en - Assets - Bohlin ADS User Manual English MAN0377 1 0 - tcm50 11548 PDF

Bohlin
ADS
www.malvern.com Bohlin
ADS
user manual user manual

Malvern Instruments Limited Printed in England MRK0863-01
Enigma Business Park

Grovewood Road, Malvern
Worcs, WR14 1XZ, U.K.
Tel: +44 (0) 1684 892456
Fax: +44 (0) 1684 892789
I N S T R U M E N T S
MAN0377-1.0 ADS User Guide.book Page ii Thursday, March 8, 2007 2:42 PM
© Malvern Instruments Ltd. 2007
Malvern Instruments makes every effort to ensure that this document is correct. However, due to
Malvern Instruments’ policy of continual product development we are unable to guarantee the
accuracy of this, or any other document after the date of publication. We therefore disclaim all
liability for any changes, errors or omissions after the date of publication. No reproduction or
transmission of any part of this publication is allowed without the express written permission of
Malvern Instruments Ltd.
Head office:

Enigma Business Park,
Grovewood Road,
Malvern,
Worcestershire WR14 1XZ
United Kingdom.
Tel + [44] (0)1684-892456

Fax + [44] (0)1684-892789
Windows 2000 and XP are registered trademarks of the Microsoft Corporation.
Printed in England
MAN0377-1.0 ADS User Guide.book Page i Thursday, March 8, 2007 2:42 PM
Table of Contents
Part 1 - Operator’s Guide
Introduction to this manual

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
How to use this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Access to the instrument . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Assumed information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Where to get help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
What is the ADS?

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
How the ADS works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Available configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Gap setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Temperature Control Units (TCUs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Hardware features
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Temperature Control Units (TCUs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Software features and tests

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Logging on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
TruGrade software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
TruGrade tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
ADS Rheometer Page i

Table of Contents ADS Rheometer
Initial procedures
Checking the air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Removing the immobilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Levelling the instrument . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Installing the measuring systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Checking the fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Checking the flow rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Powering on the components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Temperature calibration/verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Making a measurement
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
The Asphalt wizard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Loading the sample . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Making a manual measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Interpreting the results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Closing down the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Maintenance and Troubleshooting

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Setting up the fluids circulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Rheometer maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Circulator maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Changing fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Page ii MAN 0377

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ADS Rheometer Table of Contents
Part 2 - Supervisor’s Guide
Security
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
The User Configuration dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Setting up a user group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Creating users . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
ADS Rheometer Page iii

MAN0377-1.0 ADS User Guide.book Page iv Thursday, March 8, 2007 2:42 PM
Part 3 - Appendices
Health and Safety

General warnings and regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Electrical warnings and regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Crush hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Hot components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Fluids circulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Power cords and Power safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Sample handling warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Specification
TCUs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
Minimum computer specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
Chemical compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
Test specifications and criteria. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
Site requirements
Bench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
Space required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
Power requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
Operating environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
Air bearing supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
Cooling air/water supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
Fluids circulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5
Air supply filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-6
Unpacking instructions
Installation
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1
Moving the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1
Upgrading the computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-3
Changing the computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-3
Page iv MAN 0377

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ADS Rheometer Table of Contents
Regulatory statements
CE Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-2
Index
ADS Rheometer Page v

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Page vi MAN 0377

MAN0377-1.0 ADS User Guide.book Page 1 Thursday, March 8, 2007 2:42 PM
Part 1 -
Operator’s Guide
Introduction
to this manual
Introduction
This manual covers the operation and maintenance of the Bohlin ADS (Automatic
Dynamic Shear) rheometer. In simple terms this is a dynamic shear rheometer
used with a software package for measurement of rheological properties. The
instrument is especially suited to analysing asphalt and meets the AASHTO stand-
ards.
The aims of this manual are to:
Explain what the ADS is and how it works.
Describe the ADS hardware components.
Describe the software and the tests it can run.
Explain how to set up the instrument before making a measurement.
Explain how to use the instrument to make a measurement, and how to inter-
pret the results.
Identify the user maintenance and troubleshooting procedures.
Show a supervisor how to set up users.
Explain all Health and Safety issues.
How to use this manual

Users must read the Health and Safety information in Appendix A before operat-
ing the instrument. The information given in that appendix applies to the ADS
instrument itself. If using a circulator, users must also read the Health and Safety
information in the manual supplied by its manufacturer.
We recommend reading this manual fully before starting the first measurement.
ADS Rheometer Page 1-1

1 Chapter 1 Introduction to this manual
The manual is divided into the following three sections.
Part 1 – Operator’s guide

The Operator’s guide contains all the information required by an operator using
the ADS. Topics covered are:
What the ADS does.
The hardware components of the ADS.
The software and the available tests.
Initial procedures – what needs to be done at the start of the day before the
rheometer can be used. This includes pre-start checks and setting up the
instrument.
A tutorial on making a measurement.
Basic maintenance procedures and troubleshooting information.
Part 2 – Supervisor’s guide

The Supervisor’s guide describes the security system; how to set up users and user
groups, giving these permissions as necessary.
Part 3 - Appendices
Appendix A contains essential Health and Safety information which all users must
read. Appendices B and C give the specification and site requirements. Other
appendices contain supplementary information not necessary for the general opera-
tion of the system.
Access to the instrument

This manual refers to the various people who will have access to the instrument, as
follows.
Malvern personnel
Malvern personnel (service engineers, representatives, etc.) have full access to the
instrument and are the only people authorised to perform service procedures that
may require the removal of the covers.
Warning!
Removal of the covers by unauthorised personnel will invalidate the war-
ranty of the instrument.
Page 1-2 MAN 0377

Introduction to this manual Chapter 1
Supervisor
The supervisor is the person responsible for the management and safety of the
instrument and its operation. The supervisor is responsible for training the opera-
tors. The supervisor can perform all user maintenance routines identified in Chap-
ter 7.
Operator
An operator is a person trained in the use of the system. The operator can perform
all user maintenance routines identified in Chapter 7.
Warning!
Under no circumstances should the supervisor or an operator remove the
main cover of the instrument. Failure to follow these guidelines could
result in exposure to hazardous voltages.
Assumed information
Naming convention
The ADS is referred to either in full as the ADS, or as “the instrument”.
The combination of the ADS instrument, the computer and the software is
referred to as “the system”.
Menu commands
Menu commands in the software are always shown in bold text in this form:
main menu-menu item-submenu item.
For example, the command Tools-Options refers to selecting the Options
command from the Tools menu.

Chapter 1 Introduction to this manual
Where to get help

Manual and online help
The primary source of information on the ADS system is this manual. In addition
the software has online help which gives detailed information. Each dialog within
the software has a Help button giving information specific to that dialog.
The fluid circulator has its own manual. Read this carefully.
Help desk
Direct all queries about the system to the local Malvern representative initially.
Please quote the following information:
Model and serial number of the instrument (given on the back panel).
The software version (to find this, select Help-About in the software).
In the USA telephone 508-480-0200 x 350 or email support@malvern.com.
Contact the United Kingdom help desk if the local Malvern representative is not
available. Its direct line is +44 (0) 1684 891800.
i
Note
This help line is primarily English speaking.
Remote support
Malvern Instruments offers a remote support service, delivered by an Internet con-
nection. Benefits include fast and efficient fault diagnosis, reducing downtime and
costs.
On-line user training is also available, plus software updates. A high speed Internet
connection is recommended for making use of this facility.
Malvern Website - www.Malvern.com

The Malvern website offers a comprehensive range of particle characterisation
resources for use by customers 24 hours a day, seven days a week.
Resources include software downloads, frequently asked questions, a knowledge
base and application notes, plus information on other particle characterisation solu-
tions that Malvern can provide.
Page 1-4 MAN 0377

What is the ADS?

Introduction
This chapter describes:
How the ADS works.
Available configurations.
Gap setting.
Temperature Control Units (TCUs).
Software – the TruGrade and research software packages. This includes a
description of the TruGrade test setup.
How the ADS works

The Bohlin Automatic Dynamic Shear (ADS) rheometer is the industry standard
dynamic shear rheometer for SHRP and AASHTO asphalt test. It complies with
AASHTO T-315 and all ASTM specifications in both the D04 & D08 sections.
In normal operation:
1. The sample under test is positioned between the lower and upper measuring
systems, normally two plates. The top measuring system is a plate attached to
the air bearing stress-head motor assembly and the lower measuring system is a
plate attached to the TCU located in the base housing.
2. The rheometer automatically sets the gap the user requires.
3. During testing:
The stress-head applies the appropriate frequency and strain amplitude to
the sample.

2 Chapter 2 What is the ADS?
Sample temperature is controlled and monitored for conformance to the

specification.
Data is automatically collected and monitored for conformance to the
specification.
The measurements are read and processed by the computer and the results are
displayed by the software.
Available configurations
The main options are:
Instrument – CVO-100-ADS, CVOR-200-ADS and Gemini-ADS.
Motor controller – the instrument can be configured as analog or digital.
Torque – the CV0-100-ADS is 100mNm, the C-VOR-200-ADS is 200mNm
and the Gemini-ADS is generally 150mNm, but can be 200mNm.
Gap setting
The instrument can automatically change the required gap setting as demanded by
testing specifications. The trim gap and testing gap are pre-programmed for each
test. The user can re-zero the gap using the front panel or the software.
Once zeroed, the instrument remembers the zero position so this does not need to
be reset. The instrument can be configured to correct automatically for changes
due to thermal expansion/contraction.
Temperature Control Units (TCUs)

Bituminous materials are very temperature-sensitive, with large variations in their
material properties over a fraction of a degree Centigrade. Even small temperature
gradients in the sample and errors between the sensor temperature and the mean
sample temperature can render rheological data unreliable.
To overcome this problem, two interchangeable TCUs are available:
Total Immersion Cell (Wet System) – this (commonly called the “water
bath”) is the recommended TCU. It provides the greatest precision, control
stability and fewest thermal gradients across the sample for asphalt testing.
This ensures the most accurate results.
The sample is completely submerged in the immersion chamber, which is
sealed from the environment by the thermal enclosure, preventing ambient
Page 2-2 MAN 0377

What is the ADS? Chapter 2
conditions from affecting sample temperature. The sample temperature is

measured by a PT100 located directly below the lower plate for superior accu-
racy and minimal offsets.
A digital circulator drives liquid at a precise temperature through the Total
Immersion Cell, controlling the sample temperature. Easily replaced foam
filters minimise asphalt contamination of the circulator lines.
Peltier Thermal Chamber – this is a “dry” system; though water is used for
cooling, the sample is not immersed in it. The lower plate is conductively
heated while the upper plate is heated via the upper chamber's radiant element.
To increase the rate of heat transfer to the sample, a small amount of preheated
air is used within the chamber.
For research use

Researchers can use other types of temperature control: for example, forced gas
convection and electrical heating can be installed.
Software
The ADS combines with a computer running the Bohlin Windows software. Two
software packages are available:
TruGrade – the standard package for SuperPave Specification and grade
determination testing.
Research – a range of research grade software makes the unit into a full
research grade instrument.
Note
The ADS cannot be used without the computer connected.
TruGrade tests
Tests are categorised by type and mode. These are described briefly here and in
detail in Chapter 4.
Test types
There are three test types, each of which has a different application within the
AASHTO standard:
Original Binder (OB) – this is for testing a binder which has not had any
treatment.

Chapter 2 What is the ADS?
Rolling Thin Film Oven (RTFO) – this is used for samples which have been
through an RTFO, simulating the aging that occurs during mix production and
pavement construction.
Pressure Aging Vessel (PAV) – this is used for samples which have been
through a PAV to simulate real-world aging conditions of the asphalt binder.
The PAV exposes the binder to the high pressures and temperatures that would
occur naturally during a pavement's life. Use 8mm plates for this type of test
because the aged sample is very stiff.
Test modes
There are four test modes:
Grade Determination and Pass /Fail – these are the common test modes.
Linearity – this is only run for qualifying other results.
The fourth test mode combines Grade Determination and Linearity.
Tests available
Taking the above combinations of test mode and type, the list of tests available to
an operator is as follows:
Linearity
Original binder
Original Grade Determination
PAV binder
PAV Grade Determination
RTFO binder
RTFO Grade Determination
Research software
The following tests are available if the research software is used:
Oscillation as a function of time, temperature, frequency and shear stress.
Viscosity as a function of shear rate, shear stress, temperature and time.
Creep and Creep Recovery (for compliance measurement and analysis).
Time Temperature Superposition and Viscoelastic Analysis.
These are described in detail in the online help, not in this manual.
Page 2-4 MAN 0377

Hardware features
Introduction
This chapter describes the hardware components of the instrument. It covers:
Main components – describes the main parts of the rheometer.
The control panel.
Connections, which are on the rear and base of the instrument.
Temperature Control Units (TCUs) – the Total Immersion Cell and Peltier
Thermal Chamber.

