01
-----:------:--------:-----------T: Temp: Wt. Loss: %Loss
---------------------------------Filter Set Pt: 750C
Chamber Set Pt: 538C

An example of the time/date function of the balance not

properly set. The decimal place is actually moved 4 digits
to the left.

Tested by:______________
Mix Type: ______________
Sample ID:______________
Time: 10:03:32
Date: 10-13-01

77

ERRORS

Elapsed Time: 30:12

Sample Weight:1093g
Weight Loss: 0.8g
Percent Loss: 0.03%
Temp Comp:
0.00%
Calib. Factor: 0.00%
Bitumen Ratio: 0.03%
===================
Calibrated Asphalt Ctnt
0.03%
===================
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
An I.C. chip on the main PC board was not properly placed
0.00%
in the socket; causing the print out to look like this.
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
-----:------:--------:-----------T: Temp: Wt. Loss: %Loss
---------------------------------Filter Set Pt: 750C
Chamber Set Pt: 538C
Tested by:______________
Mix Type: ______________
Sample ID:______________
Time: 10:03:32
Date: 10-13-01
78

ERRORS

Elapsed Time: 30:12

Sample Weight:1093g
Weight Loss: 57.7g
Percent Loss: 5.27%
Temp Comp:
0.13%
Calib. Factor: 0.00%
===================
Calibrated Asphalt Ctnt
4.98%
===================
30
533
14.7
1.99
29
534
32.2
3.14
28
534
57.5
5.26
27
535
108.6 8.81
26
536
56.9
5.16
25
537
56.4
5.15
24
538
107.2 8.80
23
539
55.0
4.94
22
541
54.1
4.85
21
542
1.14
2.33
20
542
17.6
2.01
19
543
50.7
4.51
18
544
48.1
4.40
17
544
175.2 9.98
16
544
45.1
4.12
15
543
43.3
3.96
14
542
0.05
0.01
13
540
39.7
3.72
12
536
175.1 11.4
11
534
12.1
2.44
10
512
26.9
2.46
9
511
14.1
1.29
8
492
10.3
0.32
7
481
102.5 3.31
6
477
10.1
2.22
5
472
17.2
0.02
4
469
15.0
1.12
3
465
22.1
1.11
2
455
0.23
0.02
1
451
0.21
0.00
-----:------:--------:-----------T:
Temp: Wt. Loss: %Loss
---------------------------------Filter Set Pt: 750C
Chamber Set Pt: 538C
Tested by:______________

Balance plate is catching or the support columns holding

the balance plate is rubbing against the sides causing the
balance to bounce in weight loss. The basket could also
be rubbing the sides of the chamber.

Mix Type: ______________

Sample ID:______________
Time: 10:03:32
Date: 10-13-01
79

ERRORS

Elapsed Time: 30:12

Sample Weight: 1093g
Weight Loss: 57.7g
Percent Loss: 5.27%
Temp Comp:
0.14%
Calib. Factor: 0.29%
===================
Calibrated Asphalt Ctnt
4.98%
===================
30
533
57.7
5.27
29
534
57.6
5.26
28
534
57.5
5.26
27
535
57.3
5.24
26
536
56.9
5.16
25
537
56.4
5.15
24
538
55.7
5.09
23
539
55.0
4.94
22
541
54.1
4.85
21
542
53.1
4.75
20
542
52.0
4.63
19
543
50.7
4.51
18
544
48.1
4.40
17
544
25.7
4.27
16
544
14.2
3.89
15
543
10.3
3.32
14
542
9.9
2.21
13
540
9.2
2.01
12
536
8.9
1.99
11
534
8.4
1.54
10
512
8.1
1.02
9
511
6.2
0.95
8
492
5.2
0.81
7
481
5.1
0.76
6
477
3.2
0.45
5
472
2.1
0.24
4
469
0.9
0.05
3
465
0.7
0.04
2
459
0.2
0.02
1
451
0.1
0.01
-----:------:--------:-----------T: Temp: Wt. Loss: %Loss
---------------------------------Filter Set Pt: 750C
Chamber Set Pt: 538C
Tested by:______________
Mix Type: ______________
Sample ID:______________
Time: 10:03:32
Date: 10-13-01
80

The sample did not lose 15 grams in the first 15 minutes.

