75-PV50A0X - Analiz Autom Solvent - Rev 2 - en - 21-11-2013

75-PV50A05, PV50A06
PV50C05, PV50C06
Automatic Closed System
Asphalt Analyzer
MANUALE DI ISTRUZIONI
INSTRUCTION MANUAL
Manuale di Istruzioni Analizzatore Automatico Bitume
Instruction Manual Automatic Asphalt Analyzer
Index
1. INTRODUCTION 1
1.1 Icons appearing in the manual ............................................................................................. 4
1.2 Manual revision history ....................................................................................................... 5
1.3 Symbols used ....................................................................................................................... 6
1.4 Intended use and improper use ............................................................................................ 7
1.5 Safety information ............................................................................................................... 8
1.6 Environmental risks and disposal ...................................................................................... 16
1.7 CE declaration ................................................................................................................... 17
2. DESCRIPTION 18
2.1 Functional block diagram .................................................................................................. 20
2.2 Identification plate ............................................................................................................. 21
2.3 Commands and controls .................................................................................................... 22
2.4 Technical specifications..................................................................................................... 23
3. INSTALLATION 24
3.1 Shipment ............................................................................................................................ 25
3.2 Unpacking and inspection.................................................................................................. 26
3.2.1 How to remove the equipment from the shipping crate ................................................. 27
3.3 Positioning of the unit and space requirements ................................................................. 29
3.4 Electrical requirements ...................................................................................................... 31
3.5 External connections.......................................................................................................... 32
3.5.1 Electrical connection ...................................................................................................... 32
3.5.2 Cool water line connections ........................................................................................... 33
3.5.3 Connection to the air ...................................................................................................... 34
3.5.4 Filling the clean solvent tank ......................................................................................... 35
4. USE OF THE EQUIPMENT 36

4.1 Operating phases................................................................................................................ 37
4.2 Switching on the equipment .............................................................................................. 44
4.3 Operators interface description ........................................................................................ 47
4.3.1 MAIN MENU ................................................................................................................ 48
4.3.2 Cleaning of the dirty solvent tank .................................................................................. 58
4.3.3 SETUP screen ................................................................................................................ 62
4.3.3.1 LANGUAGE SELECTION screen................................................................................ 63
4.3.3.2 PROGRAM SETTING screen ....................................................................................... 64
4.3.3.3 SYSTEM INFO screen .................................................................................................. 65
4.3.3.4 MANUAL MODE screen .............................................................................................. 66
Rev.2 EN i 21/11/2013
Manuale di Istruzione Analizzatore Automatico Bitume
4.4 ERROR messages ............................................................................................................. 67

4.5 Carry out a Standard extraction process............................................................................ 68
4.5.1 Start up and sample loading ........................................................................................... 69
4.5.2 Process setup, start and possible actions during the process .......................................... 73
4.5.3 WASHING phase ........................................................................................................... 77
4.5.4 RINSE phase .................................................................................................................. 78
4.5.5 DRYING phase .............................................................................................................. 79
4.5.6 End of the extraction process ......................................................................................... 80
4.5.6.1 Phase SKIP function ....................................................................................................... 82
4.5.6.2 QUIT the extraction process........................................................................................... 83
4.6 Carry out a Fast extraction process ................................................................................... 85
4.7 Stopping the machine via the Emergency button.............................................................. 90
4.8 Switching off the unit........................................................................................................ 91
5. MAINTENANCE 92
5.1 Operators and Preventive maintenance............................................................................ 94
5.1.1 Clean the chamber of the solvent input line on the centrifuge ....................................... 95
6. DIAGNOSTICS & TROUBLESHOOTING 96

6.1 MANUAL MODE screen ................................................................................................. 97
6.1.1 MANUAL I/O screen ..................................................................................................... 99
6.1.2 ADVANCED SETTING screen ................................................................................... 100
6.1.3 SYSTEM COUNTERS screen ..................................................................................... 103
6.2 ERROR MESSAGES ..................................................................................................... 104
7. SCHEMATICS AND DRAWINGS 106
This instruction manual is an integral part of the machine and should be read before using the machine and be
safely kept for future reference.
CONTROLS reserves all rights of this manual, no part or whole can be copied without the written permission of
CONTROLS .
The proper use of this machine must be strictly adhered to, any other use must be considered as incorrect.
The manufacturer cannot be held responsible for damage caused by incorrect use of the machine.
The machine must not be tampered with for any reason. In case of tampering, the manufacturer declines any
responsibility of functioning and safety of the machine.
This Manual is published by CONTROLS.

CONTROLS reserves the right to update its manuals without notification in order to correct possible typing
errors, mistakes, updating of information and/or updating of programs and/or accessories.
Such changes will be inserted in the latest edition of the current manual.
The present in English is the original version of the manual. Printed in Italy
21/11/2013 ii Rev.2 EN
1. INTRODUCTION
NOTE:
The present manual is updated for the product it is sold with in order to grant an adequate
reference in operating and maintaining the equipment.
The manual may not reflect changes to the product not impacting service operations.
The PAVELAB Automatic Closed System Asphalt Analyzer is used for the separation
and extraction of bitumen, filler and aggregates from asphalt samples by use of solvents,
according to the standards ASTM D2172 and EN 12697-1.
Binder extraction and recovery is important either for determining the binder content or to
recover, using a Rotary evaporator, a representative bitumen sample used to perform
other tests such as penetration, softening point, etc.
Aggregates, including filler, are also separated, not disturbed by high temperatures and
available for sample grading.
This method allows the complete analysis of an asphalt sample.
The PAVELAB Automatic closed system asphalt analyzer consists essentially of the
following modules:
Machine body: Steel sheet, powder coated with epoxy resin. Wheel mounted.
Washing chamber: High quality stainless steel fitted with ultrasonic waves
generator, heating system, driver for the rotation of the washing drum, valves,
connections, etc.
Washing drum: Lined with screening cloth 0.063 or 0.075 or 0.090 mm opening.
This unit, which has to be ordered separately, includes seating, support and closing
ring for the cover. Each model shall be fitted with the appropriate cover.
Centrifuge: High speed centrifuge for 120 mm dia. cup, complete with safety
switch.
Condenser: Stainless steel tank complete with cooling coil for condensation of
solvent vapour during the drying operation.
Vacuum pump: For drying aggregate and filler.
Recovery/distillation unit: Double chamber: one for distillation, one used for
reservoir. The distillation chamber comprehends base and upper heater for solvent
recovery rate up to approx. 30 l/h, and cooling coils above the chamber incorporated
in the cover. Both chambers are fitted with drain valves.
7 Touch screen control panel: For machine control and operation.
Safety features: The machine stops immediately in case of door/cover openings,
lack of water, electric motor malfunctions, etc. Type of trouble is highlighted on the
control panel.
Rev.2 EN 1 21/11/2013
Main features of the equipment are:

Fully automatic extraction process:
o washing the asphalt sample (up to 3.5 kg) by solvent and ultrasonic motion with
heating and rotation of the drum lined with screening mesh;
o high speed extraction centrifuge for separation of filler from binder solution;
o condensation of solvent vapor in a stainless steel tank including cooling coil,
conforming to latest anti-pollution requirement;
o automatic recovery of solvent by continuous distillation process;
o easy binder recovery for further tests such as penetration, softening point, etc.
Extraction time (washing and drying) reduced to approx. 55 minutes;
No toxic fumes in the laboratory during the extraction process;
High extraction capacity: up to 200 g of filler for each extraction;
Automatic sample drying after extraction;
Silent operation;
Depending on the version, the unit set to use highly stabilized form of
perchlorethylene OR methylene chloride as solvent (use of any other solvent is not
allowed as it may lead to damage to the equipment and danger for the operator).
The typical operating cycle of the machine is as follows:

The asphalt sample (max. 3.5 kg) is introduced in a screening drum lined with 0.063,
0.075 or 0.090 mm opening woven cloth positioned inside a washing chamber;
Bitumen and filler are separated from the sample by washing with solvent;
Washing phase is accelerated using ultrasonic waves;
The mixture filler/bitumen/solvent is then centrifuged to separate the filler;
The aggregates and filler are dried by vacuum and the residual solvent recovered by
condensation;
The remaining solution bitumen/solvent is distilled and separated in two separate
tanks;
Part of the solution bitumen/solvent can be drained before distillation and collected
for recovery in a rotary evaporator;
The clean distilled solvent is recycled for other extractions.
The following models are available:
75-PV50A05
PAVELAB Automatic Closed System Asphalt Analyzer. For separation and extraction
of bitumen, filler and aggregates from asphalt samples by use of solvents. 400 V, 50 Hz,
3 ph
75-PV50A06
of bitumen, filler and aggregates from asphalt samples by use of solvents. 220 V, 60 Hz,
3 ph
21/11/2013 2 Rev.2 EN
75-PV50C05
of bitumen, filler and aggregates from asphalt samples by use of solvents. Complete with
washing drum 0.063mm opening, closing lid, centrifuge cup, lining paper and water
cooling system. 400 V, 50 Hz, 3 ph.
75-PV50C06
of bitumen, filler and aggregates from asphalt samples by use of solvents. Complete with
washing drum 0.063mm opening, closing lid, centrifuge cup, lining paper and water
cooling system. 220 V, 60 Hz, 3 ph.
The machine shall be connected to a suitable water cooling unit to feed the three different
cooling coils.
The device must be used in compliance with the procedures described in this manual.
Never use the device for purposes different from those herewith indicated.
WARNING:
Depending on the version, the unit set to use highly stabilized form of perchlorethylene
OR methylene chloride as solvent. Use the solvent the unit has been prepared for. Use of
any other solvent is not allowed as it may lead to damage to the equipment and danger for
the operator. CONTROLS will not to be held responsible for damages to the equipment
and injures to the operator in case of use of the wrong solvent. The warranty will be void.
This manual is applicable for units having firmware release as follows:

Machine (PLC) firmware version 1.3
Display (HMI) firmware version 1.4.
Fig. 1-1
Please read this manual thoroughly before you start using the equipment.
Rev.2 EN 3 21/11/2013
1.1 Icons appearing in the manual
This icon indicates a NOTE; please read thoroughly the items marked by this picture..
This icon indicates a WARNING message; the items marked by this icon refer to the
safety aspects of the operator and/or of the service engineer.
21/11/2013 4 Rev.2 EN
1.2 Manual revision history
Revision/Date Change description

Rev. 1 Manual release
July 12th 2013
Rev. 2 Modified as per firmware versions PCL V 1.3, HMI V
November 21st 2013 1.4
Added functioning parameters default setup for
perchlorethylene and methylene chloride solvents
(chapter 6.1.2)
Rev.2 EN 5 21/11/2013
1.3 Symbols used

In this manual and on the equipment itself, apart from the symbols indicated on the
control panel, the following icons are also used:
Symbol Description
Mains switch:
O = device not connected to the mains line
I = device connected to the mains line
Emergency stop switch
Dangerous voltage
Hot surface
Harmful or irritating substances (see the solvent safety sheet)
Conformity to the CE Directive
21/11/2013 6 Rev.2 EN
1.4 Intended use and improper use

The PAVELAB Automatic Closed System Asphalt Analyzer can only be used for the
separation and extraction of bitumen, filler and aggregates from asphalt samples by use of
solvents, according to the standards ASTM D2172 and EN 12697-1.
Depending on the version, the equipment is factory set to use the highly stabilized form
of perchlorethylene OR methylene chloride as solvent. Use of any other solvent is not
allowed as it may lead to damage to the equipment and danger for the operator.
The unit is designed to be operated by one operator that has to load the solvent, load the
asphalt sample into the drum and the latter into the washing chamber, load the cup into
the centrifuge and start the extraction process.
During normal operation the working area of the equipment is the front side where the
operators controls and the display are located.
The operator is responsible of starting-up the equipment, performing the test sequence,
shutting down the equipment and eventually stopping it in case any emergency conditions
are met.
The operator must be trained on the correct use of the machine and the relative safety
aspects of its use.
The machine should be used following the procedures described in this manual.
Never use the machine for reasons other than those for which it was designed and
manufactured. Any other use of the machine is to be considered improper, not foreseen
and hence dangerous.
CONTROLS will not be responsible for improper use of the machine.
WARNING:
Rev.2 EN 7 21/11/2013
1.5 Safety information
WARNING:
Please read this chapter thoroughly.
CONTROLS designs and builds its devices complying with the related safety
requirements; furthermore it supplies all information necessary for correct use and the
warnings related to use of the equipment.
CONTROLS will not to be held responsible for:

use of the equipment different than the intended use,
damages to the unit, to the operator, caused both by installation and maintenance
procedures different than those described in this manual supplied with the unit, and
by wrong operations,
mechanical and/or electrical modifications performed during and after the
installation, different than those described in this manual
The unit is not designed to be used in an explosive atmosphere.
Installation and any technical intervention must only be performed by qualified

technicians authorized by CONTROLS.
Only authorised personnel can remove the covers and/or have access to the components
under voltage.
During normal use, if the operator detects irregularities or damages, he/she should
immediately inform the authorized technical personnel.
Maintenance and service activities can only be performed by skilled authorized technical
personnel that have been properly trained on the residual risks of the equipment.
It is responsibility of the purchaser to make sure that the operators have been properly
instructed concerning the safety issues and the residual risks related to the equipment.
21/11/2013 8 Rev.2 EN
The machine is equipped with the following devices to limit the residual risks in using it:
1. Emergency button that de-activate all functions of the equipment, leaving active the
display unit only;
2. Electro-lock on the washing chamber door to prevent from operation with the door
open; the electro-lock includes closed and locked door sensors;
3. Electro-lock on the centrifuge door to prevent from operation with the door open; the
electro-lock includes closed and locked door sensors;
4. Safety thermal switch inside the washing chamber to prevent the temperature to
exceed the safety limits;
5. Access panels to internal parts locked with screws.
Electro-lock
Electro-lock
Emergency button
Fig. 1-2
Rev.2 EN 9 21/11/2013
The following table lists those parts of the equipment that may present some residual
risks for the safety of the personnel if the instructions provided in this manual are not
duly followed.
Personnel Area with residual risks