3 Chapter 3 Hardware features
Main components
This diagram shows the main parts of the ADS:
4
5
6
ADS 3
8 5
6
7
8
ill 7716
The components are:
Caution!
Do not use the vertical position knob unless told to do so by a Malvern
representative or the help desk.
 Vertical position knob – this adjusts the vertical position of the bearing for
servicing of the unit. It provides a manual override for moving the stage. (The
Gemini-ADS does not have this, though an optional handle is supplied.)
 Control panel – this provides a manual override of all the software controls
for moving, gapping or zeroing the stage. There is a Normal Force indicator
which displays any axial load felt by the upper plate. This panel is described in
detail below.
 Bearing – air bearing.
Page 3-2 MAN 0377

Hardware features Chapter 3
 Chuck lock – the upper measuring system shaft has two flats which this chuck
lock, fitted to the lower end plate of the bearing tube, slides into. This locks the
spindle in place.
Caution!
Do not handle the chuck or rotate the motor without the air pressure
applied; it may damage the bearing.
 Chuck – the end of the spindle is a high precision collet which is tightened and
loosened by hand. The chuck holds the upper measuring device (plate, cone,
etc.). It is used on all units and is backwards-compatible.
Caution!
During transport, even over short distances, the chuck must be secured to
prevent damage to the air bearing from vibration. For details on how to
secure the chuck, consult the Malvern Help Desk.
 Upper measuring system – for asphalt testing this is normally an 8mm or

25mm Parallel Plate (denoted by the text PP in dialogs).
 Lower measuring system – this is where the sample is placed. It is also a par-
allel plate. This fits in the Total Immersion Cell (water bath) and is secured
with a locking ring.
 TCU – a Total Immersion Cell or Peltier Thermal Chamber is fitted here. An
Easy Swap™ stage allows the quick exchange of TCUs. The illustration shows
a Total Immersion Cell. These TCUs are described in detail below.
 Feet – after the instrument is moved, readjust the feet to level it.
Base plates
The base plate fits below the lower measuring system. The base plates are inter-
changeable. The lower plates are keyed and set into the Total Immersion Cell
where they rest on the base plate’s outer edge and are secured with a locking ring.
Note
If a Peltier Thermal Chamber is used the base plates are different, featur-
ing an inbuilt PT100. This is described later in this chapter.

Chapter 3 Hardware features
The base plates for the 25mm and 8mm lower plates differ as shown below:
25mm PP and base plate 8mm PP and base plate

ill 7893
Align the base plate with the center of the rheometer base and screw it down clock-
wise. Hand tighten it only.
Caution!
To ensure proper fit and operation, take care not to drop or scratch the
plate surfaces.
Page 3-4 MAN 0377

Control panel
The control panel on the front of the ADS looks like this:
ill 7713
The controls and indicators are as follows:
NORMAL FORCE display – displays the direction and normal (axial) force
acting on the bearing. Bars lighting up to the left of centre show a negative
normal force (i.e. pulling down on the measuring system). Bars to the right of
centre indicate a positive normal force (pushing up on the measuring system).
OVLD (Overload) LED – lights up when the normal force is outside its nor-
mal operating range (i.e. too large in either direction). When in the overload
state, the motor will not move up or down.
GAP LED – this is unlit in normal use. When a user presses the GAP button
the LED illuminates. See the description of the GAP button below.

GAP SIZE display – shows the gap between upper and lower measurement
systems in microns. When the OK LED is lit, the reading is of the actual gap
between the parallel plates. (It does not display above 9mm.) If the OK LED is
off, the reading shows the required gap. To set this gap press the GAP button.
GAP button – set the gap either by using this or the software. The button has
three modes of operation:
Mode 1 Set Gap – to set the gap press the GAP button until the OK LED
is off; using the S and T buttons, adjust the display to read the desired
gap. Once the desired gap is selected, press GAP until the OK LED ena-
bles. The gap is now set and can be activated by pressing the T button, at
which time the stage will move to the gap setting.
Mode 2 Live Stage Control – after the GAP button is held down for five
seconds, the OK button starts to blink. The S and T buttons can be used
to directly move the stage to any gap. Press the GAP button again to send
the gap measurement to the computer.
Mode 3 Gap Capture – this is the same as Mode 2 without using the S
and T buttons. It captures the current gap and sends it to the computer.
ZERO button – press this for a second to zero the instrument, bringing the
upper and lower measurement systems into contact.
SPEED display – shows the current speed of the upper measurement system
movement up or down in the lower stage of gap setting. The more bars lit, the
higher the speed.
Use the SLOW and FAST buttons to reduce or increase the speed. The speed
of the stage movement can be controlled during sample loading and unloading
while within the 9mm measuring range of the gap control.
Page 3-6 MAN 0377

Connections
This section describes the connections on the rheometer back panel. (The connec-
tions to TCUs are described in the following section.)
This diagram shows the connections on the back of the ADS:
7 6 5 4 3 1
0
l
3 2
ill 7717
Set these up as follows:
 BEARING SUPPLY (only on an ADS with air bearing) – provides the air
supply for the bearing’s torque motor. Connect the blue 4mm air hose to this
inlet and switch the red open/closed valve on the air filter regulator to the open
position.
Caution!
Air must be 3 bar and must meet the specification given in Appendix B.
An alarm will sound if the air pressure falls below 2 bar.
 COOLING – depending on the instrument configuration and/or testing

needs, cooling may be required. These two ports provide the cooling medium
(air or water) for the bearing itself. Be sure to connect the inflow to the top
port and the outflow to the bottom port.
 TC1 and TC2 – these are for thermocouple connections, for example for an
oven, and are not normally used for asphalt work.
 PT100 – connector for the PT100 temperature sensor cable (described in the
TCU section below).

 TCU – connector for use with TCUs, as described below.
 GAP CONTROL – this is for the serial cable connected to a serial COM port
on the computer. Data relating to the stage, gap and temperature are communi-
cated via this connection. The digital fluid circulator is also controlled through
this cable.
 INSTRUMENT PORT – connect one end of the cable marked computer
here and its 9 pin D-type connector to an available COM port on the compu-
ter. Note the COM port number, as this will be required by the software later.
Power cables
Connect the power cable to the socket on the back of the ADS and plug it into a
power outlet but do not switch it on yet.
Fuse
The fuse provides electrical protection for the rheometer. Chapter 7 gives details
of how to change fuses.
Page 3-8 MAN 0377

Temperature Control Units (TCUs)

This section describes the TCU setup. It covers:
The Total Immersion Cell, the recommended way to control temperature.
This includes some information on the fluids circulator which supplies this
cell.
The Peltier Thermal Chamber.
Total Immersion Cell

The Total Immersion Cell keeps the sample at a constant pre-set temperature in
the range -28 to 100°C. It does this by circulating a temperature-controlled fluid
(usually water) through the chamber and in direct contact with the lower measur-
ing system. The temperature is controlled by a fluids circulator.
The cell completely immerses the test sample in the circulating fluid. A tempera-
ture sensor in the base of the chamber monitors the fluid temperature and feeds it
back to the circulator, which controls the temperature of the circulating fluid.
This graphic shows the Total Immersion Cell in place:
ill 7894
The Total Immersion Cell is EasySwap™ mounted in the base of the rheometer
housing. The fluid connections used for the chamber are under the unit (see
below). The white plastic cover, when fully seated, allows the water to cover both
the upper and lower plates.

Note
Ambient temperature measurements can be made without fluid circulating
in the chamber.
This graphic shows the connections where fluid from the circulator enters and
leaves the Total Immersion Cell:
2
2
ill 7895
The inlet  is in the centre of the cell. There are three outlets . The hoses from
the three outlets are connected by a 3:1 “banjo” connector to form a single hose
inflow to the circulator. The connection procedure is described below.
Fluids circulator
The digital fluids circulator is from the Julabo F25-HE or FP35-HE series. When
configured and operated properly, this holds a temperature accurate to ±0.01°C.
Caution!
Be sure to provide at least 20cm of space in front of the vents for air to cir-
culate through the circulator. The circulator must not be installed inside
an enclosed space or near to a heat source or direct sunlight.
The circulator must be installed at a lower height than the ADS.
Page 3-10 MAN 0377

Configuring the circulator

This section describes how to set up the Julabo circulator. This is a summary of the
information in the Julabo manuals.
Making connections
There are three steps:
Connect the 9 pin RS232 cable from the control computer to the circulator
port marked SERIAL.
Connect the PT100 cable from the rheometer’s PT100 port to the circulator
port marked ext Pt100.
Connect the supplied power cable to the rear of the circulator and plug it into a
power socket.
Connecting the hoses

The hose outlet and inlet on the circulator are marked as follows:
Connect the 8mm tubing from the Total Immersion Cell ports to these, as follows:
Ensure that the outlet from the circulator is connected to the inlet in the centre
of the Total Immersion Cell.
Connect the three outlets from the Total Immersion Cell to the 3-in-1 “banjo”
back to the circulator inflow.
Supplying the fluid

Fill the circulator tank with water (distilled if possible). If measuring at tempera-
tures below 10°C, use an Ethylene glycol/water mix. Change the fluid periodically
as needed. The recommended maximum filling level is 30mm below the bath rim.
Keep the level close to this at all times.
Caution!
Make sure no liquid enters the interior of the circulator. If the fluid level is
not maintained the heating and cooling coils may be exposed and become
damaged. Keep extra water available.
Adjusting the flow rate

To adjust the flow, use the ball valve on the circulator outlet hose.

Peltier Thermal Chamber

The Peltier Thermal Chamber supports temperatures in the range -10°C to 100°C.
It is shown below fitted to a rheometer. The upper chamber slides up/down on the
support rails.
5 6 1 2 3 4
ill 7896
Its components are:
 Upper heat exchanger thermal enclosure – the upper chamber slides up
for easy access to the lower plate for sample loading, trimming, cleaning and
plate changes.
 Lower plate with embedded PT100 – there will be one of these with an
8mm plate and another with a 25mm plate.
 Lower Peltier assembly – fits into the rheometer below the lower measure-
ment system, via the EasySwap™ base.
Page 3-12 MAN 0377

 Peltier electronics box – this is used to control the TCU.
 Heat exchanger cooling kit – this bottle contains the circulating fluid, which
is circulated by a small pump. It can simply be placed on the bench near the
rheometer.
 Tubing and fittings.
The Peltier plate itself has two electrical connections:
PT100 (round plug) – connects to the PT100 port on the back of the ADS.
This is hard-wired to the base plate which holds the lower measuring system.
D type – connects to the Peltier Drive connection on the back of the Peltier
electronics box (shown below). This is not a removable connection at the Pel-
tier plate end; it’s hard-wired.
Peltier electronics box

The Peltier is controlled by this electronics box:
3 4
2 5
6
ill 7897
The connections, described in the following section, are:
 PT100 connector – connect this to the TCU socket on the ADS.
 PELTIER DRIVE connector – connect the serial cable from the Peltier Ther-
mal Chamber to this.
 Fan – do not obstruct this.
 Mains power connection.
 On/Off switch.
 Fuse – the fuse can be changed by the user.

Connections
This diagram shows the connections between the Peltier Thermal Chamber, the
electronics box and the rheometer back panel:
3 1
ill 7718
To set up the connections:

 Connect the circular connector on the control cable from the Peltier itself to
the ADS’s PT100 port.
 Connect the D-type connector on the cable from the Peltier itself to the
PELTIER DRIVE port on the electronics box.
 Connect the cable with two circular connectors from the PT100 port on the
electronics box to the TCU port on the ADS.
Cooling fluid supply

A flow of cooling fluid is required for correct operation of the Peltier at tempera-
tures away from ambient. The supply needs a minimum flow rate of 1 litre min-1.
The supply is stored in the heat exchanger cooling kit, a bottle placed on the bench
or the floor.
Simply add two cups of Ethylene glycol or commercial automotive anti-freeze to
the water to prevent algae build up in the tank. Place the cooling bottle in a suitable
position on the bench or the floor.
Page 3-14 MAN 0377

To connect the heat exchanger cooling kit:

1. Fill the water cooling bottle to approximately 50mm below the top.
2. Connect the tubing supplied to the connections on the top of the water cooling
bottle as follows:
Connect the tube from the inlet connection on the underside of the Peltier
cylinder to the pump outlet connection on the top of the bottle (normally
the outer connection).
Connect the tube from the outlet on the side of the Peltier cylinder to the
return connection on the top of the bottle (normally the central connec-
tion).
3. Connect the pump to the mains supply and power it on.
4. Check for any leaks around pipe fittings and pipe connections and rectify these
as required.