This particular sample will run non-stop as a result!

Equipment Test Procedure

Removal of the Control
Assembly (Bottom Section) in
the 1087 & 1275 Series NCAT
The control assembly is the lower section of the furnace.
It houses all the P.C. boards, relays, the balance, and
wire assemblies. When the front control panel (keypad)
is lowered, you can look into the electronic control housing. The control assembly, if properly disconnected, can
be slid out of the back of the unit.
To disconnect the control panel:
1. Remove the eight screws along the lower, outside back wall secure the control assembly from
the back. They are located from the lower lefthand corner, across the top of the control section, and the lower right-hand corner of the unit.
See photo. Screw placement is indicated by
white Xs.
Back of unit

8 screws to remove to slide out control panel.

81

EQUIPMENT TEST PROCEDURE

2.

Lowering the front panel, a washer/nut assembly

can be located at each corner (front right & front
left, right behind the hinges the panel swings
on). These nut assembles need to be loosened
because they hold down the bottom plenum of
the control assemble. See photo. Nut/washer
placement is indicated by white Xs.

Front of unit with control panel hinged downward

2 nuts/washers to loosen to slide control panel out of unit.

3.

82

After the 2 nuts are loose in front and all eight

screws are removed from the back of the control
assembly, you can slide the control assembly
out of the back of the unit. (Notice the assembly
will only slide back for about an inch. Then it
will "get stuck". Do not continue to tug on
the assembly. The various wire harnesses will
stop the control assembly from being able to be
slide out completely. Jerking or tugging will
cause wires to be separated from connectors!)

EQUIPMENT TEST PROCEDURE

4.

Next, unhook the wire harnesses that secures

the control assembly in place. IT IS VERY
IMPORTANT THAT YOU NOTE WHERE
EVERY WIRE HARNESS IS CONNECTED
BEFORE STARTING TO UNPLUG THEM.
There are a total of TEN different wire harnesses in the front that need to be disconnected and
one grounding strap. (See photo. Wire and
strap placement is indicated by white Xs.)
Starting from the left (facing the unit), disconnect the following:

Front of unit with control panel hinged downward

10 wires to disconnect, plus grounding strap to slide control panel out of unit

a. Gray ribbon cable from the printer.

b. 2 red wires and two black wires running from
the green power switch that needs to be disconnected from the lower right hand corner of a silver "box" (red wires go towards the balance
when plugging back in).
c. On the upper left hand side of the same silver "box", you will find 2 orange and 2 yellow
wires that need to be disconnected. (Two
orange wires go towards the inside of the unit
when you go to plug that connector back up.)
They are the door switch wires.

83

EQUIPMENT TEST PROCEDURE

d. There is a gray grounding-wire mounted to

control assembly floor and the swing down control panel. One end needs to be released. The
balance display board has 3 different wire harnesses plugged into it.
e. A small gray ribbon running from the balance
to "P2" on the display board needs to be
unplugged. (10-pin connector only plugs back
in one way).
f. There is a red and white DC adapter labeled
"P6".
g. A second gray ribbon connector labeled "P3".
There is a special end on this harness that distinguishes it from the others. The "L" shaped
red display board only has two wire harnesses
that need to be removed.
h. A gray ribbon cable (14 pins). Located immediately next to the plastic ribbon cable for the
keypad.
i. The second harness to unplug is a 3-pin connector. 2 little black and 1 little red wire makes
up this assembly.
j. On the far right hand side the unit; one harness needs to be unplugged. This harness has
2 yellow wires, 1 purple wire, and 1 white wire.
(Door switch and door-locking solenoid wires.)

84

EQUIPMENT TEST PROCEDURE

5.

There are two wire harnesses that need to be

disconnected in the back of the unit. (See
photo. Harness placement is indicated by white
Xs.)
Back of unit - Control panel slid out 2.5

2 wire harnesses to disconnect to slide control panel out of unit.

a. Locate a reddish-brown connector (for heating elements). The harness consists of 3 white
wires and one green/yellow wire. Push the tabs
on the sides and gently-lift the connector up to
disconnect.
b. The second wire harness in back consists of
4 white wires for the cooling fans. Lift the tab
up and gently-pull the connector apart

85

EQUIPMENT TEST PROCEDURE

6.