Operator Solvent vapors while loading/draining from the machine. Use a standard
fume extractor or dedicated aspiration system.
Contact with solvent. Use suitable personal protection devices (e.g. glasses,
gloves, mask, etc. Refer to the solvent safety sheet).
The washing chamber, washing chamber drum, centrifuge parts, due to high
temperature. Use suitable personal protection devices (e.g. thermal gloves,
etc.).
The pre-heated sample, due to high temperature, during loading into the
washing drum. Use suitable personal protection devices (e.g. thermal
gloves, etc.).
Technical personnel Above listed areas
Areas around compartments closed by removable panels
Areas around compartments that contain electrical parts
For continued fire protection, replace fuses with same type and rating. Also,
in case of failure, components may only be replaced by using original spare
parts. It is in the responsibility of the purchaser to insure that fire prevention
policies are properly implemented according to the CE provisions.
Personnel Raising and moving of the equipment from the wooden crate must be
responsible of performed by people properly trained and equipped with suitable personal
transportation and protection devices (e.g. gloves, helmet, etc.). Failure to follow the
moving of the instructions above may endanger the personnel involved.
equipment
21/11/2013 10 Rev.2 EN
Here follows a list of all WARNINGs present in the manual; please see relevant chapters
for full details on each related safety issue.
WARNING:
When operating with the covers open/removed and the unit is attached to the mains line,
care must be taken as high voltage is present in some parts of the unit (e.g. electrical
panel). Only authorized and qualified service technicians are allowed to open /remove
covers.
WARNING:
All safety devices must be functional at all times. Damaged protective covers or devices
must be replaced immediately. When safety components are replaced, the protective
devices are to be properly attached and tested. Any manipulation of the safety devices
endangers the operating personnel.
WARNING:
Raising and moving of the equipment must be performed by people properly trained and
equipped with suitable personal protection devices (e.g. gloves, helmet, etc.). Failure to
follow the instructions above may endanger the personnel involved.
WARNING:
The wooden crate is high; be careful in balancing while raising it.
WARNING:
If the instructions to remove the equipment from the shipping box are not carefully
followed, damage to the equipment cabinet may result. This will void the warranty terms
of the equipment.
WARNING:
Do not stand under suspended loads
WARNING:
Do not turn OFF the machine until the solvent is completely drained off the washing
chamber otherwise residual of solvent may remain into the system and this may cause
damages to the centrifuge at next switch ON.
Rev.2 EN 11 21/11/2013
WARNING:
Considering the weight of the equipment and the footprint (see chapter 2.4), check the
maximum allowed floor load before installation.
WARNING:
If the equipment is brought from a cold environment into a heated room, condensation on
and in the unit can constitute a danger and lead to malfunctioning of the unit when
started. Wait to connect and operate the unit until it is at room temperature.
WARNING:
The general grounding must comply with the rules in force; a wrong quality of the
grounding could be dangerous for the operators safety and cause bad function of the
electrical devices.
WARNING:
WARNING:
Covers/doors can only be removed/opened by maintenance people, by using relevant
tools/buttons. These tools and buttons are for use by maintenance personnel only. Never
leave the tools and buttons attached to the unit as this may endanger operator safety.
After performing maintenance/repair, make sure that all covers/doors are properly closed
and locked.
WARNING:
Before proceeding, it is important to close the valve on the recovery-distillation unit to
avoid draining out the dirty solvent during the remainder of the extraction process.
21/11/2013 12 Rev.2 EN
WARNING:
It is recommended performing the cleaning cycle of the dirty solvent tank once a day, at
the end of the extraction process. This is to avoid collecting too much bitumen that may
become stiff and therefore very difficult to drain afterwards. CONTROLS will not be
responsible for any damage caused by the lack of cleaning procedure. Warranty of the
equipment will be void.
WARNING:
Access to the MANUAL MODE is allowed for CONTROLS authorized technical
personnel only. CONTROLS will not be responsible for any damage caused by improper
setting of these parameters and/or unauthorized access to these menus. Warranty will be
void if this menu is used by unauthorised personnel.
WARNING:
Avoid direct contact with the solvent. Use suitable personal protection devices (e.g
glasses, gloves, mask, etc. Refer to the solvent safety sheet).
WARNING:
During the extraction process, if procedures described in this manual are strictly
followed, no toxic fumes are released in the laboratory.
Anyway, it is recommended installing the unit under a standard fume extraction
cupboard, or other dedicated aspiration system, to collect vapors of solvent while
handling it (e.g. loading of solvent into the clean solvent tank, draining of solvent-
bitumen mix from the dirty solvent tank).
WARNING:
The sample must be preheated before loading into the washing chamber drum. Use
suitable personal protection devices while handling the sample (e.g. thermal gloves, etc.)
WARNING:
Washing chamber and washing chamber drum reach high temperature while the unit is
operating. Use suitable personal protection devices (e.g. thermal gloves, etc.).
WARNING:
Only use highly stabilized form of the indicated solvent. Use of different types of solvent
can lead to the destruction of the unit
Rev.2 EN 13 21/11/2013
WARNING:
The default parameters stored into the machine have been optimized during the
development of the equipment. Figures above shown for each parameter are generic.
Different versions of the machine will have different values. Do not change any
parameters stored into the machine unless specifically authorized by the technical
personnel of CONTROLS. CONTROLS will not be held responsible for damage to
persons and/or property caused by the improper use of this program.
WARNING:
WARNING:
Failing to perform the recommended maintenance actions or maintenance performed by
unauthorized people can void the warranty.
CONTROLS will not be responsible for maintenance and service actions performed by
unauthorized people.
WARNING:
Before opening/removing the covers, disconnect the mains supply to the device and wait
at least 5 minutes.
WARNING:
For continued fire protection, replace fuses with same type and rating. Also, in case of
failure, components may only be replaced by using original spare parts. It is in the
responsibility of the purchaser to ensure that fire prevention policies are properly
implemented according to the CE provisions.
WARNING:
Avoid pouring water, even accidentally, or other liquids into the device, as this could
cause short circuits. Before cleaning the device, disconnect it from the mains line.
WARNING:
Refer to qualified service organization authorized by CONTROLS to carry out the service
maintenance actions described in the chapter Diagnostic and Troubleshooting.
CONTROLS has not to be held responsible for damages to the equipment and/or injuries
to personnel in case the above is not strictly followed.
21/11/2013 14 Rev.2 EN
WARNING:
Access to the MANUAL MODE menus is allowed to CONTROLS authorized technical
WARNING:
The manual activation of the different components is not monitored by the machine.
Therefore damages may result in case wrong operation (e.g. activation of the solvent
pump in absence of solvent). CONTROLS will not be held responsible for damage to
WARNING:
WARNING:
failure, components may only be replaced by using original spare parts.
WARNING:
Stopping the machine during the extraction process causes the closure of the ball valve
and therefore the centrifuge cup will not be drained. Before starting a new extraction
process with a different sample, remove the centrifuge cup and clean it, remove the drum
from the washing chamber and clean it, clean the whole system by performing 1
WASHING CYCLE without drum in the washing chamber and cup in the centrifuge.
WARNING:
Washing chamber drum and centrifuge cup are hot. Use personal protection devices (e.g.
thermal gloves, etc.) to avoid danger to the operator.
WARNING:
The solvent is hot. Use personal protection devices (e.g. thermal gloves, etc.) to avoid
danger to the operator.
Rev.2 EN 15 21/11/2013
1.6 Environmental risks and disposal
INFORMATION TO THE OWNER OF THE EQUIPMENT
The above symbol, when attached to the equipment or to the relevant packaging, indicates
that the product must be disposed of separately from other rubbish at the end of its useful
life.
Therefore, at the end of its useful life, the owner should dispose of the product in a
suitable collection point for electrical and electronic products provided by the local
authorities.
The correct disposal of this product and the subsequent treatment encourages the
manufacture of products using re-cycled materials and limits the environmental impact of
the product caused by improper disposal.
Improper disposal of the product is subject to penalties as foreseen by the local