Page 3-16 MAN 0377

Software
features and tests
Introduction
The TruGrade software and the main differences between the supervisor and
operator levels of access. For full details on the TruGrade software, use its
online help. To open this, select Help-Contents or click the Help button on
any dialog.
The TruGrade tests which can be run; the test types and modes.
Note
The Bohlin research software is documented independently in its own
online help.
Logging on
Start the software by clicking the TruGrade icon on the desktop. This displays the
User Login dialog:
The supervisor may set up password changing; the software will remind users to
change their password if necessary.

4 Chapter 4 Software features and tests
TruGrade software
The TruGrade software is the standard package for SuperPave specification and
grade determination testing. It has two access levels:
Supervisor – gives access to all facilities. This includes setting up operator
users and their permissions, designing tests, modifying the Asphalt wizard,
etc.
Operator – gives access to a subset of the facilities. This allows the user to run
a test from the test list, but not to modify a test. Depending on their permis-
sions, an operator may be able to run calibration or validation. Tailoring the
user interface to specific operators makes testing easy for them.
Supervisor level
After initial installation only supervisor level access to the TruGrade software is
available. At this stage the supervisor should create the first user accounts.
At supervisor level the software has two main modes, selected using the list on the
toolbar. These are:
Test List View – this shows the available tests in its File Name list. The
result of a test appears on the right-hand side:
Page 4-2 MAN 0377

Software features and tests Chapter 4
Test Parameter View – in this mode the supervisor can modify the test
parameters, using the parameter area of the window, shown below. This
replaces the File Name panel shown in the above dialog:
Operator level
The operator only has access to Test List View. This allows them to select a test
from the list the supervisor has set up. In this example the user has selected
Original Binder:

Chapter 4 Software features and tests
TruGrade tests
TruGrade tests are categorised by type and mode.
Test types
There are three test types, each of which has a different application within the
AASHTO standard:
Original Binder (OB) – this is used for the binder without any treatment.
Rolling Thin Film Oven (RTFO) – this is used for samples which have been
through an RTFO, simulating the aging that occurs during mix production and
pavement construction.
Pressure Aging Vessel (PAV) – this is used for samples which have been
through a PAV to simulate real world aging of the asphalt binder. The PAV
exposes the binder to the high pressures and temperatures that would occur
naturally during its life. Use 8mm plates for this type of test because the aged
sample is very stiff.
Test modes
The test modes are summarised here then described in detail below.
Sample type Test mode Ancillary test

OB Pass/fail or Grade Determination Linearity
RTFO Pass/fail or Grade Determination Linearity
PAV Pass/fail or Grade Determination Linearity
The Grade Determination and Pass /Fail modes are the common tests. Linear-
ity is only run for qualifying other results. The fourth test mode combines Grade
Determination and Linearity.
Pass/Fail test
This mode runs a single point test at the current set temperature. The pass/fail cri-
teria shown below are applied to the result. For a PAV sample, for example, a point
with G*.sin(delta) of 4.8MPa would have a Pass result.
OB – G*./sin(delta) >= 1kPa
RTFO – G*/sin(delta) >= 2.2kPa
PAV – G*.sin(delta) <= 5MPa
The default parameters for this test are given in the next section.
Page 4-4 MAN 0377

The Pass/Fail test generates just one point. It shows all the results from that point:
12.0
404.40
Grade Determination test

This mode is used to find two temperatures, one where the sample passes and one
where it fails. This shows the nearest standard grade of the sample being tested,
displayed in the form PGnn. The nn digits give the pass temperature.
The default parameters for this test are given in the next section.
In the following example the grade is PG64:
The data can also be displayed as a graph by selecting the Graph tab.

Linearity test
This test runs a series of single test points at one temperature, but across a range of
increasing amplitudes. This is called an Amplitude Sweep. On completion, a
linearity analysis is run on the data to generate a pass/fail result to indicate whether
the sample meets the linearity requirements of the standard.
The linearity analysis depends primarily on the parameters Comparison Strain,

Reference Strain and Limit Percentage. These three parameters define the
pass/fail criteria as follows. The analysis passes if the value of Complex Modulus at
the Comparison Strain is greater than or equal to a certain percentage (the Limit
Percentage) of the Complex Modulus at the Reference Strain.
The data are also available in tabular form.
Grade Determination/Linearity Combination

This combines Grade Determination and Linearity. If the Grade stage fails, the
Linearity test is not run. If the Grade stage passes, the Linearity stage is run with the
temperature set at the Pass/Fail Temperature result from the Grade Analysis. The
linearity test validates the grade result.
Page 4-6 MAN 0377

Test parameters
The default parameters for Grade Determination and Pass /Fail modes for the
three test types are:
Thermal
Test equilibrium Initial Measuring
type time (mins) Strain stress system Gap
OB 10 12% 100Pa PP25 1.0mm
RTFO 10 10% 100Pa PP25 1.0mm
PAV 10 2% 5000Pa PP8 2.0mm
The parameters are:

Thermal equilibrium time – the length of time (at temperature and within
± bands) to wait to ensure that the sample has reached thermal equilibrium.
Strain amplitude – used in Pass/Fail, Grade Determination and Com-
bined Grade/Linearity test modes when operating the instrument in con-
trolled strain mode. It defines the strain to apply during oscillation
Temperatures
As specified by AASHTO T-315, the following temperatures are used for tests:
OB and RTFO – 46, 52, 58, 64, 70, 76, 82 or 88°C.
PAV – 40, 37, 34, 31, 28, 25, 22, 19, 16, 13, 10, 7 or 4°C.
Tests available
Taking the above combinations of test mode and type, the list of tests available to
an operator is as follows:
Linearity
Original binder
Original Grade Determination
PAV binder
PAV Grade Determination
RTFO binder
RTFO Grade Determination

Page 4-8 MAN 0377

Initial procedures
This chapter describes how to prepare the rheometer for use at the start of the day.
It covers the following:
Checking the air supply.
Removing the immobilizer.
Levelling the instrument.
Installing the measuring systems.
Checking the fluid level in the circulator bath.
Checking the flow rate.
Powering on the components.
Temperature calibration/verification – this needs to be carried out in line with
company procedures.

5 Chapter 5 Initial procedures
Checking the air supply

Check the following before connecting the air supply:
Check at the Festo filter/regulator (normally positioned on the wall; see
Appendix C) that the air pressure is at 3 bar. The instrument has a low air
alarm which will sound if the pressure falls, as well as a motor power cutoff.
Check that the air is clean and dry. For a quick pre-connection check, blow the
air onto a clean piece of white paper for 20-30 seconds at high pressure. If any
spots of oil or water are seen on the paper, or if the end of the pipe is wet, do
not connect the air line to the rheometer.
After checking the supply, connect the air supply to the BEARING SUPPLY
connector on the back of the instrument.
Removing the immobilizer

The motor shaft is locked with a small piece of plastic pipe to prevent damage dur-
ing transportation. Once the air supply has been connected to the rheometer, the
bearing immobilizer tube may be safely removed as shown below:
1 3
Immobilizer on Immobilizer off – ready for use.

ill 7898
The procedure is:
1. Ensure the shaft lock  is in the locked position shown in the left-hand pic-
ture.
2. Unscrew and remove the collet  from the chuck (anti-clockwise).
3. Remove the immobilizer tubing .
Page 5-2 MAN 0377

Initial procedures Chapter 5
4. Replace the collet  (screw it clockwise).

5. Slide the shaft lock to the open position  and verify that the motor shaft
rotates freely.
Levelling the instrument

Level the instrument on the workbench using a spirit level. Adjust the feet on the
base of the rheometer as required.
Installing the measuring systems

Once the above steps are complete, install the measuring systems.
To install the upper plate:
1. Take care to support the measuring system’s weight from below.
2. If using the 25mm plate (not the 8mm plate), place the white plastic cover over
the shaft of the upper plate.
3. Insert the shaft into the chuck, taking care to support the shaft from the bot-
tom. Push the shaft gently into the chuck until the end of the chuck stops it.
4. Tighten the chuck by rotating the chuck nut clockwise. If the shaft slips in the
chuck under a slight torque (imposed by hand), retighten the chuck.
5. If using the 8mm plate, fit the cover now after attaching the plate.
The lower measuring system is installed in the rheometer base, in the threaded
recess above the black sponge filter. It has two parts, the lower plate and the locking
ring.
To install the lower plate:
1. Place the lower plate in the recess and turn it until the two alignment pins on
the plate mate with the slots in the bath recess on the ADS.
2. Grasp the locking ring edges and rest it in the recess. To align the threads,
rotate the plate clockwise until it meets the lower plate and stops.
3. Secure the locking ring by hand.
Caution!
Never use the supplied wrench for tightening. It is only for removing
plates.

Chapter 5 Initial procedures
Checking the fluid level

If using a Total Immersion Cell, check that the fluid level in the circulator bath is
kept close to 30mm below the tank rim at all times.
Filters are mounted above each of the three drain lines located in the outer channel
of the lower bath chamber. Check that these filters are clean and free of debris.
i
Note
Filters should be large enough to adequately cover the drain holes. Avoid
using too small a filter as this may get sucked into the drain hole.
Checking the flow rate

Set the fluid flow rate at a temperature towards the top of the range which will be
used. Once set, the flow will perform correctly at all other temperatures.
Readjustment of flow may be required after changing the filters. Take care not to
over-compress the filter, causing restriction of the flow.
i
Note
Filters should be large enough to adequately cover the drain holes. Avoid
using too small a filter as this may get sucked into the drain hole.
A clogged filter will cause the system to overflow.
Aim for a flow rate high enough to immerse the sample in the fluid and low
enough that the fluid does not overflow.
Powering on the components

The components can be powered on in any convenient order, but power the
rheometer on before starting the software.
Page 5-4 MAN 0377

Temperature calibration/verification
This section describes the steps necessary for an operator with sufficient access to
verify/calibrate the rheometer using a TCD-05 meter. Each procedure runs as a
wizard, working through calibration/verification points defined by the supervisor.
i
Note
If routinely having to adjust the temperature more than two or three tenths
of a degree, or unable to hold a temperature, contact Malvern Instruments
for further in-depth calibration. (Please read the Troubleshooting sec-
tion in Chapter 7 first.)
The TCD-05 meter package is shown below assembled for use:
2 4
ill 7751
The components are:
 Power adapter.
 Temperature meter.
 Serial cable connector (connects to computer).
 Temperature sensor.

Modes of operation
There are two modes of TCD-05 operation:
Battery operation – the meter works using a standard 9V PP9 battery (pro-
vided). When running from the battery, the meter will work for up to 20 hours
on a single battery. The meter will automatically switch off if no buttons are
pressed for more than about 20 minutes. The meter will not automatically
shut down when connected to the software, so we recommend using the mains
adapter for unattended automatic calibrations with the software.
Power adapter operation – this is the recommended method of using the
meter with the software calibration procedures.
Connecting up the TCD-05

The graphic above shows the system ready for use:
To set the TCD-05 up:
1. Connect the mains power cable to the meter.
2. Connect the sensor to the meter.
3. Connect the serial cable’s DIN style connector into the flying lead from the
mains connector.
4. Plug the D-type connector for the serial cable into the COM port on the com-
puter. Make a note of the COM port number.
Code input procedure

Do the following to input the codes from the Sensor Calibration certificate. This
only needs to be done once.
To enter the codes:
1. Switch the meter on. Check that it reads a temperature from the sensor.
2. Select the Menu button to enter the Meter menu.
3. Click the S button repeatedly until the Cal option is shown.
4. Click the Menu button again to select the Cal option. The meter should show
no cal.
5. Click the S button to cycle through the calibration settings: No Cal, Op 1
and Op 2. Select Op 1.
6. Numbers will flash on the meter, showing a four digit hex code with a small
number 1 highlighted.
Page 5-6 MAN 0377

7. Read the two hex codes from the calibration certificate for the sensor.
8. Adjust the values in the first set of hex digits by clicking the S button to step
the value through the sequence from 0 - 9, A - F and back to 0. Continue until
the first digit is correct then click the T button.
The next digit will now flash. Change its value in the same way. Continue
until the four digits match the first code on the certificate.
9. Click the Menu key to accept the value. The second set of digits appears with a
small number 2 shown to the left of the code.
10. Enter the second code in the same way as described in step 8 for the first code.
11. Click the Menu key to accept the second four digit value.
12. Click the ESC key again to return to normal sensor readings.
13. The meter is now 'tuned' to the sensor.
14. From now on, when the meter is switched on, the meter should show the two
hex codes as being the calibration constants used for the sensor. This will clear
after a few seconds and the meter will then show the sensor readings.
The auto-cal procedure

Log into the software as Supervisor then select Supervisor-Calibration-
Options to display the Temperature Calibration Options dialog:

This dialog controls the four main configuration options for calibration and verifi-
cation:
Calibration points.
Verification points – used to test the calibration.
Instrument temperature control.
Calibration device – the device to be used.
Calibration points
These are the points at which a calibrated measurement is taken. The results from
these are used to calibrate for all temperatures. Set the initial value to an accessible
temperature lower than the first required calibration point. This ensures that all
calibrations work in an ascending direction; we recommend that users follow this
rule.
Set up the list of calibration points using the Calibration Points temperature grid.
Points can be added to the end of the list with the Add button and removed with
the Delete button. Clear All removes all temperatures from the list.
Verification points
These are the points at which a calibrated measurement is verified. Each verifica-
tion point consists of a temperature and a tolerance. The results and the report
show pass or fail depending on whether the verified points are within the set toler-
ances. Set the tolerances to give a reasonable definition of whether a calibration is
suitable or not, typically 0.2°C.
As with calibration points, an initial value is required. This must be less than or
equal to the first verification point.
Verification points are shown in the points grid. Use the Add button to add new
points to the end of the list. Remove them using the Delete button. Clear All
removes all points from the list. Tolerances can be entered manually or alterna-
tively a fixed absolute or percentage value can be applied to all points in the list
using the Set Absolute and Set Percentage buttons in conjunction with the
Quick Set Tolerance value.
Instrument temperature control

Before a measurement at a calibration or verification point is taken, we need to be
certain that the entire calibration system is in a state of equilibrium. This means
that both the TCU and any temperature measurement device must have settled
down to stable readings.
Two settings are defined to control the temperature via the instrument to help
achieve this equilibrium state. These are shown in the Temperature Control
Options section of the Temperature Calibration Options dialog.
Page 5-8 MAN 0377

The settings are:
Parameter Function
Tolerance Defines the range of temperatures permitted while taking a
point. If the temperature measured by the instrument is outside
this range, the calibration or verification of the point will restart.
The permitted range of temperatures is defined as Target
Temperature ± Tolerance.
Equilibrium Defines the period of time (in seconds) to allow to ensure that
Buffer the temperature controller has stabilised and for the probe
connected to the external calibration meter to reach a state of
thermal equilibrium.
Calibration device
Malvern Instruments can provide a calibrated device that has been integrated with
the software application to provide an automated solution. Alternatively, any cali-
bration device can theoretically be used to take the calibrated temperature measure-
ments. This means, however, that the operator must manually type the calibrated
measurements into the software application when prompted to do so.
Note
To use a non-Malvern device, set the Calibration Measurement
Options parameter to Manual. This changes the behaviour of the calibra-
tion and verification wizard to prompt for measurements.
To use the Malvern Instruments integrated device, set the Calibration Measure-
ment Options parameter to Automatic. This enables the following options that
the user must configure to identify the location of the device and to define equilib-
rium criteria for taking a measurement:
Parameter Function
Device Type Set this to TCD-05.
Stability Buffer Defines stability of measurements from the TCD-05 device. A
measurement is taken if all measurements taken over the buffer
time are within the Stability Tolerance (see below). The
resulting measurement value is then an average of all
measurements during the buffer time.
COM Port Defines the serial port the TCD-05 device is connected to.
Stability Defines the stability of measurements from the TCD-05 device.
Tolerance A measurement is taken if all measurements within the stability
buffer time are within ± the stability tolerance of the midpoint of
the total range of measurements during this time.

Note
Changing these options does not affect the current calibration or verifica-
tion until the next time the Calibration/Verification wizard is run.
Software configuration
For this TCU set the parameters in the software up as follows:
Field Value
Calibration Measurement Options
Manual/automatic Automatic
Device type TCD-05
COM Port Select the correct COM port for the device
connection
Stability buffer * 600 seconds
Stability tolerance 0.1°C
Temperature control options
Tolerance 0.1°C
Equilibrium buffer * 300 seconds
Calibration Points
Initial Value 2.0°C (should be lower than 1st Cal Point)
Temperature Table See the following table
Verification Points
Initial Value 2.0°C (should be lower than 1st verification Point)
Temperature table See the following table
Note
Do not decrease in value the settings in the table marked with *.
Increasing the values will make the calibration/verification times longer.
Page 5-10 MAN 0377


For this TCU set the parameters in the software up as shown in the table above,
except for the following parameters:
Calibration Measurement Options

Stability buffer * 1800 seconds
Stability tolerance 0.3°C
Temperature control options
Tolerance 0.3°C
Note
Do not decrease in value the setting in the table marked with *.
Increasing the value will make the calibration/verification times longer.
Recommended temperatures
Calibrate the specific temperatures regularly used.
The way the calibration software operates, each programmed temperature is
uniquely calibrated and the software interpolates between these calibrated tempera-
tures for any other temperature selected.
This table shows the default calibration and verification temperatures. The initial
value for each is shown in bold text:
Verification (°C)
Calibration (°C) (Initial value in bold)
Intermediate 13, 16, 19, 22, 25, 28, 31 10, 22, 34
High 46, 52, 58, 64, 70, 76, 82, 88 46, 52, 64, 76
Full 13, 16, 19, 22, 25, 28, 31, 10, 22, 34, 46, 52, 64, 76
46, 52, 58, 64, 70, 76, 82, 88
As a minimum perform a two point calibration. This requires calibration at two

temperatures and verification at one temperature.

Calibration procedure
This procedure uses the standard Bohlin software not the TruGrade software.
To load the sensor:
1. Fit the upper Parallel Plate, PP25 DSR. Initialise and zero the instrument then
set a gap of approximately 4000 microns.
2. Set a temperature of 90°C in the Manual Settings box in the CREEP/
CREEP RECOVERY page of the main software:
3. Leave the temperature at 90°C for 10 minutes, then return it to 4°C.

4. Load the temperature sensor  as shown below:
ill 7899
5. Close the gap to secure the sensor between the upper and lower plates.
6. Check that the sensor and mains power are plugged into the TCD-05 and the
communication cable is plugged into the correct serial port on the computer.
Page 5-12 MAN 0377

7. From the CREEP/CREEP RECOVERY page select Options-Auto-Gap

Control-Auto Tension and set the options up as displayed below:
8. Enable the Auto Tension check box in the Manual Settings section and set
it to 40%. This keeps a constant force on the probe throughout the calibration/
verification, compensating for thermal expansion.
9. Select Supervisor-Calibration-Options. Check that all the information is
entered from the table previously discussed, then click on OK.
10. Select Supervisor-Calibration-Calibration. This starts the wizard as shown
below; follow the on-screen instructions:

11. The wizard initializes, showing this dialog:
12. The wizard approaches the Initial Value set in the table (2.0°C) then contin-
ues to the first calibration point. Once within the tolerance band (± 0.1°C), it
holds for 600 seconds.
13. After taking the readings at the first point, it moves on to the next:
14. After all the calibration points have been taken, the instrument cools down to
the Initial Value temperature set in the Verification Points grid.
15. The wizard continues, verifying at the points selected.
Page 5-14 MAN 0377

Note
During the wizard’s Verification stage, the temperature shown on the main
page differs from that shown in the wizard. This is due to the correction
applied during the Calibration/Verification. Upon completion this will be
applied to the main temperature reading.
16. After completion of the verification stage this table is displayed:
17. The Status row gives the pass or fail information. To view or print a report,
click the Report button.
18. Select Finish to complete the calibration/verification process.
To perform a verification only:
1. Select Supervisor-Temperature Calibration-Verification.
2. The procedure will follow the same sequence as for calibration but will only
verify the temperatures set in Verification Points on the Options page.
Note
When carrying out further verifications, the probe must be placed in the
same orientation as previously used.

Recalibration of the TCD-05 and sensor(s)

We recommend that the temperature calibration equipment is re-calibrated every
12 months using a recognised UKAS / NIST calibration body.
Page 5-16 MAN 0377

Making a
measurement
Introduction
This chapter shows how to measure a sample. It assumes that the initial procedures
described in the previous chapter have been carried out.
This section covers:
Using the Asphalt wizard to make a measurement.
Loading the sample – this is a detailed description of this stage. Users may want
to read this at the appropriate stage in the Asphalt wizard section.
Making a manual measurement (i.e. without using the Asphalt wizard).
Interpreting the measurement results.
Closing down the system.

6 Chapter 6 Making a measurement
The Asphalt wizard

The Asphalt wizard guides a user through the testing regime, from loading the
sample to cleaning it at the end of the test. The wizard gives instructions. It asks for
information such as sample reference and uses this to save the data automatically
with a unique id.
The wizard runs through the following steps:
Pre-test checks.
Enter sample information and temperature.
Lock the chuck.
Raise the stage.
Check the geometry.
Zero the gap, if this is required.
Load the sample.
Lower the stage to trim the gap.
Trim the sample.
Lower the stage to test the gap.
Unlock the chuck.
Close the thermal cover.
Run the test.
Save the data and print report.
Lock the chuck.
Raise the stage.
Clean the plate and geometry.
In the wizard click the Next button after each step. To return to an earlier step,
click on it in the list in the left-hand side of the dialog (this list grows longer as the
user steps through the wizard, showing the steps which have already been per-
formed).
To stop the wizard at any time click its Abort button.
Page 6-2 MAN 0377

Making a measurement Chapter 6
To run the wizard:

1. In the Test List View select the desired test in the File Name list. In the Test
Parameter View select the combination of test and sample type.
2. Click the Start Measure button. The Start dialog lists the pre-test checks to
make:
3. These were covered by the previous chapter so should not require any action.
Click Next to display the Sample dialog:
4. Type in the sample information, enough for other people to track the sample in
the future. The sample reference and test number must be entered before the
test begins. More general notes can be entered while the test is running.

Chapter 6 Making a measurement
5. Click Next to display the Lock dialog:
Lock the air bearing assembly by sliding the chuck locking plate from the right
to the left as shown in the picture. The shaft has two flats which fit the slot on
the lock and these hold the shaft in place, stopping it turning. It may be neces-
sary to rotate the motor to align the flats on the shaft to fit within the locking
plate to prevent it rotating.
6. Click Next to display the Geometry dialog:
Page 6-4 MAN 0377

Set the appropriate plate or spindle in the Geometry list (PP = Parallel Plate):
PP 25mm (diameter) for Original Binder or RTFO aged material.
PP 8mm (diameter) for PAV aged material.
Check that the geometry in the ADS is the one shown in the dialog. If the
plates need zeroing, click the Zero button to do this.
7. Click Next to display the Load dialog:
Load sample by any approved method (the following section details these). The
wizard graphic shows use of a silicone mold for upper plate sample transfer.

8. After loading sample on one of the plates, click Next to display the Trim dia-
log:
The wizard automatically lowers the stage to the appropriate sample trim gap
for trimming the sample. Note the following:
For best results, use a heated tool for sample trimming. The tool should be
hot enough to cut through the sample but not so hot as to cause it to melt
away or burn from the plates. Excessive heat will impair the results.
Trim the edge for a clean uniform surface in one or two swipes. Avoid
excessive trimming, for it will remove too much sample, degrading the
quality of the results.
When trimming a high temperature sample, the tool does not need to be
heated unless the sample is modified material. If it is modified, heat the
tool until it’s just warm enough to cut away material.
For modified or PAV-aged material at intermediate temperatures, over-
heating the trimming tool can cause too much material to escape.
Page 6-6 MAN 0377

9. Once the sample is correctly trimmed, click Next to display the Gap dialog
(for PAV-aged material this dialog will show 2000 not 1000):
Push the white plastic thermal cover down into place.