Proceed to slide the control section out of the

back of the unit. See photo below. As soon as
the control section is approximately half way
out, the thermocouple wires (Red and Yellow)
will come into view and prevent the control section from sliding any further. The thermocouple
connectors are green, the connectors also have
a "C" for chamber, and "F" for filter printed on
them, disconnect each one.

2 wire harnesses to disconnect to slide control panel out of unit.

Control panel slid out 1/2 way

86

EQUIPMENT TEST PROCEDURE

7.

The complete control assemble will slide all the

way out now.

Control section pulled from unit

8.

To reinstall the control panel, perform the same

steps in the reverse order. (Remember to plug
your thermocouple wires back in as you slide
the control section back into the unit.)

The biggest cause of failure when reinstalling the control

section is having wire harnesses that are not plugged in
properly. TIP: Do not ever "tug" on wires in an attempt to
disconnect them. Some harnesses have tabs that need
to be released in order for the harness to slide freely
apart. TIP: Labeling wires prior to disconnecting will aid
in reconnection.

87

EQUIPMENT TEST PROCEDURE

Warning
Unit should be at ambient temperature before attempting to replace the
back wall insulation.

1087 Series Back Wall

Insulation Removal
Procedure to remove/replace JC1087X3

Warning
Unit should be disconnected from
the power source before attempting
to replace the back wall insulation.

Tools needed:
- Phillips screw-driver (power screw driver is
available)
- Flat head screw-driver & Needle nose pliers
- Refer to drawings "ZD", "ZC, & "ZB" at the
back of this manual for pictorials.

1.

Disconnect unit from power source.

2.

Detach the exhaust tubing from blower motor.

3.

Position unit in an area where all four sides can

be easily accessed.

4.

Remove the back cover of the chamber section

(CV 1087X10)

5.

Remove the filter thermocouple (upper thermocouple - TC1087X1), taking care not to physically break the thermocouple (back of unit).

6.

Remove the chamber thermocouple (lower thermocouple - TC859X1A), taking care not to physically break the thermocouple (back of unit).

7.

Loosen the screws that secure the afterburner

element lead wires on each terminal block (back
of unit).

8.

Loosen the screws that secure the top, both

sides, and bottom heating element lead wires on
each terminal block (back of unit).

9.

Detach blower motor wire harness.

10. Remove the top cover assemble (CV1087X15 &

CV1087X13)
11. Remove metal sheet cover (CV1087X1)
88

EQUIPMENT TEST PROCEDURE

12. Remove blanket insulation (JC1087X7)

Note
Refer to the pictures and parts list in
the back of this manual.

13. Remove insulation material (JC1087X4)

14. Remove afterburner element (EL1087X1)
15. Remove the filter (FL859X2)
16. Remove insulation material (JC1087X4)
17. Remove metal brace (BC1087X13)
18. Open chamber door
19. Remove top element (slide/pull out of chamber
from the front) (EL1087X3)
20. Remove both side elements (slide/pull out of
chamber from the front) (EL859X3 & EL859X4)
21. Remove the bottom element (slide/pull out of
the chamber from the front) (EL1087X2)
22. Remove the back wall ceramic piece (PH412X1)
23. Remove the back wall insulation piece
(JC1087X3)

Install the replacement JC1087X3 (position into place).

By following the procedure to remove the JC1087X3 in
the reverse order, the NCAT can be put back together.

Heating Elements
A) Heating Elements (Quick & Simple Test)
**This test must be preformed with the chamber at room
(ambient) temperature.
Equipment needed:
- None
1)

Power up the NCAT unit.

2)

Allow the NCAT to step through the startup

countdown and go into the preheat mode. Note
89

EQUIPMENT TEST PROCEDURE

when the CYCLE FILTER and CYCLE CHAMBER LEDs illuminate on the front control panel.
3)

Allow the NCAT to heat for 30 seconds.

a) The 30 seconds begin when the CYCLE
FILTER and CYCLE CHAMBER LEDs illuminate.

Caution
The internal walls are the actual heating elements and may be to hot to
touch if the unit was allowed to heat
for more than 30 seconds or the
chamber was not at ambient condition to begin with.