regulations.
21/11/2013 16 Rev.2 EN
1.7 CE declaration
This page shows a copy of the CE declaration. The original is supplied with the
equipment as a separate document.
Rev.2 EN 17 21/11/2013
2. DESCRIPTION
Here follows a description of the main modules of the machine (also refer to next figure).
1. Machine body: Steel sheet, powder coated with epoxy resin. Wheel mounted.
2. Washing drum: Lined with screening cloth 0.063 or 0.075 or 0.090 mm opening.
This unit, includes seating, support and closing ring for the cover. Each model shall
be fitted with the appropriate cover.
3. Washing chamber: High quality stainless steel fitted with ultrasonic waves
generator, heating system, driver for the rotation of the washing drum, valves,
connections, etc.
4. Centrifuge: High speed centrifuge for 120 mm dia. cup, complete with safety
switch.
5. Condenser (located inside the cabinet): Stainless steel tank complete with cooling
coil for condensation of solvent vapour during the drying operation.
6. Vacuum pump (located inside the cabinet): For drying aggregate and filler.
7. Recovery/distillation unit: Double chamber: one for distillation, one used for
reservoir. The distillation chamber comprehends base and upper heater for solvent
recovery rate up to approx. 30 l/h, and cooling coils above the chamber incorporated
in the cover. Both chambers are fitted with drain valves.
8. Valve to drain bitumen and contaminated solvent.
9. Valve to drain the recovered solvent.
10. Control panel with 7 Touch screen display: For machine control and operation.
Each working phase (Washing, Rinse, Drying) is displayed on the screen with
specific synoptic panels that show the main machine modules involved.
11. Valve to fill the ampoule of solvent-bitumen mix for testing in the rotary evaporator
(fast extraction method).
The machine includes safety features that allows stopping the running phase in case of
door/cover openings, lack of water, electric motor malfunctions, etc. Type of trouble is
shown on the control panel.
21/11/2013 18 Rev.2 EN
10
9
7
8
6
11
1
4
5
2
3
Fig. 2-1
Rev.2 EN 19 21/11/2013
2.1 Functional block diagram
Fig. 2-2
21/11/2013 20 Rev.2 EN
2.2 Identification plate

The identification plate is located on the rear side of the equipment control unit, near the
power cable.
Fig. 2-3
Rev.2 EN 21 21/11/2013
2.3 Commands and controls

This chapter describes the commands and controls of the equipment. The operators
interface description and the use of the touch screen display is provided in chapter 4.3 of
the present manual.
1 6
2 7
Fig. 2-4
Ref. Description
1 LINE ON lamp (ON when the MAINS SWITCH is turned ON)
2 ALARM lamp (ON when an alarm condition is detected; see relevant list in chapter 4.4)
3 Touch screen display
4 EMERGENCY BUTTON
5 Mains switch
6 START (green) push button
7 STOP (red) push button
21/11/2013 22 Rev.2 EN
2.4 Technical specifications
Main characteristics
Product Automatic closed system asphalt analyzer
Manufacturer CONTROLS Cernusco s/N (MI) Italy
Product code 400VAC/50Hz 75-PV50A05 75-PV50C05
Product code 220VAC/60Hz 75-PV50A06 75-PV50C06
Three- phase line voltage 400 VAC / 220 VAC +10%, -10%
Frequency 50/60 Hz
Power 6000 W excluded water cooling system
Method of power entry Power cable with 5-pole plug (R-S-T, neutral, ground)
Maximum sample size 3,5 kg
Centrifuge rotation speed 6000 rpm
Cup external dimension 122 mm dia.x 200 mm height
Max. filler capacity 200 g approx.
Extraction time (including
Approx. 55 min
drying of aggregate and filler)
Solvent used per extraction 10 litres approx. (recycled)
75-PV5X010, PV5X040,
Accessories included No
PV5X135, PV5X150, PV0005/2
Acoustic pressure < 70db(A)
Net weight (approx.) 240 kg
Overall dimensions (l x d x h) Approx. 1400x750x1500 mm
Environmental conditions
Operating temperature + 10 + 40C
Operating humidity 50%RH @ 40C
Rev.2 EN 23 21/11/2013
3. INSTALLATION
The instructions indicated in this chapter enable you to perform a correct installation and
interfacing in order to grant a regular operation of the equipment.
Included are initial inspection procedure, power requirements and instructions for
installing the unit.
The information in this chapter is intended for authorized service-trained personnel.
CONTROLS can supply the assistance and the necessary technical advice for pre-
installation, all the pre-installation phases are at the purchasers charge and must be
performed complying with the indications given below.
WARNING:
When operating with the covers open/removed and the unit is attached to the mains line,
care must be taken as high voltage is present in some parts of the unit (e.g. electrical
panel). Only authorized and qualified service technicians are allowed to open /remove
covers.
WARNING:
WARNING:
WARNING:
21/11/2013 24 Rev.2 EN
3.1 Shipment
The equipment is normally shipped in a wooden crate having the following dimensions
and gross weight depending on the model:
Minimum
Overall dimensions
Models Gross weight fork lift
(L x D x H)
length
PV50A0X 500 Kg approx. 1700x1000x1800 mm 1200 mm
PV50C0X 500 Kg approx. 1700x1000x1800 mm 1200 mm
Use a proper fork lift with minimum fork length as above indicated to raise and move the
wooden crate (see figure below).
Fig. 3-1
WARNING:
WARNING:
The wooden crate is high; be careful in balancing while raising it.
Rev.2 EN 25 21/11/2013
3.2 Unpacking and inspection

