INSTROTEK COREDRY (01) PDF Document

The INSTROTEK COREDRY is an automatic system for rapid drying of compacted asphalt core samples and other materials. It uses vacuum and a fast-circulating air system to remove moisture from the sample, providing a fast and accurate alternative to conventional drying methods.

Key features of the INSTROTEK COREDRY include:

– Fully automatic operation with a single button press.

– High-speed drying, typically within 15 minutes for most samples.

– Accurate and repeatable results.

– An electronic moisture removal system that does not require desiccant.

– A built-in vacuum pump.

– A large 7-inch color touch screen display for easy operation.

– Data storage and download capabilities via a USB port.

– Conforms to AASHTO T166 & ASTM D2726 standards.

The following items are included with your INSTROTEK COREDRY:

– INSTROTEK COREDRY unit with built-in vacuum pump

– Power Cord

– USB Memory Stick

– 250ml Oil Mist Filter

– 1 Liter Vacuum Pump Oil

– Small Funnel

Follow these steps to set up your INSTROTEK COREDRY:

1. Unpack the unit and all accessories from the shipping container. Inspect all items for any signs of damage.

2. Place the unit on a flat, level, and sturdy surface. Ensure there is enough space around the unit for proper ventilation.

3. Check the vacuum pump oil level. The oil should be between the MIN and MAX lines on the sight glass. Add oil if needed.

4. Install the oil mist filter. Remove the red plug from the pump exhaust port and screw the filter in its place.

5. Connect the power cord to the back of the unit and plug it into a grounded 110VAC/60Hz or 220VAC/50Hz outlet, depending on the model.

6. Turn on the unit by flipping the power switch on the back to the ON position. The display on the front panel will light up, and the Main Menu will appear.

The main external components of the INSTROTEK COREDRY are:

– Main Power Switch: Turns the main power to the unit ON and OFF.

– Power Inlet: Connection point for the main power cord.

– Fuse Holder: Contains the AC line fuse.

– Oil Mist Filter: Reduces oil mist from the pump exhaust.

– Oil Fill Port: Used to add oil to the pump.

– Oil Drain Port: Used to drain oil from the pump.

– Oil Level Indicator: A sight glass to view the pump oil level.

– USB Port: For downloading test data to a USB flash drive.

– Touch Screen Display: A 7-inch color display for user interface.

– Chamber Lid: Covers the vacuum chamber during testing.

– Vacuum Chamber: Houses the asphalt core sample during the drying process.

The Main Menu is the primary screen on the INSTROTEK COREDRY. It appears when the unit is turned on. From this screen, you can access all the functions by touching the corresponding buttons on the screen.

– **LOAD:** Touch this button to enter the initial weight of the sample. This is the first step in starting a new test.

– **START:** After entering the initial weight, this button becomes active. Touch it to begin the drying process.

– **REPORT:** This button allows you to view, print, or download test data stored in the unit’s memory.

– **SETTINGS:** Access this menu to set the date, time, units, and language, as well as perform system checks and calibrations.

Follow this procedure to dry a sample with the INSTROTEK COREDRY:

1. From the Main Menu, press the **LOAD** button.

2. A screen will appear prompting you to enter the initial weight of the sample (SSD weight). Use the on-screen numeric keypad to enter the weight and press **OK**.

3. The Main Menu will reappear with the initial weight displayed. Place the sample in the chamber and close the lid.

4. Press the **START** button to begin the drying process. The screen will display real-time information, including elapsed time, vacuum level, and chamber temperature.

5. The unit will automatically run through the drying cycle. The vacuum pump will start, and the system will monitor the rate of moisture loss.

6. When the sample is dry (i.e., when the rate of weight loss stabilizes), the pump will turn off, the chamber will vent to atmospheric pressure, and the screen will display “TEST COMPLETE”.