4)

Power off the NCAT unit.

5)

Open the chamber door and physically feel the

top, sides, and bottom of the chamber with your
hand. CAUTION: Element may be hot!
a) An element that is generating heat will be
warm to the touch. An element that is not generating heat will be cold to the touch. Because
of the series/parallel relationship of the elements
in the circuit, this test method will not isolate
which cold element is actually burned out and
what cold element may still be good.

***The afterburner element in the 1087 or 1275 series

NCAT can not be tested in this manner because the surface area of the element is embedded in the top plenum
of the chamber.
B) Heating Elements (ohm check performed without
power applied to the unit)
Equipment needed:
- Digital ohm meter (DMM)
- Phillips screw driver
- Flat-head screw driver
- NCAT Element Configuration print

90

1)

Disconnect the NCAT unit from the power

source.

2)

Remove the back panel from the NCAT

a)

14 screws around the outer edges hold the back

panel in place (4 on each side, top & bottom).

3)

Loosen and remove the screws and nuts that

hold down the element lead wire on each terminal block. Refer to page 94.

EQUIPMENT TEST PROCEDURE

4)

Open the chamber door and slide the top element straight out the front of the unit.

5)

Remove the each side element in the same

fashion. Refer to photos on page 94.

6)

Remove the bottom element in the same fashion.

7)

The afterburner element in the 1087 series units

can remain in the unit

8)

Measure the resistance between the element

lead wires on each element with an ohmmeter.
Refer to chart on page 95 to obtain element cold
resistance value.

9)

If the cold resistance of each element is off by

more than 10 ohms, element replacement is
needed.

***When reinstalling the elements, the bottom element

must be slid into position first, followed by each side &
finally the top element.

Element removal (top element shown)

91

92

93

EQUIPMENT TEST PROCEDURE

H
A

1087 or 1275 series back view

Element terminal block close up

Element lead wire

94

Key
A
B
C
D
E
F
G
H
I

Description
Element terminal blocks
Element terminal blocks
Element terminal blocks
Element terminal blocks
Element terminal blocks
Element terminal blocks
Element terminal blocks
Filter thermocoupler
Chamber thermocoupler

EQUIPMENT TEST PROCEDURE

Element Part Numbers & Cold Resistance

Series 1087 & 1275
Part Number
EL859X3
EL859X4

Description
Right Side
Left Side

Voltage
All Voltages
All Voltages

Cold Resistance
55 Ohms
55 Ohms

EL1087X1
EL1087X2
EL1087X3

Afterburner
Bottom
Top

220-240V
220-240V
220-240V

36 Ohms
10 Ohms
10 Ohms

EL1087X4
EL1087X5
EL1087X6

Afterburner
Bottom
Top

208V
208V
208V

30 Ohms
8 Ohms
8 Ohms

Description
Top
Bottom
Right Side
Left Side

Voltage
220-240V
220-240V
220-240V
220-240V

Cold Resistance
36 Ohms
55 Ohms
55 Ohms
55 Ohms

Top
Bottom
Right Side
Left Side

208V
208V
208V
208V

36
55
55
55

Series 859 & 945

Part Number
EL859X1
EL859X2
EL859X3
EL859X4
EL859X5
EL859X6
EL859X7
EL859X8

Ohms
Ohms
Ohms
Ohms

NOTE: Elements must be electrically isolated from one another for accurate resistance measurements to be
taken. Remove element lead wires (back of unit) to properly isolate. Note correct orientation of wires prior to
removal to reconnect properly.

95

96

97

EQUIPMENT TEST PROCEDURE

1087 or 1275 series back view

Thermocouples
H
A

A type K thermocouple generates a millivolt signal. As

the temperature rises in the chamber and filter section,
the millivolt signal generated by the thermocouple
increases. The generated millivolt signal is utilized by
the main microprocessor to detect chamber and filter
temperature changes.
I

Key
A
B
C
D
E
F
G
H
I

The NCAT utilizes two type K thermocouples. One

thermocouple is routed into the back of the chamber.
The other is routed into the top plenum (filter).