The unit was carefully checked both mechanically and electrically before shipment; it
should be inspected for any damage that may have occurred in transit.
NOTE:
If the shipping container or packaging material is damaged, it should be kept until the unit
has been mechanically and electrically checked.
If there is mechanical damage and/or the contents are incomplete (see the shipping list),
please notify the local CONTROLS representative.
If the shipping container is damaged or shows sign of stress, notify the carrier as well as
the CONTROLS representative. Save the shipping material for carriers inspection. Also
take some pictures.
Here follows the procedure for the unpacking of the equipment.
21/11/2013 26 Rev.2 EN
3.2.1 How to remove the equipment from the shipping crate
The following table shows the net weight of the different models of the equipment:
Model Net weight

PV50A0X 240 Kg approx.
PV50C0X 240 Kg approx.
Follow the instructions below to remove it from the shipping crate:

1. Inspect shipping crate (see NOTES above);
2. Open the shipping crate;
3. Cut and remove vacuum bag (if present) to expose the equipment;
4. The equipment must only be lifted up by means of a forklift whose forks must be fit
between the pivoting wheels of the machine. Do not lift it by any other part to avoid
damaging the equipment (see Fig. 3-2).
Fig. 3-2
Rev.2 EN 27 21/11/2013
WARNING:
If the instructions to remove the equipment from the shipping box are not carefully
followed, damage to the equipment cabinet may result. This will void the warranty terms
of the equipment.
WARNING:
WARNING:
Do not stand under suspended loads
5. Before powering on the unit, check for loose connections of cables inside the
equipment.
21/11/2013 28 Rev.2 EN
3.3 Positioning of the unit and space requirements
WARNING:
Considering the weight of the equipment and the footprint (see chapter 2.4), check the
maximum allowed floor load before installation.
The unit must be placed on a flat and level surface.

The area around the equipment must be kept free from obstacles and from
substances that may cause sliding of the personnel.
It is responsibility of the purchaser to provide an installation place with
adequate lighting.
Parts used to build the machine and electrical/electronics component are fire-proof.
It is anyway the responsibility of the owner of the equipment to make sure that the
installation place is equipped with proper fire extinguishing systems and that the
operators have been instructed on the relevant procedures.
Use a proper mean to bring the unit to the installation place.
Place the unit in its final location, taking into account the free space around the unit: the
equipment requires at least 100 cm of clearance on the front and at least 50 cm on the 3
sides for maintenance and service purposes.
50cm
Fig. 3-3
Rev.2 EN 29 21/11/2013
Also consider that mains electricity connection and the tubes for the cool water in-outlet
chiller unit are achieved on the rear side of the equipment cabinet.
The unit requires adequate air circulation around it to assure proper cooling of the internal
devices.
Anyway, we recommend installing the unit under a standard fume extraction cupboard, or
other dedicated aspiration system, to collect vapors of solvent while handling it (e.g.
loading of solvent into the clean solvent tank, draining of solvent-bitumen mix from the
dirty solvent tank, etc.).
The machine is equipped with pivoting wheels that can be locked when the unit is in use.
Before activating the equipment, remove the soft material used to hold in position the
centrifuge assembly during the shipment.
Soft material to remove
Fig. 3-4
WARNING:
If the equipment is brought from a cold environment into a heated room, condensation on
and in the unit can constitute a danger and lead to malfunctioning of the unit when
started. Wait to connect and operate the unit until it is at room temperature.
21/11/2013 30 Rev.2 EN
3.4 Electrical requirements

The next table shows the electrical specifications of the equipment:
Item Specifications
Three-phase voltage, plus Neutral and Ground 400AC / 220 VAC
+10%, -10%
Frequency 50Hz/60Hz
Maximum power 6 kW
The equipment shall be connected to a proper earth system, the efficiency of which shall
be checked by qualified personnel. Earth shall be via the power cable, as specified above.
WARNING:
The general grounding must comply with the rules in force; a wrong quality of the
grounding could be dangerous for the operators safety and cause bad function of the
electrical devices.
The power supply line shall be equipped with a safety device (breaker and ground fault
switch) properly sized with respect to the electrical specifications provided above.
Rev.2 EN 31 21/11/2013
3.5 External connections
3.5.1 Electrical connection
The electrical connection of the machine is achieved with a cable on the rear panel of the
machine, ended with a 16A 5-pole plug (3-phase R-S-T, Neutral, Ground).
Power cord
Fig. 3-5
The machine is equipped with a phase sequencer device that checks for proper
sequencing (e.g. connection) of the electrical phases.
At switch ON (see chapter 4.2), in case 2 phase are swapped, the equipment generates an
error message that will be displayed on the screen (see figure below).
Fig. 3-6
To change the phase connection, change the position of two wires of the phases (wires of
the phases are brown, black and gray) within the plug of the power cable. Do not change
the position of the wires of ground (yellow-green) and neutral line (blue).
21/11/2013 32 Rev.2 EN
3.5.2 Cool water line connections
The unit requires the connection to a source of cool water. This is achieved via 2 pipes to
be connected to the relevant ports located on the rear panel of the machine.
Water OUT
Water IN
Fig. 3-7
Cooling water temperature must be between 10 and 15C. Use the tubes supplied with the
machine for this connection (internal diameter 10 mm, external diameter 12 mm).
It is possible to use a chiller unit (e.g. our code 75-PV5X13) with the following
specifications:
Water temperature 15C
Flow rate minimum 10 l/min with a pressure up to 4 bar
Cooling capacity 6KW (with fluid @ 20C).
Refer to the manual of the cooling unit for its setup and use. Maximum allowed length of
the interconnection tubes is 5 meters (longer tubes may cause raising of the temperature
of the water supplied).
Rev.2 EN 33 21/11/2013
3.5.3 Connection to the air
The tube of the outlet to air on the rear side of the equipment should be led via a pipe
approx. 1,5 meter upward and then outward.
Quick fit for

outlet tube to air
Fig. 3-8
Use the PTFE tube code 2.3253.005.0 supplied with the machine (external dia. 12mm,
1mm thick) for this connection.
21/11/2013 34 Rev.2 EN
3.5.4 Filling the clean solvent tank
Fill the clean solvent tank through the relevant port (unscrew its cap). Typical tank
capacity is 20 litres. Fill it until the level is approx. 2 cm below the upper black mark on
the glass indicator.
Clean solvent
filling port
Fig. 3-9
WARNING:
WARNING:
Rev.2 EN 35 21/11/2013
4. USE OF THE EQUIPMENT