7. Open the lid, remove the sample, and obtain the final dry weight. The test data is automatically saved.

To manage test reports on the INSTROTEK COREDRY, follow these steps:

1. From the Main Menu, press the **REPORT** button. The Reports Menu will appear, showing a list of all stored tests.

2. You can scroll through the list of tests using the **UP** and **DOWN** arrows.

3. To view the details of a specific test, select it from the list and press the **VIEW** button.

4. To download all the stored test data, insert a USB flash drive into the USB port and press the **DOWNLOAD ALL** button. The data will be saved as a .CSV file, which can be opened with spreadsheet software. The file will be named with the unit’s serial number.

5. To delete all stored test data from the unit’s memory, press the **DELETE ALL** button. A confirmation message will appear. Press **YES** to proceed with deleting the data.

6. Press the **BACK** button to return to the Main Menu.

The Settings Menu allows you to configure various parameters of the INSTROTEK COREDRY. To access it, press the **SETTINGS** button from the Main Menu. The available options are:

– **DATE/TIME:** Set the current date and time. Use the UP/DOWN arrows to adjust each value (Month, Day, Year, Hour, Minute, AM/PM) and press OK to save.

– **UNITS:** Select the desired units for temperature (°C or °F) and vacuum (kPa, mbar, or inHg). Touch the button for the desired unit and press OK.

– **LANGUAGE:** Select the display language. English is the default.

– **VAC PUMP TEST:** Performs a diagnostic test on the vacuum system to check for leaks and proper pump operation.

– **CALIBRATION:** Access the calibration menus for the temperature and vacuum sensors. This is password protected and should only be performed by qualified personnel.

– **ABOUT:** Displays information about the unit, including the model number, serial number, and software version.

Press the **BACK** button to return to the Main Menu.

The vacuum pump test is a diagnostic tool to check the performance of the pump and the integrity of the vacuum system. To run the test:

1. Navigate to the Settings Menu and press **VAC PUMP TEST**.

2. The screen will display the message “PUMP TEST IN PROGRESS”.

3. The INSTROTEK COREDRY will turn on the pump and monitor the vacuum level for a short period. The test ensures that the pump can reach the required vacuum level within a specified time and that the vacuum holds, indicating there are no significant leaks.

4. If the test is successful, a “PASS” message will be displayed. If the test fails, a “FAIL” message will be displayed, and you should check for potential issues like low pump oil, a dirty chamber seal, or other leaks.

Temperature calibration should be performed by qualified technicians. To calibrate the temperature sensor:

1. From the Main Menu, go to **SETTINGS**, then **CALIBRATION**.

2. Enter the password when prompted.

3. Press the **TEMPERATURE** button.

4. Place a calibrated temperature probe inside the chamber, near the unit’s internal sensor.

5. Close the lid and allow the temperature to stabilize.

6. Compare the temperature displayed on the INSTROTEK COREDRY screen with the reading from your calibrated probe.

7. Use the on-screen keypad to enter the actual temperature reading from your calibrated probe and press **OK**.

8. The system will apply the offset. Press **BACK** to exit.

Vacuum calibration should be performed by qualified technicians. The procedure involves adjusting two points: atmospheric pressure (zero vacuum) and full vacuum.

**Atmospheric Pressure (Zero) Calibration:**

1. From the Main Menu, go to **SETTINGS**, then **CALIBRATION**, and enter the password.

2. Press the **VACUUM** button.

3. With the chamber lid open and vented to the atmosphere, press the **ZERO** button. The system will read the current atmospheric pressure and set it as the zero vacuum point.

**Full Vacuum (Span) Calibration:**

1. Connect a calibrated external vacuum gauge to the system.

2. Close the chamber lid and press the **SPAN** button. The pump will turn on and draw a vacuum.

3. Allow the vacuum to stabilize.

4. Use the on-screen keypad to enter the vacuum reading from your external calibrated gauge and press **OK**.

5. The system will apply the new span calibration. Press **BACK** to exit.

The INSTROTEK COREDRY uses a high-vacuum technology combined with a circulating air system to rapidly dry samples. The process works as follows:

1. A core sample is placed in the vacuum chamber, and the lid is sealed.

2. The built-in vacuum pump removes air from the chamber. Lowering the pressure inside the chamber also lowers the boiling point of water.