Description
Element terminal blocks
Element terminal blocks
Element terminal blocks
Element terminal blocks
Element terminal blocks
Element terminal blocks
Element terminal blocks
Filter thermocoupler
Chamber thermocoupler

A type K thermocouple is manufactured with nickelchromium and nickel-aluminum wires and has definite
polarity (positive and negatively charged wires). The
negative wire has a RED insulator sleeve. The positive wire has a YELLOW insulator sleeve and a (+)
sticker. It is also marked with a black indicator mark on
the terminal end of the actual wire itself. Barnstead
International recommends replacing the chamber and
filter thermocouples every 12 months.
A) Chamber Thermocouple
Equipment needed:
- Digital ohm meter or continuity tester
- Phillips screw driver
1)

Disconnect the NCAT from the power source.

2)

The chamber must be at ambient temperature to properly test the thermocouple. Allow
unit to cool to ambient if necessary.

3)

Remove the back panel from the NCAT.

a) 14 screws around the outer edges hold
the back panel in place (4 on each side, top
& bottom).

4)

Disconnect the chamber thermocouple from

the terminal block located near the
middle/bottom of the back of the chamber.
a) The thermocouple has a yellow and red
wire that run lengthwise up the back of the
chamber wall, entering into the chamber
approximately half way up the back wall.

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EQUIPMENT TEST PROCEDURE

b) This will electrically isolate the thermocouple from

the rest of the circuitry.
c) It is important to label or note the color of the wire
at the terminal block connection for polarity purposes.
5)

Using a continuity tester, measure across the lead

wires of the thermocouple.
a) A good thermocouple will have a very low resistance measurement or continuity.

6)

Replace the thermocouple if it does not exhibit low

resistance or continuity.

B) Filter Thermocouple
Equipment needed:
- Digital ohm meter or continuity tester
- Phillips screw driver
1)

The filter thermocouple is tested in the same manner as the chamber thermocouple.
a) The filter thermocouple is connected to the same
terminal block located near the middle/bottom of the
back of the chamber. However, the lead wires run
lengthwise up the back wall of the chamber, protruding into the NCAT near the very top.

2)

Disconnect the yellow and red lead wires from the

terminal block. This will electrically isolate the thermocouple.
a) It is important to label or note the colors of the
wires at the terminal block connection for polarity
purposes.

3)

Using a continuity tester, measure across the lead

wires of the thermocouple.

4)

A good thermocouple will have a very low resistance

measurement or continuity.

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EQUIPMENT TEST PROCEDURE

5)

Replace the thermocouple if it has high resistance or no continuity.

**Do not attempt to connect a voltmeter in parallel with

either thermocouple, attempting to monitor the millivoltgenerated signal. A meter will load the circuit, resulting in
inaccurate measurements.

100

EQUIPMENT TEST PROCEDURE

Solid State Relays

There are a total of three solid-state relays in the NCAT.
All three are located in the lower control section. Refer to
photo of keypads on page 38. The solid state relays,
activated by a 5 - 15Vdc signal from the main microprocessor P.C. board, act as switches that allow AC voltage to the chamber heating elements, filter element
(afterburner), and blower motor (exhaust fan).
A) Solid State Relay
Equipment needed:
- Digital voltmeter (DMM)
- Phillips screw driver
1)

Disconnect the NCAT unit from the power

source.

2)

Remove the eight screws from the back of the

control section.

a)

There are 4 screws along the top of the control

section and 2 on each side.

3)

Lower the control panel (keypad) in the front of

the NCAT.
a) There are 4 screws along the top of the control panel.
b) The control panel hinges from the bottom.

Solid State Relays

4)

Loosen two nuts on the bottom, front edge of

the control section.

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EQUIPMENT TEST PROCEDURE

a) Each nut is physically located 1/2 to 1

directly behind the hinges. These nuts secure
the control section to the front of the NCAT.
5)

The control panel will slide out from the back

side of the NCAT (Approximately 2 out from the
unit.)
a) It is important not to pull the control section
too far back with force, as several wire harnesses are still connected securing the control section in the NCAT.