10. Click Next to display the Unlock dialog:
Unlock the chuck by sliding the lock plate away.

11. Click Next to start the test. Any notes for the test will be displayed in this dia-
log:
Note
Operators can enter comments in the Notes field or data in predefined
fields at any time while the test is running, or after the test completes.
12. When the test completes, save the results. Press the Save button on the toolbar
or use the File-Save command. The Save As dialog appears:
Choose the correct location and file name (if unsure, ask a supervisor about
naming conventions) then click the Save button.
13. Clean the plates as described in Chapter 7 before looking at the results.
Page 6-8 MAN 0377

Loading the sample

This section describes the steps in preparing a test specimen. Placing the right
amount of sample in the right position is very important.
Note
Always follow the industry’s Best Practices guidelines for proper testing
and handling of asphalt samples.
To load the sample:

1. Anneal the asphalt binder by heating it in a covered container in an oven at
135ºC until it’s fluid enough to pour. Higher temperatures may be required
with some modified binders but do not exceed 163ºC, unless specified by the
asphalt manufacturer.
2. For PAV material pre-heat the plates to approximately 45ºC after setting the
gap. This ensures a good bond between asphalt and plates. For the Total
Immersion Cell, this can be achieved by removing the plates and warming
them to 45ºC on a hot plate before loading the sample remotely from the ADS.
3. Stir the fluid binder to obtain a homogenous sample free of air bubbles. There
are two ways to prepare a sample:
Pour it straight onto the plate in a single stream so it spreads out to form a
disc shape with a diameter within 2mm of the plate edge.
Pour it into a silicone mold as shown below and allow it to cool. This is a
convenient way to prepare a sample because it can be poured at a distance
from the ADS. Malvern can supply molds.
ill 7900

Inspect the sample in the mold for air bubbles or lines which indicate that
it is not homogenous. For most materials, one minute of cooling at room
temperature is sufficient for de-molding; check the sample by pulling
down on the corners of the mold as shown below:
ill 7901
If the sample does not release easily from the mold, put it in a refrigerator
for one to two minutes and try again.
Place the sample on the upper or lower plate by touching the center of the
plate with the sample, centering it, and slowly peeling back the silicone
mold. If the sample is not centered, use the corner of the mold to move it.
4. Lower the upper plate, slowly squeezing the sample between the two plates
until it reaches the gap setting (1.05mm or 2.05mm). Excess material must be
squeezed out between the plates.
5. Trim the excess material with a tool at least 4mm wide Here are some trim-
ming tips:
Make or purchase a good trimming tool, something like this:
ill 7902
When trimming a sample in the high temperature range, do not overheat
the tool. Heat it just enough to be able to cut away material.
When testing modified or PAV-aged material in the intermediate tempera-
ture range, overheating the trimming tool can cause too much material to
leak out from between the plates, ruining the sample.
Page 6-10 MAN 0377

On the other hand, not heating the tool enough can cause the binder mate-
rial to be pulled out from between the plates. Knowing the proper amount
of heating comes with experience.
i
Note
It is best to heat the trim tool on a temperature controlled hot plate set to a
suitable temperature.
6. Once trimmed, close the plates an additional 50 microns to produce a slight

bulge around the edge of the sample.
7. The sample should now fill the required gap:
1mm gap with a slight bulge for the 25mm plates.
2mm gap (with a bulge that is difficult to see) for the 8mm plates.
This graphic shows what to aim for (the sample is ):
ill 7921
8. Lower and secure the white plastic cover in place, allowing the water to cover
both plates.
9. Release the shaft lock by sliding it from left to right.

Making a manual measurement

This section shows how to make a measurement without using the Asphalt
wizard. An operator user cannot change the main test parameters defined by the
supervisor for each test type, but may be able to change the temperature.
i
Note
Supervisors defining tests should use the online help for information on
the parameters to use, etc.
To measure the sample:

1. Log into the software and go into Test List View.
2. The tests authorised for a user are listed in the File Name list as shown below.
Page 6-12 MAN 0377

3. Select the test to run. Additional notes can be added to the Notes field during
the test.
4. Click the Start Measure button to run the test.
5. Two commands are available to control the test:
Test Control-Bypass current wait – to skip a temperature stage. This is
the same as pressing the Bypass button.
Test Control-Abort test – to terminate the test.
6. When the test completes, save the results. Press the Save button on the toolbar
or use the File-Save command. The Save As dialog appears:
Choose the correct location and file name (if unsure, ask the supervisor about
naming conventions) then click the Save button.
7. Look at the results for the test type as described below.

Interpreting the results

This section shows what results for each test type look like. Report the test findings
according to company procedures.
Pass/fail test
The Pass/Fail Results tab shows the result details, like this:
The critical parameter is the first, G*/Sin (Delta).
Grade Determination test

This test performs the single point pass/fail test over a range of temperatures until
there is both a pass and a fail result.
The grade is reported, along with the pass/fail temperature (the interpolated tem-
perature at which G*/Sin (Delta) crosses the limit value).
Page 6-14 MAN 0377

The Grade Determination graph page shows the pass/fail limit (the horizontal
line) and the data, like this:
The line and data points in the failure area below the last pass point will be col-
oured red.
Linearity test
The linearity calculation is used to check that over a set range of strain values the
data falls between the appropriate limits. The results are presented in table and
graph form. This example shows the graph:
Selecting the Results tab displays the table.

Grade Determination/Linearity test

This test runs the grade test and then the linearity test at the pass/fail temperature.
For grade or linearity results in the form shown earlier, select the appropriate tab.
Auto report
A report summarising the test data is available. Its data will be appropriate for the
test method used. To preview the report, press the Print Preview button on
the toolbar. The report format is shown below:
Page 6-16 MAN 0377

Press the Print button to print a hard copy of the report.

A printed record should not be used instead of saving the data, but in addition
to saving the data.
Closing down the system

It is important to shut down the system components in the correct order.
Caution!
Follow this procedure closely. Turning the air supply off too soon may
cause damage to the rheometer.
To close down the system:

1. Remove the upper measuring system (if not already done) and make sure the
air bearing lock is in place.
2. Power off the TCU at the circulator.
3. Select File-Exit to quit the software.
4. Power off the rheometer using the switch on the back panel.
5. Quit the Windows software then power off the computer.
6. Turn off the compressed air supply.

Page 6-18 MAN 0377

Maintenance and
Troubleshooting
Introduction
Setting up the fluids circulator.
Rheometer maintenance.
Circulator maintenance.
Changing fuses.
Troubleshooting – this section lists possible problems and their solutions.
Note
The ADS cannot be used without the computer connected.

7 Chapter 7 Maintenance and Troubleshooting
Setting up the fluids circulator

This section describes how to set up the Julabo F25-HE and FP35-HE circulators.
Note
Before operating the circulator after transport, wait about one hour after
setting it up. This will allow any fluid that has accumulated laterally during
transport to flow back down, ensuring maximum cooling performance.
To set up the circulator:

1. Stand the circulator upright with at least 20cm of open space around the front
and rear vents. Avoid heat sources and direct sunlight.
Caution!
Check that the line voltage matches the supply voltage specified on the
identification plate.
2. Use a 19mm (¾") wrench to unscrew the collar nuts on the pump connectors
labelled (the input) and (the output) and remove the sealing disks. Screw
the fittings back on.
3. Connect the tubing or hose from the circulator to the ADS (circulator output
to ADS input and vice versa). The three outlets from the ADS are fed into a
“banjo” which forms a single input back into the circulator.
4. Connect the mains power cable from the circulator’s control head to the mains
power outlet on the rear of the bath. Connect the mains power cable from the
rear of the bath to a grounded power outlet.
5. Connect the five pin control cable between the connectors. Secure it by screw-
ing until tight.
6. Connect one end of the PT100 cable to the output labelled ext Pt100 on the
rear of the control head (the top part of the circulator). Connect the other end
to the PT100 connector on the ADS.
7. Connect the circulator side of the GAP cable to the RS232 port on the back of
the circulator’s control head.
8. Fill the circulator with the fluid. (The recommended maximum filling level
with water as the bath liquid is 25mm below the tank rim.)
9. Ensure the water flow control valve on the instrument or line in is closed to
prevent overflow when the circulator is switched on.
Page 7-2 MAN 0377

Maintenance and Troubleshooting Chapter 7
10. Turn on both mains power switches.

11. When the display ends its self check mode, it displays OFF. Press MENU to
display PUMP, then ENTER, then S to select speed 2.
12. Press ENTER to accept then press ESC (this displays MENU PUMP).
13. Press MENU again to display MENU CONTROL then press ENTER. Use
the S and T buttons to select EXT then ENTER.
14. Exit by pressing the ESC button. The display will show MENU CONFIG.
15. Press MENU again to display MENU SERIAL. Press ENTER and confirm
that the Baud rate is 300, that PARITY is NO and H-SHAKE is HARD.
16. Check for any error messages.
17. Verify that communication with the software is working. To do this, set a tem-
perature of 25°C using the software and check that the circulator reacts to the
set point.
18. If the temperature does not stabilise to within 0.01°C of the target, work
through the test procedure described below.
19. Press ESC to return to MENU LIMITS. Use ENTER and the S and T
keys to set temperature limits to 90°C and 5°C if using water and suitable lim-
its for other coolant fluids. (For example, 90°C and -20°C would be suitable
for a 1:2 ethylene glycol/water mix.)
20. Repeatedly press ESC until the display shows OFF.
21. Press the I/0 button to start the circulator and confirm that the instrument and
software can control the TCU.
22. Check that the water flow is normal.
23. Verify the temperature in the external bath and perform temperature calibra-
tion if needed.
The setup is now complete.

Chapter 7 Maintenance and Troubleshooting
Testing that the system stabilises

If a stable temperature (say within 0.1°C of a 25°C target) is not achieved, do the
following:
1. Press MENU repeatedly until CONTROL is displayed. Press ENTER.
2. Use the S and T keys to select EXT. Press ENTER to store the setting.
3. Press MENU repeatedly until SELFTUN is displayed. Press ENTER.
4. Use the S and T keys to select ALWAYS. Press ENTER to store the setting.
5. Press ESC twice to leave the menu.
6. In the Bohlin software set a temperature of 5°C.
7. Wait five minutes for the temperature to settle then set a temperature of 30°C.
8. Wait five minutes for the temperature to settle then press MENU repeatedly
until CONTROL is displayed. Press ENTER.
9. Use the S and T keys to select EXT. Press ENTER to store the setting.
10. Press MENU repeatedly until SELFTUN is displayed. Press ENTER.
11. Use the S and T keys to select OFF. Press ENTER to store the setting.
12. Press ESC twice to leave the menu.
13. Use the Bohlin software to set a temperature of 25°C and confirm that the sta-
bility is within ±0.1°C.
Page 7-4 MAN 0377

Rheometer maintenance
To ensure accurate measurements, the instrument must be properly maintained.
Routine checks and cleaning

To minimise test-sequencing difficulties, we recommend that plates are cleaned
immediately after each use. This section describes the proper care of spindles and
filters.
Caution!
Samples left in place may attack the surfaces of the measuring systems.
After a test is completed:

1. Align and lock the shaft lock by moving it to the left.
2. Loosen the upper plate by turning the chuck clockwise (viewed from above).
3. Raise the bearing using the vertical position knob.
4. With the upper spindle or plate resting on the base plate, remove the white
plastic cover.
5. Remove the base plate together with the upper plate by turning the base plate
anti-clockwise. Use the large hex spanner to remove the base plate if necessary.
6. Place the base plate on a hot plate for few seconds until the binder can be wiped
clean with a paper towel or soft cloth. Do not use abrasive or sharp imple-
ments since these may scratch or pit the surface.
Warning!
Take care near the hot plate; use proper tools to handle the heated base
plate.
7. Let the base plate cool before rinsing it with solvent, followed by a final rinsing
with acetone. Dry it with a clean paper towel or cloth.
8. Clean the upper plate by placing a paper towel on the hot plate and gently drag-
ging the plate across the paper towel until clean. Avoid scratching the plate.
9. Let the upper plate cool then rinse it with solvent, followed by a final rinsing
with acetone. Dry it with a clean paper towel or cloth. (Adjust the temperature
of the hot plate to avoid igniting the paper towel.)

Caution!
Do not contaminate the circulator bath fluid with solvents.
Filters
The ADS has both fluid and air filters.
Replacing circulator fluid filters

Replace circulating fluid filters as needed. Below the base plate there are two filters:
A black circular disk (Bohlin part 250614) which rarely needs replacing.
A fine-meshed fiber filter used to catch the asphalt residue. Inspect this filter
daily and change it as needed. A clogged filter will cause temperature fluctua-
tions and water flow problems.
To replace a filter, switch off the circulator and remove the lower plate, then the fil-
ter. Discard it and replace with a new Bohlin filter. Filters should be replaced every
couple of months and inspected monthly.
If the system is overflowing, try operating the unit without filters. If it still over-
flows, adjust the flow valve on the circulator.
Cleaning the electronics fan filter

The fan must draw a sufficient volume of air to cool the electronics. Keep the fan
filter clean by periodically vacuuming the screen to remove any dust.
Replacing air filters

Remove and clean or replace the filters in the general filter according to the manu-
facturer’s documentation. If using the JUN-AIR filter supplied by Malvern as the
general filter, check and clean/replace both the high efficiency and drier filters in
the top part and the dust/oil filter in the bottom part.
Check the Festo filter/regulator regularly, again proceeding according to the manu-
facturer’s instructions.
Caution!
If any material or oil at all is seen reaching the right-hand cylinder below
the Festo filter, contact Malvern immediately.
If using the additional Domnick Hunter system, proceed according to its manufac-
turer’s documentation.
Page 7-6 MAN 0377

Circulator maintenance
The Julabo circulator manual gives full maintenance information. This section
briefly describes the main tasks.
Changing the circulator bath fluid

Replace the circulator bath fluid monthly.
Warning!
Always disconnect the power cord before starting.
Take care when emptying hot bath fluids. Check the temperature of the
bath fluid prior to draining (by switching the unit on for a moment, for
example).
To drain the fluid:

1. Power off the circulator.
2. Pull out and remove the venting grid .
ill 7903
3. Slide a short piece of tube  onto the drain port and hold the end over a
bucket.