3. By significantly reducing the pressure, water can be vaporized and removed from the sample at near-ambient temperatures. This avoids the high temperatures used in conventional ovens, which can damage the asphalt binder.

4. A sensor system continuously monitors the amount of moisture being removed. The drying cycle is automatically terminated when the rate of moisture loss falls below a preset level, indicating the sample is dry.

5. The chamber is then vented back to atmospheric pressure, and the dry sample can be removed for weighing.

Regular maintenance is essential for the proper operation of your INSTROTEK COREDRY.

Chamber and Lid Cleaning (Daily or as needed):

The inside of the vacuum chamber and the rubber lid seal must be kept clean to ensure a proper vacuum seal. After each test, wipe down the inside of the chamber and the lid seal with a clean, lint-free cloth. Use a mild detergent and water if necessary, but ensure the chamber is completely dry before the next use. Do not use solvents, as they can damage the seal and acrylic lid.

Vacuum Pump Oil (Check daily, change as needed):

The vacuum pump requires clean oil to function correctly. Check the oil level and clarity daily through the sight glass. The oil should be clear and between the MIN and MAX marks. If the oil appears cloudy, milky, or dirty, it needs to be changed. The frequency of oil changes depends on usage and the moisture content of the samples being tested.

Follow these steps to change the vacuum pump oil:

1. Turn on the INSTROTEK COREDRY and run the vacuum pump for about a minute to warm up the oil. This helps suspend any contaminants and allows the oil to drain more easily. Turn the unit off.

2. Place a suitable container under the oil drain port located on the back of the unit.

3. Remove the oil drain plug using an appropriate wrench. Allow all the old oil to drain completely.

4. Once drained, securely replace the oil drain plug.

5. Remove the oil fill cap (or the oil mist filter, which serves as the fill port).

6. Using a funnel, slowly add new, clean vacuum pump oil until the level is between the MIN and MAX lines on the sight glass.

7. Replace the oil fill cap or oil mist filter.

8. Dispose of the used oil in accordance with local environmental regulations.

If your INSTROTEK COREDRY does not power on, please check the following:

1. Ensure the power cord is securely plugged into both the unit and a working electrical outlet.

2. Verify that the main power switch on the back of the unit is in the ON position.

3. Check the AC line fuse located in the fuse holder on the back panel. Replace it if it is blown.

If the display is not working, check if the unit is powered on. If the unit is on but the screen is blank, there may be a loose internal connection or a failed display module.

The INSTROTEK COREDRY will not start a test if the initial weight has not been entered. Before pressing START, you must first press LOAD and enter the initial SSD weight of the sample.

If you are experiencing slow or no vacuum, check for the following potential causes:

– The lid is not properly sealed. Ensure the lid seal and the top edge of the chamber are clean and free of debris.

– The vacuum pump oil is low or contaminated. Check the oil level and condition through the sight glass and change if necessary.

– The vacuum pump may be faulty.

A “VACUUM LEAK” error indicates that the system is unable to achieve or maintain the required vacuum level. To resolve this:

– Check that the chamber lid is properly seated and sealed.

– Clean the rubber lid seal and the top rim of the chamber to remove any debris that could be preventing a tight seal.

– Inspect all vacuum hoses and connections for cracks or looseness.

If the drying time seems excessively long, consider the following:

– The sample may have an unusually high moisture content.

– There could be a vacuum leak, which reduces the efficiency of the drying process. Check the lid seal and connections.

– The vacuum pump performance may be degraded due to old or contaminated oil. Check and change the pump oil.

These error messages indicate a malfunction with the respective sensor. It could be due to a faulty sensor or a loose connection. The unit may require service.

If data is not saving to the USB drive, try the following:

– Ensure the USB drive is fully inserted into the port.

– The USB drive may be full. Check the available space on the drive.

– The USB drive could be faulty or improperly formatted. Try using a different USB drive.

If the lid is difficult to open, it means there is still a vacuum inside the chamber. The system should automatically vent the chamber at the end of a test. If it fails to do so, there may be an issue with the vent valve. Do not force the lid open. Wait for the pressure to equalize slowly. If the problem persists, the unit may require service.