This chapter describes the operators interface and the execution of a test.
WARNING:
WARNING:
tools/buttons. These tools and buttons are for use by maintenance personnel only. Never
leave the tools and buttons attached to the unit as this may endanger operator safety.
and locked.
WARNING:
WARNING:
WARNING:
21/11/2013 36 Rev.2 EN
4.1 Operating phases

The standard extraction includes a preparation phase, 3 main machine phases and a
cleaning phase as follows:
Preparation
Washing
Rinsing
Drying
Sample collection.
The whole extraction process is performed automatically by the machine; default

parameters are pre-set into the system, and can be modified by the operator in case of
special needs (e.g. additional washing cycles).
During the whole description of the machine the following assumption are used:
PROCESS: the whole extraction;
PHASE: one of the 3 main parts of the process (e.g. WASHING, RINSE, DRYING)
CYCLE: each phase (e.g. WASHING) is composed by one or more cycle (e.g. 3
washing cycles compose the washing phase).
Here follows a brief description of each phase:
Preparation
Turn on the machine and check the level of the clean and dirty solvent tanks;
As soon as the machine has been turned ON, the recovery of the dirty solvent starts
immediately; it is suggested to wait for the end of the recovery before starting with
the extraction process;
Clean the dirty solvent tank by referring to chapter 4.3.2 of this manual (if needed)
Load the sample into the washing drum;
Load the cup (lined with filter paper) into the centrifuge.
Washing phase
The washing drum is put into rotation and bitumen plus filler is washed out by
means of heated solvent filled into the washing chamber, rotation and ultrasound;
The solvent rich of bitumen and filler goes into the cup lined with filter paper in the
centrifuge and, thanks to the centrifuge effect, solvent plus bitumen are spun out of
the cup while the filler is held by the paper filter; during the Fast extraction
method, a dedicated valve must be manually closed to keep the mixture into the
washing chamber during the first washing cycle in order to obtain a bitumen
saturated solvent to be drained into a glass balloon for further separation into a rotary
evaporator;
Solvent with bitumen is filled into the dirty solvent tank and is cleaned thanks to
the distillator in the tank; the bitumen remains on the bottom of the tank;
Steam out of the centrifuge is converted into solvent by the condenser and fed to the
clean solvent tank;
The solvent recovered in the distillator is routed back to the washing chamber thus
maintaining the cycle.
Rev.2 EN 37 21/11/2013
Rinse phase:
Same phase as per the washing phase with the only difference that the solvent is
sprayed into the washing chamber and the ultrasound is not activated. Aim of the
phase is to clean the circuits.
Drying phase:
The outlet of the centrifuge is closed in order to create a closed circuit composed by
washing chamber, centrifuge and condenser;
The washing drum is put into continuous rotation throughout the phase;
The condenser collects the solvent steam from washing chamber and centrifuge,
converts it into liquid and feeds it to the clean solvent tank;
The vacuum pump circulates hot air to dry the aggregate in the washing chamber and
the filler in the centrifuge.
Sample collection:
Aggregate and sands are collected from the washing drum for weighing
Filler is collected from the centrifuge cup for weighing
Clean solvent is recovered into the relevant tank
Bitumen on the bottom of the dirty solvent tank can be drained via the relevant
valve; if the dirty solvent tank was properly cleaned before starting the extraction
process (see chapter 4.3.2), the bitumen collected in the dirty solvent tank belongs to
the last sample processed and therefore can be collected for analysis
For the Fast extraction method, a sample of bitumen rich solvent can be drained
into a glass balloon through a manual valve located on the Recovery/distillation unit.
The next diagrams depict, for each functional phase, the flows inside the different
components of the system (thick lines with arrows) and the active components in each
phase (with circles).
21/11/2013 38 Rev.2 EN
DYRTY SOLVENT RECOVERY PHASE
Valve closed
Valve open
Fig. 4-1
Rev.2 EN 39 21/11/2013
WASHING PHASE and RINSE PHASE (STANDARD EXTRACTION METHOD)
Valve closed
Valve open
Fig. 4-2
21/11/2013 40 Rev.2 EN
1st WASHING CYCLE FOR FAST EXTRACTION METHOD
Valve closed, to
open when
prompted
Valve closed, to
open when
prompted
Fig. 4-3
Rev.2 EN 41 21/11/2013
DRYING PHASE
Valve closed
Valve open
Fig. 4-4
21/11/2013 42 Rev.2 EN
DIRTY SOLVENT TANK CLEANING PHASE
Valve closed
Valve open
Fig. 4-5
Rev.2 EN 43 21/11/2013
4.2 Switching on the equipment

1. Once all the connections have been made, release the EMERGENCY BUTTON (if
pressed) and turn ON the MAINS SWITCH on the equipment front panel, the LINE
ON lamp will lit;
POWER ON lamp
EMERGENCY BUTTON
MAINS SWITCH
Fig. 4-6
2. The electro-locks of washing chamber door and of the centrifuge door are unlocked,
the heating resistors of the dirty solvent tank are activated (if there is solvent in it) in
order to start the distillation phase, the system firmware starts and, at the end of the
boot phase, the display will show the logo;
3. The system is equipped with a touch screen display that allows activating the
different functions just touching the relevant icons on the screen; touch the screen to
access the MAIN MENU screen;
Fig. 4-7
21/11/2013 44 Rev.2 EN
NOTE:
Hitting the screen heavily may damage it. Never use a pen or a sharp object as damage
may result. The warranty will be void in case the screen is damaged due to improper use.
4. In case ATTENTION conditions and/or ERROR conditions are encountered, the

system, will show the relevant message on the screen (see below an ERROR
message);
Fig. 4-8
Refer to chapter 6.2 for troubleshooting tips;

5. In case at switch ON the level of dirty solvent in the relevant tank is high (beyond
the level of the second level sensor located approx. at of the tank), the system will
show the following screen;
Fig. 4-9
Similar messages may also appear during other phases of the process (e.g. at the
beginning of the extraction phase and/or at the end of the extraction phase). Refer to
the next chapters for possible actions to take.
Rev.2 EN 45 21/11/2013
6. Now it is possible to:
a. Press the button to go directly to the MAIN MENU,

OR
b. Wait for the end of the distillation phase and, once al dirty solvent has been
distillated, the machine will automatically show the MAIN MENU;
WAIT
PRESS BUTTON
Fig. 4-10
7. In case this message appears, it is suggested to allow the machine to complete the
distillation phase and reach the MAIN MENU by itself; in fact, in case the test is
started with high level of dirty solvent (and therefore low level of clean solvent) it
may happen that the process be paused waiting for the completion of the distillation,
thus increasing the total time of the extraction process.
8. The system is sensing the presence of cool water supply:
a. At switch ON
b. With the heating resistors of the distillation unit active
c. Any time the distillation process is active.
In case of lack of water supply the system will show the following screen:
Fig. 4-11
Activate the source of cooling water and press the button to proceed, the
system will return to the MAIN MENU. Without cooling water, it will not be
possible to activate and/or change the power of the heating resistors of the
distillation unit (icon shown on the screen).
21/11/2013 46 Rev.2 EN
4.3 Operators interface description