4. Unscrew the drain tap  and empty the unit completely.

5. Tighten the drain tap.
6. Hand tighten when complete and refill the tank through the top opening.
Changing fuses
Warning!
Fuses must only be changed by a qualified electrician.
Rheometer fuse
If the ADS power fails this is probably a fuse problem. The fuse is located below
the power cable inlet on the back of the rheometer (see Chapter 3).
To remove the fuse, remove the mains cable and pry the fuse cover out with a
screwdriver.
The following fuse ratings apply:
Mains Operating Voltage Fuse Type and Rating

110 volts AC 5 Amp Slow Blow (20mm)
220 – 240 volts AC 2.5 Amp Slow Blow (20mm)
Peltier electronics box fuse

The Peltier fuse is below the power cable inlet on the back of the electronics box
(see Chapter 3).
To remove the fuse, remove the mains power cable and work the fuse cover out
with a screwdriver.
Page 7-8 MAN 0377

Troubleshooting
This section describes how to fix possible problems.
Upper spindle accelerates on its own

If the upper spindle accelerates to a high rpm on its own:
1. Exit the Bohlin and Windows software.
2. Power off and restart the computer and rheometer.
3. If the air bearing shaft continues to spin when the computer and rheometer are
both operational, turn everything off and call the Malvern Help Desk.
4. Check all electrical power connections are correct; see Chapter 3.
Poor temperature control/water overflow

If temperature control is poor or water overflows from the top of the plate, check
the circulating fluid filter in the rheometer base (see the section above on Filters).
Change the filter and/or adjust the flow rate before calibrating/verifying the
temperature.
Adjust the flow rate into the rheometer using the inlet valve. This is on the
outflow hose near to the back of the circulator. Keep the flow rate high enough
to immerse the sample in the fluid but low enough that the fluid does not over-
flow.
The flow rate may need changing after a change in filter size/thickness.
Fluid flow lines clogged with asphalt

If the fluid flow lines become clogged with asphalt residue:
1. Remove the filters.
2. Set the bath temperature at 80°C and allow the water to circulate at high tem-
perature for 45 minutes.
3. Fit a new outer filter and capture any loose residue.
4. Fit a new outer filter.
5. Return the black circular disk filter to its location. If the lines are too full of
asphalt residue or fail to clear, replace the lines.

Bath temperature does not change

With this problem, changing the temperature in the software does not change the
bath temperature.
If the TCU does not acknowledge the change in temperature, click back and forth
between the test types, Intermediate and High, in the Bohlin research software.
Listen for the solenoid on the bath unit switching on and off.
Check the cable connections from the computer, data acquisition and the bath unit.
PAV sample does not adhere to the plates

Clean the plates as described earlier. After setting the gap, preheat the plates as
described in Chapter 6.
Page 7-10 MAN 0377

Part 2 -
Supervisor’s Guide
Security
Introduction
This chapter shows supervisors how to set up their users’ access permissions.
The User Configuration dialog

Use the command Supervisor-User Configuration to add user groups and then
users. This opens the User Configuration dialog:
Use this dialog to set up users and user groups.

8 Chapter 8 Security
Setting up a user group

To create a user group:
1. In the User Configuration dialog select Groups-Add Group to open this
dialog:
2. Name the group and supply an (optional) description.

3. Set up the password parameters. If Force Password Change is selected, users
are prompted to change their passwords at the frequency given.
4. Click OK to save the group.
Page 8-2 MAN 0317

Security Chapter 8
Creating users
To create a user:
1. In the User Configuration dialog select Users-Add Users to open this dia-
log:
2. Type in all details for the user. These are self-explanatory.

3. Switch to the Application Support tab and use this to specify which applica-
tions the user can access.
4. Click OK to save the user.

Chapter 8 Security
Page 8-4 MAN 0317

Part 3 -
Appendices
Health and Safety

General warnings and regulations
Warning!
The instrument or the samples to be measured may be hazardous if mis-
used. Read and fully understand this section before operating the system.
The instrument must only be stored or operated in environmental conditions con-

forming to the specification in Appendix C - Site requirements.
Warning!
Use of the system in a manner not specified by Malvern Instruments may
impair the protection provided by the system.
Electrical warnings and regulations

Warning!
The ADS system contains high voltage components. Only Malvern Instru-
ments trained personnel are permitted to remove the main cover of any
part.
Warning!
This product must be connected to a protective earth. The metal parts of
the unit are earthed using a protective earth connection.
ADS Rheometer Page A-1

A Appendix A Health and Safety
The ADS system components are mains powered devices and all power cables and
electrical sockets should be treated accordingly. Do not place cables in positions
where they are likely to become wet.
Crush hazard
Warning!
Keep hands out of the area between the plates when closing the gap.
Hot components
Warning!
The Total Immersion Cell, the Peltier Thermal Chamber and the lower
plate may become very hot. Take care when touching these, for example
for cleaning. Wear heat proof gloves if required.
Take care with all hoses and hose connections carrying hot fluids to/from
these components.
Fluids circulator
Follow all health and safety information in the circulator manufacturer’s documen-
tation. In particular observe the following warnings:
Warning!
Do not touch hot surfaces. Take care with liquids at high temperatures.
Do not use any flammable or acidic liquids within the bath.
Page A-2 MAN 0377

Health and Safety Appendix A
Power cords and Power safety

The notes in this section indicate best practice. Follow these when connecting the
Malvern instrument to the power supply.
Power cord set requirements

Power cord sets must meet the requirements of the country where the product is
used. For further information on power cord set requirements, contact a Malvern
Instruments representative.
General requirements
The requirements listed below are applicable to all countries:
The power cord must be approved by an acceptable accredited agency respon-
sible for evaluation in the country where the power cord set will be installed.
The power cord set must have a minimum current capacity of 10A (7A in Japan
only) and a nominal voltage rating of 125 or 250 volts AC, as required by each
country's power system.
The area of the wire must be a minimum of 0.75mm2 or 18AWG, and the
length of the cord must be less than 3m.
Route the power cord so it is not likely to be walked on, or pinched by items
placed upon it or against it, or become wet. Pay special attention to the plug,
the electrical outlet, and the point where the cord exits the product.
Warning!
Do not operate this product with a damaged power cord set. If the power
cord set is damaged in any manner, replace it immediately.
Warning!
Do not use the power cord received with this product on any other
products.
Power safety information

The following notes indicate guidelines to follow when connecting the Malvern
Instruments power supply using single and multiple extension leads, connection
via AC Adapters and use of Uninterruptible Power Supplies (UPS).

Appendix A Health and Safety
Warning!
To prevent electric shock, plug the instrument or accessory into correctly
earthed electrical outlets.
The power cord supplied is equipped with a grounding connection to ensure

grounding integrity is maintained.
Advice on use of Extension leads

Follow this advice when using single or multiple socket extension leads. These are
also called trailing sockets.
Ensure the lead is connected to a wall power outlet and not to another exten-
sion lead. The extension lead must be designed for grounding plugs and
plugged into a grounded wall outlet.
Ensure that the total ampere rating of the products being plugged into the
extension lead does not exceed the ampere rating of the extension lead.
Use caution when plugging a power cord into a multiple socket extension lead.
Some extension leads may allow a plug to be inserted incorrectly.
Incorrect insertion of the power plug could result in permanent damage to the
instrument or accessory, as well as risk of electric shock and/or fire. Ensure that
the ground connection (prong/pin) of the power cord plug is inserted into the
mating ground contact of the extension lead
Advice on use of AC adapters
Warning!
Do not use adapter plugs that bypass the grounding feature, or remove the
grounding feature from the plug or adapter.
Place the AC adapter in a ventilated area, such as a desk top or on the floor.
The AC adapter may become hot during normal operation of the instrument
or accessory. Use care when handling the adapter during or immediately after
operation.
Use only the Malvern-provided AC adapter approved for use with the instru-
ment and/or accessory. Use of another AC adapter may cause a fire or explo-
sion.
Advice on use of Uninterruptible Power Supplies (UPS)

To help protect the instrument and/or accessory from sudden, transient increases
and decreases in electrical power, use a surge suppressor, line conditioner or UPS.
Page A-4 MAN 0377

Sample handling warnings

Always handle all substances in accordance with the COSHH (Control Of
Substances Hazardous to Health) regulations (UK) or any local regulations
concerning sample handling safety.
Before using any substance, check the Material Safety Data Sheets for safe han-
dling information.
Use the instrument in a well ventilated room, or preferably within a fume cup-
board, if the fumes from the sample or dispersant are toxic or noxious.
Wear personal protective equipment as recommended by the Material Safety
Data Sheets if toxic or hazardous samples are being handled, particularly dur-
ing sample preparation and measurement.
Wear protective gloves when handling hazardous materials, or those that cause
skin infections or irritations.
Do not smoke during measurement procedures, particularly where inflamma-
ble samples are used or stored.
Do not eat or drink during measurement procedures, particularly where haz-
ardous samples are used or stored.
Take care when handling glass (e.g. beakers). Hazardous materials may enter a
wound caused by broken glass.
Always test a new sample or dispersant for chemical compatibility before use.
After measuring hazardous samples, scrupulously clean the system to remove
any contaminants before making another measurement.
Always label samples for analysis using industry standard labelling, particularly
if they are handled by a number of staff or stored for long periods. Clearly mark
any operator hazard and associated safety precautions that are required for the
handling of dangerous materials.
Keep a record of all hazardous substances used in the system for protection of
service and maintenance personnel.
Always adopt responsible procedures for the disposal of waste samples. Most
local laws forbid the disposal of many chemicals in such a manner as to allow
their entry into the water system. The user is advised to seek local advice as to
the means available for disposal of chemical wastes in the area of use. Refer to
the Materials Safety Data Sheets.
The surfaces of the system may be permanently damaged if samples are spilt on
them. If a spillage does occur, disconnect the system from the power supply
before scrupulously cleaning it up.

Moving the system

If it is necessary to move the system, follow the guidelines given in Appendix E -
Installation.
Warning!
Use proper lifting techniques to avoid back injury. Always lift the instru-
ment by holding it under its base.
Never lift an instrument by precision parts such as the bearing or TCU, or

by its covers. Refer to the handling procedures and diagrams in Appendix
D - Unpacking instructions.
Disposing of the instrument

When the need eventually arises to dispose of the system, this should be done in a
responsible manner. Follow these guidelines:
Refer to any local regulations on disposal of equipment; in Europe refer to the
information below.
Seek advice from the local Malvern Instruments representative for details.
Decontaminate the instrument if hazardous materials have been used in it.
Disposal of Electrical & Electronic Equipment

The following is applicable in the European Union and other European countries
with separate collection systems.
ill 7610
Page A-6 MAN 0377

This symbol on the product or on its packaging indicates that when the last user
wishes to discard this product it must not be treated as general waste. Instead it
shall be handed over to the appropriate facility for the recovery and recycling of
electrical and electronic equipment.
By not discarding this product along with other household-type waste, the volume
of waste sent to incinerators or landfills will be reduced and natural resources will
be conserved.
For more detailed information about recycling of this product, please contact the
local city office, a waste disposal service, or a Malvern Instruments representative.

Page A-8 MAN 0377

Specification
This appendix gives general information on the system and also on test specifica-
tions and criteria.
Dimensions
Peltier
Gemini ADS CVO(R) ADS Circulator control box
Height 50cm 50cm 64cm 10.5cm
Width 34cm 30cm 23cm 24cm
Depth 34cm 30cm 42cm 22cm
Weight 28kg 28kg 32kg 0.7kg
Torque
The maximum torque for the CV0-100-ADS is 100mNm, the C-VOR-200-ADS
is 200mNm and the Gemini-ADS is generally 150mNm, but can be 200mNm.
Measuring system constants

Name: C1 C2 C3 C4
PP08 ADS 9947000 4.00 1 7.4e-08
PP25 ADS 325900 12.50 1 6.8e-07
The PP notation is simple. For example:

PP08 = parallel plate of 8mm diameter.
PP25 = parallel plate of 25mm diameter.
ADS Rheometer Page B-1

B Appendix B Specification
TCUs
Digital circulator/Total Immersion Cell
Circulator JULABO F25-HE JULABO FP35-HE
Temperature range -28°C to 100°C -28°C to 100°C
Temperature stability ± 0.01°C ± 0.01°C
The FP35-HE heats and cools faster than the F25-HE.

The Total Immersion Cell design exceeds industry standards for asphalt test equip-
ment (AASHO T-315 and SHRP B003) and is the most accurate method of testing
asphalt samples.
The circulator is for indoor use only. Its operating environment is described in the
manufacturer’s manual.