6)

The solid-state relays are now visible, mounted

on the back wall, on the lower left side (a heat
sink device is mounted on the outside of the
NCAT). See photo on previous page.
a) The relay on the far left side is for the blower
motor (exhaust fan). This relay will have two
black wires connected to pins 1 and 2; a yellow wire to pin 3; and a green wire to pin 4.
b) The relay in the middle is for the chamber
elements. This relay will have two white wires
connected to pins 1 and 2; a red wire to pin
3; and a black wire to pin 4.
c) The relay on the right side (near the center of
the furnace) is for the filter element (afterburner). This relay will have two white wires connected to pins 1 and 2; an orange wire to pin
3; and a brown wire to pin 4.

7)

Connect the voltmeter leads to terminal pins

number 3 and 4 of the solid-state relay. CAUTION: You will also be measuring live voltage, a
potential shock hazard!
a) Each relay has 4 screw terminals, each
labeled 1, 2, 3, 4. Terminal pins 1 and
2 on all three relays are considered the output
and will only have AC voltage across them at
various times of operation. Terminal pins 3
and 4 on all three relays are considered the
input and will only have DC voltage across them
at various times of operation. Pin 3 is the DC

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EQUIPMENT TEST PROCEDURE

positive terminal. Pin 4 is the DC negative terminal. Refer to page 96.

8)

Power on the NCAT unit.

9)

Allow the NCAT to step through the startup

countdown and go into the preheat mode.

10) Note if the CYCLE FILTER and CYCLE CHAMBER LEDs illuminate on the front control panel.
a) These LEDs indicate the main microprocessor control board is attempting to apply power to
the solid-state relays. If they are not illuminated,
the solid-state relays should not have power
applied to them and the main logic board may
be defective.
11) How to determine if a solid-state relay is defective:
a) A solid state relay can be considered good, if
the input of the relays (pins 3 and 4) have a
5 to 15Vdc signal applied across them and at
the same time no AC voltage can be measured
across pins 1 and 2.
b) A solid-state relay is also considered good, if
the input of relay, pins 3 and 4, have no DC
voltage signal applied across them and at the
same time an AC voltage can be measured
across pins 1 and 2.
c) A solid state relay is considered defective, if
the input of the relays (pins 3 and 4) have a
5 to 15Vdc signal applied across them and at
the same time full potential line voltage (AC) can
be measured across output pins 1 and 2.
12) To test the blower motor (exhaust fan) solidstate relay, activate the blower motor by pressing the start/stop key to initiate a cycle run.
(The blower motor is not activated in the preheat
mode. Only when a cycle is being run in the
test mode!) If the blower motor turns on, your

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EQUIPMENT TEST PROCEDURE

solid-state relay is working properly. Taking voltage

measurements at this point is not necessary.
However, if the blower motor does not run or is running while the NCAT is in the preheat mode, the
solid-state relay may be defective. Take voltage
measurements as described in step 11 to determine
if the solid-state relay is defective.

Keypad
A) Keypad
Equipment needed:
- Phillips screw driver
- Jumper wires or needle nose pliers
1)

Disconnect the NCAT unit from the power source.

2)

Lower the control panel by removing the 4 screws

along the top edge. Control panel hinges downward.

3)

Locate and disconnect keypad from J2 terminal of

display board.

4)

Reconnect the NCAT to the power source.

5)

Use jumper wires or needle nose pliers to short two

pins together on the J2 display board to simulate
pressing a key. (Use the matrix chart below to identify what to pins to short out to simulate a keystroke.)
a) The J2 terminal is an 8 pin electrical connection
point. Connection terminal is orientated such that
pin 1 is nearest D7 and pin 8 is nearest the J1 connection terminal.

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EQUIPMENT TEST PROCEDURE

b) Matrix chart:
7 Key

8 Key

9 Key

Temp Key
4 Key

6 Key

Weight Key

2 Key

3 Key

Cal. Key
Timer Key

5 Key

1 Key

0 Key

Start/Stop

Enter Key

Pin 1

Pin 2

Pin 3

Pin 4

Pin 5

Pin 6

Pin 7

Pin 8

105

106

107

108

109

Maintenance
Lift Test Procedure
The efficiency of the blower and/or exhaust system is
monitored by a quick test procedure, referred to as the
lift test. Steps to perform a lift test:
1.

Chamber must be at ambient (room temperature) condition before attempting to perform a lift
test.
a) Allow the unit to cool to ambient condition.