The present chapter describes the different pages of the equipment program, with all
details on the different functions made available.
Read this chapter carefully before starting to operate the equipment.
Once the user is fully acquainted of all the functions of the machine, for the day-by-day
use he/she can refer to chapter 4.5.
During the whole description of the machine the following assumption are used:
PROCESS: the whole extraction;
PHASE: one of the 3 main part of the process (e.g. WASHING, RINSE, DRYING)
CYCLE: each phase (e.g. WASHING) is composed by one or more cycle (e.g. 3
washing cycles composes the washing phase).
Rev.2 EN 47 21/11/2013
4.3.1 MAIN MENU
The MAIN MENU includes those functions that allows:

Setting the main parameters of the extraction process;
Recalling of the pre-set programs parameters;
Starting the extraction process;
Performing of the dirty solvent tank cleaning phase (see chapter 4.3.2);
Accessing the SETUP screen (see chapter 4.3.3).
Fig. 4-12
Here follows a detailed description of each icon/field on the MAIN MENU screen;
Shows the number of WASHING CYCLES presently set; once a

pre-set cycle is selected, it automatically shows the number of
cycle set into it; at switch ON, the number of WASHING
CYCLES carried out during the last extraction is shown;
Shows the number of DRYING CYCLES presently set; once a

pre-set cycle is selected, it automatically shows the number of
cycle set into it; at switch ON, the number of DRYING
CYCLES carried out during the last extraction is shown;
Pressing one of these 5 buttons, allows recalling the

parameters of the selected pre-set program. Once it is pressed,
the number in the button becomes red, the relevant
... parameters appear on the display of WASHING CYCLES
and DRYING CYCLES and the button to START
EXTRACTION appears on the screen (see next figure where
pre-set program #2 was selected);
21/11/2013 48 Rev.2 EN
Fig. 4-13
In case the WASHING CYCLES display is 0, the machine will start the process from the
first DRYING CYCLE.
In case also the DRYING CYCLES display is 0, the machine will start and immediately
end the process.
Press the button to select among the two extraction methods:

STANDARD BITUMEN EXTRACTION: will perform the whole extraction
process;
FAST BITUMEN EXTRACTION: during the first washing cycle, will allow
draining an aliquot of bitumen reach solvent out from the dedicated valve on the
recovery/distillation unit. After this, the extraction process will proceed normally.
Once this button is pressed, the system will show the following screen:
Fig. 4-14
Selecting the desired extraction method, the system will return to the MAIN MENU with
the selected method displayed. Press the button to return to the MAIN MENU
without changing the previous method selection.
Rev.2 EN 49 21/11/2013
Selecting the FAST BITUMEN EXTRACTION method the MAIN MENU will show an
additional counter referred to the SPECIMEN SOACKING TIME.
Fig. 4-15
Before starting the fast extraction process it is required to close manually the valve on the
centrifuge head.
During the 1st washing cycle, once the SPECIMEN SOAKING TIME is elapsed, a
dedicated popup screen will inform the operator to open the valve on the centrifuge head
and the valves on the recovery-distillation unit to drain the solvent-bitumen mixture into
the ampoule for further processing with a rotary evaporator.
Fig. 4-16
WARNING:
Press the button to proceed with the extraction process.
21/11/2013 50 Rev.2 EN
The button allows setting the power (in percentage) delivered to the heating
resistor of the recovery/distillation unit.
This may be required in case of processing of special bituminous mixtures that, with the
highest power, may cause the build up of foam inside the tank.
Pressing this button, the following pop up will appear on the screen:
Fig. 4-17
Select the power to be delivered to the heating resistor and press the button to
return to previous screen. From now on, the power delivered to the heating resistor will
be the selected one.
A red frame around the button indicates that the heating resistor is supplied.
The same button is also present on the screens of the three phases of the process. In this
case it will allow changing the power delivered to the heating resistor but will not indicate
the relevant status (red frame not shown).
In case of lack of cooling water, the icon on the MAIN MENU will be the following
Rev.2 EN 51 21/11/2013
Pressing the START EXTRACTION button and the START (green) push button on the
equipment front panel will initiate the extraction process.
In case the level of dirty solvent in the relevant tank is high (beyond the level of the
second level sensor located approx. at of the tank), the system will show the following
screen;
Fig. 4-18
Now it is possible to:
d. Press the button to start the first phase of the extraction process
(typically WASHING) without waiting for the end of the distillation phase,
OR
e. Wait for the end of the distillation phase and, once all dirty solvent has been
distillated, the machine will automatically start the first phase of the extraction
process (typically WASHING);
WAIT
PRESS BUTTON
Fig. 4-19
NOTE:
The button appears only if there is a minimum level of clean solvent in the
relevant tank.
21/11/2013 52 Rev.2 EN
In case this message appears, it is suggested to allow the machine to complete the
distillation phase and start the first phase of the distillation process automatically; in fact,
in case the test is started with high level of dirty solvent (and therefore low level of clean
solvent) it may happen that the process be paused waiting for the completion of the
distillation, thus increasing the total time of the extraction process.
As previously mentioned, the extraction process is composed by three phases:

WASHING: during this phase, Fig. 4-20 is shown on the display
RINSING: during this phase, Fig. 4-21 is shown on the display
DRYING: during this phase Fig. 4-22 is shown on the display
Fig. 4-20
Fig. 4-21
Fig. 4-22
Rev.2 EN 53 21/11/2013
The live displays on the screens show:
: actual temperature value within the washing chamber and of the heating
resistor of the washing chamber;
: number of completed cycles and total cycles;
: elapsed time since the beginning of the extraction process. This

time does not account possible process stop due to lack of solvent (either at the
beginning or during the process);
Active components in each phase are identified by yellow lamps on the screen.
Pressing the button will cause the skipping to the next phase at the end of the
present cycle (e.g. if the machine is running one cycle of the WASHING phase, at the end
of the cycle it will go directly to the RINSE phase).
NOTE:
Once the SKIP function has been activated it is not possible to stop it.
At the end of the extraction process the system will show the following screen;
Fig. 4-23
Remove the drum from the washing chamber and the cup from the centrifuge (both doors
will be automatically unlocked).
21/11/2013 54 Rev.2 EN
Press the button to return to the MAIN MENU (see Fig. 4-13) and start a
new process; the number of cycles in the display will be the same as for the last process
conducted.
In case, at the end of the test, the level of dirty solvent in the relevant tank is high (beyond
Fig. 4-24
a. Press the button to directly return to the MAIN MENU where it