The Peltier Thermal Chamber meets all industry standards for asphalt testing
equipment including AASHTO T-315 and SHRP B003.
Temperature range -10°C to 100°C

Temperature stability ± 0.1°C
Accuracy ± 0.1°C
Page B-2 MAN 0377

Specification Appendix B
Accessories
Solids clamping system
Maximum sample width 13mm with a free sample length of 50mm.
Working temperature range -15°C to 95°C depending upon the fluid
medium used
Torsion Rectangular Fixtures

Maximum sample dimension Free length of 50mm, width 13mm and
(solid sample) thickness 10mm
Working temperature range The minimum can be extended from ambient
to -150°C when the liquid Nitrogen cooling
option is used. The maximum is 550°C.
Minimum computer specification

Contact the Malvern Helpdesk or website for the recommended computer specifi-
cation, otherwise consult the Software Update Notification document supplied
on the software CD. The computer is supplied with the system.
Chemical compatibility
Components of the instrument that may come into contact with the sample are
manufactured from materials that are considered to give the widest protection from
chemical attack. However, it is important to check that any sample used is chemi-
cally compatible with the materials mentioned.

Appendix B Specification
Test specifications and criteria

The SHRP test specifications are listed below. As these are subject to change, refer
to the relevant AASHTO specification for the current criteria:
Intermediate Temperature test (Pressure Aging Vessel Residue)
Parameter Values
Plate Diameter Range 8-15mm diameter
Gap range 1-3mm
Applied Shear Stress or 40 to 60kPa, 0.8 to 1.2%
Nominal Strain
Frequency 1.6Hz or 10rads-1
Temperature Range 5, 10, 15, 20, 25, 30, 35, 40°C ±0.2°C
Any temperature between 5°C and 40°C can be

entered. The SHRP specification cites the
temperatures above.
Pass/Fail Criteria Maximum (G*sin δ): 5.0 MPa
Calculation Method Dynamic loss modulus calculated from 512 point
FFT spectrum obtained over a 16 cycle continuous
interval. Ten cycles are applied immediately prior to
measurement.
Page B-4 MAN 0377

Specification Appendix B
High Temperature test (Original Binder)
Parameter Value
Gap range 1-3mm
Applied Shear Stress or 90 to 150Pa, 9 to 15%
Nominal Strain
Temperature Range 45, 55, 65, 75°C ±0.2°C
Any temperature between 5 and 40°C can be

temperatures above.
Pass/Fail Criteria Minimum (G*Sin δ): 1.0k Pa
Method of Calculation Dynamic loss modulus calculated from 512 point
FFT spectrum obtained over a 16 cycle continuous
measurement.
High Temperature test (RTFO Residue):
Parameter Values
Gap range 1-3mm
Applied Shear Stress or 80 to 260Pa, 8 to 12%
Nominal Strain
Temperature Range 45, 55, 65, 75°C ±0.2°C
Any temperature between 40 and 75°C can be

temperatures above.
Pass/Fail Criteria Minimum (G*/Sin δ): 2.2kPa
Method of Calculation Dynamic loss modulus calculated from 512 point FFT
spectrum obtained over a 16 cycle continuous
measurement.

Appendix B Specification
Page B-6 MAN 0377

Site requirements
This is a copy of Appendix C of the manual MAN0377 issue 1.0.
ADS Rheometer Page C-1

© Malvern Instruments Ltd. 2007
Malvern Instruments makes every effort to ensure that this document is correct. However,
due to Malvern Instruments’ policy of continual product development we are unable to
guarantee the accuracy of this, or any other document after the date of publication. We
therefore disclaim all liability for any changes, errors or omissions after the date of
publication. No reproduction or transmission of any part of this publication is allowed
without the express written permission of Malvern Instruments Ltd.
Head office:

Enigma Business Park,
Grovewood Road,
Malvern,
Worcestershire WR14 1XZ
United Kingdom.
Tel + [44] (0)1684-892456

Fax + [44] (0)1684-892789
Windows 2000 and XP are registered trademarks of the Microsoft Corporation.
Printed in England
Site requirements Appendix C
Bench
Seat the rheometer on a solid bench which will not be unduly affected by vibration.
If such a table is not available, the rheometer could be stood on top of a heavy slab
placed on a normal table; this helps to reduce the vibrations detected by the instru-
ment. If using a Peltier Chamber TCU, place its electronics box and fluid bottle on
the bench.
If using a fluids circulator, place this on the floor.
Space required
Provide enough space to allow easy access to all components of the system. If using
the Peltier Chamber allow 100cm (width) x 70cm (depth) of bench space. Allow at
least 800mm above the bench surface for access to the ADS.
Dimensions of the main components of the system are given below:
Component Width Depth Height

Gemini ADS 34cm 34cm 50cm
CVO or CVOR ADS 30cm 30cm 50cm
Peltier control box 24cm 22cm 10.5cm
Peltier fluid bottle 18cm 18cm 30cm
Fluids circulator See manufacturer’s documentation
Computer and printer See manufacturer’s documentation
Power requirements
The mains power supply must be clean and filtered. If necessary, fit an Uninter-
ruptible Power Supply (UPS) to remove any spikes or noise. The power require-
ment for each component of the system is given below:
Power sockets
Component Power requirement required
ADS ~ 100-240V, 50-60Hz 1
Fluids circulator ~ 100-240V, 50-60Hz 1
Peltier control box ~ 100-240V, 50-60Hz 1
Computer See manufacturer’s documentation 1
Computer monitor See manufacturer’s documentation 1

Appendix C Site requirements
Operating environment
Altitude Up to 2000m
Ambient temperature +5 ... +40°C (for storage and transportation)
Air humidity Max. relative. humidity 80% for temperatures up to +31°C
Linear decrease down to 50% relative humidity at a tem-
perature of +40°C
Protection class IP21 (IEC 60529)
Power supply Corresponds to Class I; according to VDE 0106 T1
Not for use in an explosive atmosphere
Max. mains fluctuation of ±10% are permissible
Overvoltage category II (IEC 60664)
Pollution degree 2 (IEC 60664)
Air bearing supply

The motor must be operated with a supply of compressed air at 3 Bar connected to
the unit. If the air supply pressure falls below 2 Bar, the air pressure sensor disables
the drive to the motor.
Parameter Specification
Specification [ISO Standard 8573.1, quality class 121].
Maximum size for dirt 0.1 microns
Maximum size for oil: 0.01 microns
Maximum moisture dew point -40ºC
Air delivery at 25 litres/min [ISO Standard 8573.1, quality class 121 air]
Cooling air/water supply

The CVO-100-ADS is equipped with air lines for cooling. Cooling is optional but
installed for most applications.
The CVOR and Gemini versions are equipped with cooling kits. These are recircu-
lating tanks of water.
Page C-4 MAN 0377

Fluids circulator
Read the circulator manufacturer’s documentation for full details.
Parameter Specification
Altitude Up to 2000m - normal zero
Ambient temperature +5°C ... +40°C (for storage and transportation)
Air humidity: Max. relative humidity 80% for temperatures up to
+31°C, linear decrease down to 50% relative
humidity at a temperature of +40°C
Protection class IP21 (IEC 60 529)
Power supply Corresponds to Class I, according to VDE 0106 T1
Overvoltage category II
Pollution degree 2
In addition:
The circulator is for indoor use only.
It is not for use in an explosive atmosphere.
Maximum mains fluctuations of ±10% are permissible.
The Total Immersion Cell design meets or exceeds industry standards for
asphalt test equipment (AASHTO TP5 and SHRP B003).
Cooling water quality

The cooling water supply must meet this specification:
pH at 25°C 7 to 8.5
Suspended matter <30mg/l
Size of suspended matter max. 0.1mm
Growth of algae not permissible

Air supply filters

The rheometer air bearing needs to be supplied with clean air/Nitrogen so this
needs to pass through the filter drier system. This is fed with 3 Bar air at a flow rate
of 20 litres/min.
Filter setup
The filter setup involves two or three filters as shown below:
This shows the following:

 Compressor - provides the initial unfiltered air or
 Nitrogen supply.
 General air filter - Malvern supplies a JUN-AIR

 filter. The top section of this has a high efficiency
filter and a drier. The bottom section has a dust/oil
filter.

 Optional Domnick Hunter filter system to further
improve quality.
  Festo filter/regulator - supplied as standard, this
regulates the air to the correct pressure for the air
bearing.
  Rheometer.
The filters in the above components are user-replaceable; refer to the manufac-
turer’s documentation for each filter.
Note
If the ETC oven is to be supplied with the same air/Nitrogen source, an
additional regulator (part 250456) can be attached to the main filter/regula-
tor.
Page C-6 MAN 0377

The Festo filter/regulator

The Festo filter/regulator shown below is supplied as standard with the ADS and is
used to regulate the air to the correct 3 bar pressure for the air bearing.
2
3
ill 7904
Air enters the regulator at  and leaves through . Open/close the air passage
using the switch . To adjust the pressure, lift the upper blue knob  and turn it.
Push it down to relock it in the new position.
Caution!
If any material or oil at all is seen reaching the right-hand cylinder  below
the Festo filter, contact Malvern Instruments immediately.

Page C-8 MAN 0377

Unpacking
instructions
Appendix D of the ADS User Manual MAN 0377 Issue 1.0
Déballez l’instrument
Auspacken des Gerates
Desempaquetado del aparato
Desempacotamento do instrumento
ADS Rheometer Page D-1

D Appendix D Unpacking instructions
To unpack the instrument:

1. If there is any sign of damage contact the freight carrier immediately.
Si vous constatez des signes de dommages quel-
conques, contactez immédiatement le transpor-
teur.
Bei irgendwelchen Zeichen von Transport-
schäden den Spediteur sofort benachrichtigen.
Si se advierte algún signo de deterioro, contactar
inmediatamente con el transportista.
Contacte imediatamente a empresa transportadora

se houver qualquer sinal de embalagem danificada.
2. Cut through the plastic bonding straps.

Découpez les courroies d’attache en plastique.
Die Kunststoffbänder durchschneiden.
Cortar las tiras de sujeción de plástico del
embalaje.
Corte as tiras plásticas que prendem o conjunto.
3. Carefully cut the plastic packing tape along the fold lines.
Découpez avec précaution le ruban d’emballage en
plastique, le long des pliures.
Die Kunststoffverpackungsbänder vorsichtig
entlang den Falzlinien durchschneiden.
Cortar con cuidado la cinta de embalaje de plástico
por la líneas de doblado.
Com cuidado, corte a fita de embalagem plástica
ao longo das dobras.
Page D-2 MAN 0377

Unpacking instructions Appendix D
4. Open the wings of the carton and remove the top foam insert.
Ouvrez les rabats du carton et retirez
les blocs de mousse du haut.
Die Klappen des Kartons öffnen und
die oberen Schaumeinlagen ent-
fernen.
Abrir los costados de la caja y extraer
las piezas intercaladas de espuma de la
parte superior.
Abra as abas da caixa e retire o enchi-
mento de espuma que está em cima.
5. Remove all other packages from the carton and unwrap these.
Sortez tous les autres paquets du carton et déballez-les.
Sämtliche andere Pakete aus dem Karton nehmen und auspacken.
Retirar todos los demás paquetes de la caja y desenvolverlos.
Retire todas as outras embalagens da caixa e abra-as.
6. Keep all packaging in case the instrument requires transporting in the

future.
Conservez tous les emballages, au cas où l’instru-
ment devrait être transporté ultérieurement.
Das gesamte Verpackungsmaterial aufbewahren,
falls in Zukunft ein weiterer Transport des Geräts
erforderlich wird.
Conservar todo el material de embalaje por si el
aparato debiera ser transportado en el futuro.
Guarde todo o material de embalagem, caso seja
necessário no futuro transportar o instrumento.
ADS Rheometer Page D-3

Appendix D Unpacking instructions
Page D-4 MAN 0377

Installation
Introduction
The ADS system should initially be commissioned by Malvern trained personnel.
This appendix shows how to re-install the system, typically required under the
following circumstances:
Moving the instrument
If the system has to be moved from one laboratory to another, use the informa-
tion in this appendix to reconnect the system correctly.
Upgrading the computer
It may be company policy to upgrade computers periodically. Detail is given on
the actions required.
If required to change the computer, contact Malvern Instruments.
Only install the system in a suitable environment as detailed under Environmen-
tal conditions in Appendix C.
Moving the system

Handle the instrument carefully. Do not subject it to any strong physical shock.
Warning!
Use proper lifting techniques to avoid back injury. Always lift the instru-
ment by holding it under its base.
Never lift an instrument by precision parts such as the bearing or TCU, or

by its covers. Refer to the handling procedures and diagrams in Appendix
D - Unpacking instructions.
ADS Rheometer Page E-1