2.

Press the green power button on front display.

a) Allow the unit to complete the diagnostic test
upon power up.

3.

Press the 0 key on the keypad.

a) This zeros the balance.

4.

Press the start/stop key on the keypad.

a) This initiates the blower motor.

5.

The green display will indicate a number

approximately 20 seconds after pressing the
start/stop key.
a) This number is the negative lift.

6.

Record the number on paper.

a) Ideally, the number should be between 3.0
and 8.2
b) Detach the exhaust tubing and repeat the test
to determine if the exhaust system is restricting
the airflow or if the top plenum of the NCAT is
restricting the airflow.

7.

110

Refer to the NCAT cleaning procedure if the lift

test falls out of this range.

MAINTENANCE

Cleaning Procedure for NCAT

The NCAT unit must be kept clean in order to ensure
proper operation. The lift test procedure is a tool to indicate when the unit needs to be cleaned. (See Lift Test
Procedure) Follow the instructions below for proper
cleaning. Cleaning routine should be started with NCAT
at room temperature.
1. Disconnect power. Disassemble the top vent
tube from the blower motor. Using a Shop-Vac,
clean out the vent tube of all soot build up.
Shop-Vac the chamber as well, if needed.
2.

Remove the top cover of furnace and oil the

blower motor with Anderoll 465 lubricant (part
number AYX6).

3.

Open the chamber door. Inspect the door insulation for black streaks of soot. (Usually running
from the outside corners of the insulation
towards the center.) If black streaks are present, it is a sign the door is loose and the chamber is sucking in air. (If there is no black streaks
then continue to step 4.) Tighten the door by
opening it at a 90-degree angle in reference to
the front of the chamber. Loosen the door hinge
screws and push the edge of the door into the
front left edge of the chamber. Tighten down
the hinge screws while the door is being pushed
in, towards the front left edge of the
chamber/hinges. Replacing the door insulation
maybe necessary (part number JC412X10,
quantity to order = 4).

4.

In the 1087 and 1275 series NCATs there is a

hole in the back of the chamber. This hole is
the opening that extends upward into the top
plenum. It acts like a chimney to prevent
smoke buildup in the chamber. Ensure this
chimney is free of any soot buildup. A pipe
cleaner or stiff wire can be used to clean out the
chimney. NOTE: This piece of insulation may
need to be replaced if lift tests remain out of
spec after this entire cleaning procedure is executed. (See troubleshooting section for more
details.)

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MAINTENANCE

5.

Reconnect power. Increase the chamber set

point temperature to 650C using the chamber
set button. Increase the filter set point temperature to 900C by performing a hidden key 5 to
change filter set point temperature as follows:
Turn the green power switch off. Press and
hold the #5 key in while pressing the green
power switch. Once the furnace beepsrelease
the #5 key.)

6.

Allow the unit to reach and maintain the

650C/900C condition for at least 3 hours.
(The furnace has a course filter in the top
plenum that will burn itself clean.) Do not initiate a cycle, let the unit in the idle mode for the
duration.

7.

After this 3-hour period, reset the chamber temperature to your desired burning level. Reset
the filter temperature to 750C by performing the
hidden key #5 routine.

Routine cleaning of the NCAT is complete.

Chamber Temperature
Verification/Calibration
NCAT Specifications:
Chamber Size = 14 x 14 x 14
Chamber max set point = 650C
Filter max set point = 900C
Factory default set point temperatures = 538C
chamber; 750C filter
NOTE: The 859 or 945 Series NCATS do not have a
predrilled calibration port. Customer may need to remove
back cover and drill their own 1/4 diameter port through
the back wall. View page 115 for a view of the back of
the unit and the location of the port.
NOTE: 1087 & 1275 series NCATS have a predrilled calibration port-hole with an access cover on the back of the
furnace. You do not need to remove the back cover to
access the port-hole.