E Appendix E Installation
Short distance movements

To move the system:
1. Power off all components.
2. Lock the air bearing assembly using the immobilizer tubing shown in Chapter
5 to avoid damage to the air bearing in transit.
3. Disconnect the mains power cables from the ADS and other components.
4. Disconnect the hoses and drain any fluid from the system into a suitable con-
tainer. Take care if the fluid is hot.
5. Move the Fluids circulator according to the supplier’s instructions.
6. Move the computer equipment according to its supplier’s instructions.
7. At the new location, reverse steps 2 to 6.
8. Set up the connections as described in Chapter 3.
Warning!
This product must be connected to a protective earth.
Longer distance movements
Caution!
The CVO-ADS can be moved by users.
The CVOR-ADS and Gemini-ADS must not be moved without an

internal transit lock first being set by a Malvern engineer. If the instrument
is moved without contacting Malvern it will be damaged.
If moving the system a significant distance or shipping it, pack all components, if
possible in their original packaging. Pack the fluids circulator, computer and moni-
tor according to their manufacturer’s instructions.
Page E-2 MAN 0377

Installation Appendix E
Upgrading the computer

If an upgrade CD is provided, follow this procedure.
Note
If the original software is subsequently updated with a new version, any
custom tests, user groups and users, etc. will be preserved.
Before reloading a previous software version on the computer, contact the

Malvern Help Desk to review updates and software settings that may apply
to the instrument configuration.
To upgrade the software:

1. Remove the old version of the software using the Add/Remove Programs
function in the Windows Control Panel.
2. Insert the new CD in the CD drive.
3. If Autorun is enabled on the computer, the software will start to install auto-
matically. Follow all on-screen instructions to complete the installation.
4. If Autorun is not enabled, select Start-Run-Setup.exe and follow the on-
screen instructions.
Changing the computer

If the computer used with the instrument has to be changed, contact Malvern
Instruments.
ADS Rheometer Page E-3

Appendix E Installation
Page E-4 ADS Rheometer

Regulatory
statements
This appendix presents regulatory information.
ADS Rheometer Page F-1

F Appendix F Regulatory statements
CE Declaration of Conformity
The CE badge on this product signifies conformance to European Commission
Directives.
ill 7982
Page F-2 MAN 0377

Regulatory statements Appendix F
The CE badge on this product signifies conformance to European Commission

Directives.
ill 7983
ADS Rheometer Page F-3

Appendix F Regulatory statements
Page F-4 ADS Rheometer

MAN0377-1.0 ADS User Guide.book Page i Thursday, March 8, 2007 2:42 PM
Index
A Checking air supply 5-2
Checking flow rate 5-4
AASHTO T-315 2-1 Checking fluid level 5-4
AC adapter safety A-4 Chemical compatibility B-3
Access to the instrument 1-2 Chuck lock 3-3
Accessories B-3 Chuck overview 3-3
Adjusting flow rate 3-11 Circulator fluid filters 7-6
After a test 7-5 Circulator maintenance 7-7
Air bearing Cleaning 7-5
locking 6-4 Closing down system 6-17
position 3-2 Code input 5-6
Air bearing supply C-4 Comparison Strain 4-6
Air filter Computer
replacing 7-6 changing E-3
setup C-6 specification B-3
Air supply Connecting the hoses 3-11
checking 5-2 Connections 3-7, 3-14
Annealing binder 6-9 Connections (Peltier) 3-14
Application Support tab 8-3 Constants B-1
Asphalt wizard Control panel
running 6-3 details 3-5
stages 6-2 overview 3-2
ASTM specifications 2-1 Cooling air supply C-4
Auto report 6-16 COOLING connector 3-7
Auto-cal procedure 5-7 Cooling fluid supply 3-14
B Cooling water quality C-5
Cord set safety A-3
Base plate Creating users 8-3
cleaning 7-5 CREEP RECOVERY page 5-12
description 3-3 Crush hazard A-2
Bath temperature not changing 7-10 CVO-100-ADS 2-2
Bearing 3-2 CVOR-200-ADS 2-2
BEARING SUPPLY 3-7
Bench specification C-3 D
C Dimensions B-1
Cable safety A-3 E

Calibration device 5-9 Earthing A-1
Calibration points 5-8 Electrical warnings A-1
Calibration procedure 5-12 Equilibrium Buffer 5-9
CE Declaration F-2 Extension lead safety A-4
Changing circulator fluid 7-7
ADS Rheometer Page i

Index ADS Rheometer
F Help desk 1-4

High Temperature Test (Original Binder) B-5
Festo filter/regulator C-6, C-7 High Temperature Test (RTFO Residue) B-5
File name list 6-12 High temperature trimming 6-6
Filling the circulator 7-2 Hose
Filter maintenance 7-6 connecting 7-2
Filter setup C-6 connecting up 3-11
Flow rate Hot components A-2
adjustment 3-11 How the ADS works 2-1
checking 5-4
Fluid flow lines clogged 7-9 I
Fluid supply 3-11, 3-14
Immobilizer 5-2
Fluids circulator
changing fluid 7-7 Initial procedures 5-1
Installation E-1
connecting 3-11
Installing measuring systems 5-3
health and safety A-2
position 3-10 INSTRUMENT PORT connector 3-8
Intermediate Temperature Test B-4
setting up 7-2
specification C-5 L
Force Password Change 8-2
Function of ADS 2-1 Levelling 5-3
Fuse Limit Percentage 4-6
overview 3-8 Linearity test
replacing 7-8 results 6-15
results display 4-6
G Load dialog 6-5
Loading sample 6-9
GAP button 3-6
GAP cable 7-2 Lock dialog 6-4
Locking ring 5-3
GAP CONTROL connector 3-8
Logging on 4-1
Gap dialog 6-7
GAP LED 3-5 Lower measuring system 3-3
Lower plate 3-12, 5-3
Gap setting 2-2
GAP SIZE display 3-6 M
Gemini-ADS 2-2
Geometry dialog 6-4 Maintenance 7-1
Geometry list 6-5 Malvern personnel 1-2
Grade Determination test Manual control 6-12
details 4-5 Measuring system constants B-1
mode 4-4 Measuring systems
results 6-14 base plates 3-4
Grade Determination/Linearity test installing 5-3
function 4-6 Measuring the sample 6-12
results 6-16 Menu commands in text 1-3
Model number 1-4
H Moving the system A-6, E-1
Hardware features 3-1 N
Health and Safety A-1
Heat exchanger cooling kit 3-13 NORMAL FORCE display 3-5
Page ii MAN 0377

MAN0377-1.0 ADS User Guide.book Page iii Thursday, March 8, 2007 2:42 PM
ADS Rheometer Index
O Replacing circulating fluid filters 7-6

Report printing 6-17
Operating environment C-4 Report summarising data 6-16
Operator access 4-2, 4-3 Research software
Operator tasks 1-3 role 2-3
Original Binder (OB) 2-3, 4-4 tests available 2-4
OVLD (Overload) LED 3-5 Rolling Thin Film Oven (RTFO) 2-4, 4-4
P Routine checks 7-5
Parallel Plate 3-3 S

Pass/Fail test Sample dialog 6-3
details 4-4 Sample handling warnings A-5
mode 4-4 Sample information 6-3
results 6-14 Sample loading 6-9
PAV material loading 6-9 Sample trimming 6-6
PAV sample does not adhere 7-10 Saving test results 6-8
PAV-aged material 6-7 Security 8-1
Peltier Sensor Calibration certificate 5-6
connections 3-13 Sensor loading 5-12
specification B-2 Serial number 1-4
PELTIER DRIVE connector 3-13 SERIAL port 3-11
PELTIER DRIVE port 3-14 Shaft lock 6-11
Peltier electronics box 3-13 Silicone mold 6-9
Peltier electronics box fuse 7-8 Site requirements C-1
Peltier Thermal Chamber Software configuration (TCD-05) 5-10
described 3-12 Software features 4-1
overview 2-3 Solids clamping system B-3
setup 5-11 Space required C-3
Poor temperature control 7-9 Specification B-1, D-1
Power cables 3-8 SPEED display 3-6
Power cord safety A-3 Start dialog 6-3
Power requirements C-3 Start Measure button 6-13
Power safety information A-3 Strain amplitude 4-7
Powering on 5-4 SuperPave 2-3
Pressure Aging Vessel (PAV) 2-4, 4-4 Supervisor access 4-2
Print Preview 6-16 System shut down 6-17
PT100 3-3, 3-7, 3-12
PT100 port 3-13 T
R TC1 and TC2 3-7
TCD-05
Recalibration of TCD-05 and sensor 5-16 battery operation 5-6
Recommended temperatures connecting up 5-6
for calibration 5-11 overview 5-5
Reference Strain 4-6 power adapter operation 5-6
Regulatory statements F-1 TCU
Remote support 1-4 specification B-2
Removing the immobilizer 5-2 TCU connector 3-8
Replacing air filters 7-6 Temperature calibration/verification 5-5
ADS Rheometer Page iii

MAN0377-1.0 ADS User Guide.book Page iv Thursday, March 8, 2007 2:42 PM
Index ADS Rheometer
Temperature control 2-3, 5-8 details 4-1

Temperature control poor 7-9 overview 2-3
Temperature Control Unit tests 2-3
overview 3-9 TruGrade tests 4-4
placement 3-3
U
uses 2-2
Temperature of bath not changing 7-10 Uninterruptible Power Supply (UPS) safety A-4
Temperature range 3-12 Unlock dialog 6-7
Temperature sensor 5-5 Upgrading the computer/software E-3
loading 5-12 Upper measuring system 3-3
Temperatures for tests 4-7 Upper plate 5-3
Test control 6-13 Upper spindle accelerates 7-9
Test list view 4-2 User Configuration dialog 8-1
Test modes 2-4, 4-4 User creation 8-3
Test parameter view 4-3 User group creation 8-2
Test parameters 4-7
Test specifications B-4 V
Test temperatures 4-7 Verification of temperature 5-5
Tests available 2-4, 4-7 Verification only 5-15
Thermal equilibrium time 4-7 Verification points 5-8
Tolerance (TCD-05) 5-9 Vertical position knob 3-2
Torque 2-2, B-1
Torsion Rectangular Fixtures B-3 W
Water cooling bottle 3-15
descibed 3-9
Water overflow problems 7-9
fluid level 5-4
overview 2-2 Water supply C-4
Website 1-4
Setup 5-10
Trim dialog 6-6 Z
Trimming excess sample 6-10
Troubleshooting 7-1 ZERO button 3-6
TruGrade software
Page iv ADS Rheometer

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Bohlin

user manual user manual

Enigma Business Park

© Malvern Instruments Ltd. 2007

Malvern Instruments Ltd.

Tel + [44] (0)1684-892456

Windows 2000 and XP are registered trademarks of the Microsoft Corporation.

Introduction to this manual

What is the ADS?

Software features and tests

ADS Rheometer Page i

Table of Contents ADS Rheometer

Maintenance and Troubleshooting

Page ii MAN 0377

ADS Rheometer Table of Contents

Part 2 - Supervisor’s Guide

ADS Rheometer Page iii

Table of Contents ADS Rheometer

Health and Safety

Page iv MAN 0377

ADS Rheometer Table of Contents

ADS Rheometer Page v

Table of Contents ADS Rheometer

Page vi MAN 0377

How to use this manual

ADS Rheometer Page 1-1

1 Chapter 1 Introduction to this manual

The manual is divided into the following three sections.

Part 1 – Operator’s guide

Part 2 – Supervisor’s guide

Access to the instrument

Page 1-2 MAN 0377

Introduction to this manual Chapter 1

ADS Rheometer Page 1-3

Chapter 1 Introduction to this manual

Where to get help

Malvern Website - www.Malvern.com

Page 1-4 MAN 0377

What is the ADS?

How the ADS works

ADS Rheometer Page 2-1

2 Chapter 2 What is the ADS?

 Sample temperature is controlled and monitored for conformance to the

Temperature Control Units (TCUs)

Page 2-2 MAN 0377

What is the ADS? Chapter 2

conditions from affecting sample temperature. The sample temperature is

For research use

ADS Rheometer Page 2-3

Chapter 2 What is the ADS?

Page 2-4 MAN 0377

ADS Rheometer Page 3-1

3 Chapter 3 Hardware features

Page 3-2 MAN 0377

Hardware features Chapter 3

 Upper measuring system – for asphalt testing this is normally an 8mm or

ADS Rheometer Page 3-3

Chapter 3 Hardware features

25mm PP and base plate 8mm PP and base plate

Page 3-4 MAN 0377

Hardware features Chapter 3

ADS Rheometer Page 3-5

Chapter 3 Hardware features

Sample temperature is controlled and monitored for conformance to the