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MAINTENANCE

NOTE: It is not possible to calibrate or verify the filter

temperature of NCAT furnaces.
NOTE: To verify or calibrate chamber temperature, you
will need an N.I.S.T. traceable digital pyrometer
(Barnstead International part number = PM20700) & an
N.I.S.T. 10 Type K thermocouple probe (Barnstead
International part number TC405X2). These can be calibrated to N.I.S.T. standards and shipped with a certification of calibration (Barnstead International part number =
C5000) dated for 1 year. Calibration of the two test
pieces of equipment will need to be performed every year.
Contact Barnstead International for more details at
800-553-0039
NOTE: Chamber temperature calibration should only be
performed in the IDLE mode. Attempting calibration in
the TEST mode will produce inaccurate results primarily
because the exhaust fan is activated in the TEST mode,
pulling ambient air (approximately 10CFM) through the
chamber.

Chamber Temperature Calibration

Procedure
PLEASE READ ENTIRE CALIBRATION PROCEDURE
BEFORE PROCEEDING.
1.

Power the NCAT on while holding the #5 key in

(Hidden Key #5 routine). When the unit beeps,
you may release the #5 key. The Hidden Key
#5 routine will allow you change the filter set
point temperature. Key in 500C for the filter set
point.

2.

Cycle the power to the NCAT unit off and back

on to exit the hidden key #5 routine and return
to idle mode.

3.

Set the chamber temperature to 500C.

4.

Allow the unit to heat to the chamber/filter set

point (approximately 2 hours) and stabilize for
an additional 2 hours before proceeding.

5.

Insert 10 Type K probe (B/I part number

TC405X4) through the temperature calibration
port on the back of the unit.
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MAINTENANCE

6.

Connect the probe to the digital pyrometer (B/I

part number = PM20700) & power up the
pyrometer.

7.

Record the chamber temperature reading as

indicated by the pyrometer.

8.

Power off the NCAT.

9.

Power the NCAT back up while holding the #3

key in (Hidden Key #3 routine). When the unit
beeps, you may release the #3 key. The displays will read CHBR CAL in the percent loss
and elapsed time windows. The Hidden Key #3
routine will allow you to key in the chamber temperature as measured by the pyrometer and
recorded in step 7.

10. Enter the new chamber temperature value

(recorded in step 7) followed by pressing the
enter key. The new offset value will be calculated and the entered temperature value will be
displayed. (The entered temperature is a temporary set point. The original set point will
return upon exiting the hidden key #3 routine by
powering the unit off and back on.)
11. Power off the NCAT. (Green power switch)
12. Temperature calibration is now complete.

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MAINTENANCE

- Chamber temperature should be +/- 10C difference

between unit temperature and probe temperature at
500C.

Calibration
Port

Type K Chamber
Thermocouple
L
i

10.5

Back view of chamber section (859 & 945 series) with

cover removed. A 1/4 diameter hole is predrilled through
the stainless steel sheet metal but is not predrilled
through the chamber insulation material. A 1/4 diameter
hole must be drilled through the insulation material to
access the chamber.

Balance Calibration
Please refer to the Balance section of this manual for
complete calibration procedures.

115

Screws

Insulation material
(Harder material)

* Note the orientation of

the holes in these pieces.
The holes must be
re-aligned properly
when putting unit
back together.

Side wall insulation

Blanket Insulation

Side wall
insulation

Metal sheet cover

Screws

Side element
(240 V)

Insulators

Top element (240V)

*
*
*

** * *
*

Bottom element
(240V)

Insulation material
(Harder material)

Course
Filter

Afterburner Element

Insulators

Side element
(240V)

Back wall
hearth

Back wall
insulation

Metal back wall

Metal brace/bracket

Blanket insulation

Side Insulation

REF. ZB

Chimney-like
Port

Drawings

Chamber
Thermocouple

Filter
Thermocouple

BACK OF UNIT

Chamber T.C.

* Terminal blocks that secure element lead wires

Filter T.C.

Element lead wires are "pinched" between

the terminal block and a small flap of metal.
To loosen lead wires, loosen screws and nuts
that hold the metal flap against the terminal block.

Back of unit

Afterburner element
lead wires

Air
Deflector

REF. ZC

DRAWINGS

Back of
unit
Bracket

Washer

Nuts

Top Cover
CV1087X13

Top Cover
CV1087X15

Harness to disconnect
blower motor

Blower Motor
Screws

REF. ZD

Metal cover

Back cover
chamber section

Temperature
probe port

DRAWINGS