will be possible to start a new process without waiting for the end of the
distillation phase,
OR
b. Wait for the end of the distillation phase and, once all dirty solvent has been
distillated, the machine will automatically return to the MAIN MENU where
it will be possible to start a new extraction process;
WAIT
PRESS BUTTON
Fig. 4-25
Rev.2 EN 55 21/11/2013
distillation phase and return to the MAIN MENU automatically.
The extraction process can be quit at any time by pressing the STOP (red) pushbutton on
the front panel of the equipment; the system will show the following screen:
Fig. 4-26
Pressing the button the machine will resume the running process (that was
continuing in the meantime).
Pressing the button will quit the present test and the system will return to the
MAIN MENU.
In case the extraction is stopped when there still is solvent in the washing chamber, the
system detects it and shows the following screen:
Fig. 4-27
21/11/2013 56 Rev.2 EN
WARNING:
WARNING:
Rev.2 EN 57 21/11/2013
4.3.2 Cleaning of the dirty solvent tank
Before starting with the cleaning process, make sure that the dirty solvent tank is empty
(all dirty solvent has been distilled) and washing chamber and centrifuge doors are
closed.
This button allows accessing the screen to activate the

cleaning phase of the dirty solvent tank (left-hand tank).
Once this button is pressed, the system shows the following
screen. The cleaning procedure should be carried out once a
day, at the end of the last extraction process.
Fig. 4-28
WARNING:
It is recommended performing the cleaning cycle of the dirty solvent tank once a day, at
the end of the extraction process. This is to avoid collecting too much bitumen that may
become stiff and therefore very difficult to drain afterwards. CONTROLS will not be
responsible for any damage caused by the lack of cleaning procedure. Warranty of the
equipment will be void.
Press the START TANK WASHING button to initiate this phase. The system will show
the following screen until the cleaning phase is completed.
Fig. 4-29
21/11/2013 58 Rev.2 EN
In case the system detects an open door (washing chamber and/or centrifuge), the
following screen will be shown:
Fig. 4-30
Closing the door, the cleaning cycle will start automatically.
When the washing phase is completed, the system will show the following screen.
Fig. 4-31
Press the button STOP TANK WASHING, wait a couple of minutes to allow the bitumen
to melt and then open the valve to drain the tank.
The valve of the dirty solvent tank is equipped with a handle and a locking bolt. To open
the valve and drain the dirty solvent:
1. Place a container below the dirty solvent valve;
Rev.2 EN 59 21/11/2013
2. Loosen the locking bolt of the valve handle;
Fig. 4-32
3. Reposition the handle of the valve 180 and lock the bolt;
Handle locked (not operable) Handle free (operable but still closed)
Fig. 4-33
21/11/2013 60 Rev.2 EN
4. Open the valve by turning its handle 90 counter-clockwise;
Valve closed Valve open

Fig. 4-34
5. Drain the dirty solvent and bitumen residual, and collect them into a container;
6. At the end close the valve, reposition its handle in the non-operable position and
lock the bolt.
If the tank is still not clean completely, repeat the cleaning cycle.
See chapter 4.1 Dirty solvent tank cleaning phase to see what machine components are
involved in this phase.
Press the button to return to the MAIN MENU.
Rev.2 EN 61 21/11/2013
4.3.3 SETUP screen
This button allows access to the screen that contains the

SETUP options of the machine.
Once this button is pressed, the system shows the following
screen.
Fig. 4-35
LANGUAGE SELECTION (see chapter 4.3.3.1)
PROGRAM SETTING (see chapter 4.3.3.2)
SYSTEM INFO (see chapter 4.3.3.3)
MANUAL MODE (see chapter 4.3.3.4)
Press the button to return to the MAIN MENU.
21/11/2013 62 Rev.2 EN
4.3.3.1 LANGUAGE SELECTION screen
On the SETUP screen, press the button to access the menu for language
selection. The system will show the following screen
Fig. 4-36
Select the desired language then press the button to return to the SETUP
screen.
Rev.2 EN 63 21/11/2013
4.3.3.2 PROGRAM SETTING screen
On the SETUP screen, press the button to access the menu that allows
setting the number of cycles for the 5 pre-set programs.
Fig. 4-37
NOTE:
The number of RINSE cycles is fixed and can only be modified under the MANUAL
MODE ADVANCE SETTINGS menu (password protected), reserved to authorized
technical personnel (see chapter 6.1.2).
WARNING:
Pressing each numeric field, a pop up keyboard allows entering the desired number of
cycles. Maximum number of cycles is 9.
The number of WASHING and DRYING cycles to perform depend on the characteristics
of the sample to process and the quantity of material loaded into the washing chamber
For each stored program it is also possible to store the SOAKING TIME for the 1st
washing cycle of the FAST BITUMEN EXTRACTION METHOD.
Press the button to return to the SETUP screen.

21/11/2013 64 Rev.2 EN
4.3.3.3 SYSTEM INFO screen
On the SETUP screen, press the button to access the menu that shows:
Firmware version of the machine controller
Firmware version of the machine display
Date of last solvent check (Ph) or regeneration.
Fig. 4-38
Pressing the UPDATE button will update the date to the present one.
Rev.2 EN 65 21/11/2013
4.3.3.4 MANUAL MODE screen
The MANUAL MODE menu is reserved for CONTROLS authorized technical personnel.
It contains functions and settings that affect the functioning of the whole equipment.
Altering these settings may lead to damage to the equipment and endanger the operator
safety.
Do not access this menu unless specifically authorized by CONTROLS technical

personnel.
Refer to chapter 6.1.
WARNING:
Access to the MANUAL MODE is allowed for CONTROLS authorized technical
21/11/2013 66 Rev.2 EN
4.4 ERROR messages

In case that error conditions are detected, the machine will show an error message screen
with yellow background.
Fig. 4-39
The following error conditions are handled and can be detected by the machine:
EMERGENCY BUTTON PRESSED

WASHING CHAMBER DOOR OPEN
CENTRIFUGE DOOR OPEN
CENTRIFUGE MOTOR INVERTER ALARM
WASHING CHAMBER OVER-TEMPERATURE
WASHING CHAMBER RESISTOR OVER-TEMPERATURE
VACUUM PUMP MOTOR BREAKER TRIPPED
SOLVENT PUMP MOTOR BREAKER TRIPPED
WRONG ELECTRICAL PHASE SEQUENCE
Refer to chapter 6.2 for troubleshooting tips.
Rev.2 EN 67 21/11/2013
4.5 Carry out a Standard extraction process

The present chapter provides a quick guide for the execution of a STANDARD
BITUMEN EXTRACTION process. Full details on the various screens and options
accessed are provided in chapter 4.3.
To perform a FAST BITUMEN EXTRACTION process, refer to chapter 4.6.
WARNING:
WARNING:
WARNING:
The sample must be preheated before loading into the washing chamber drum. Use
suitable personal protection devices while handling the sample (e.g. thermal gloves, etc.)
WARNING:
Washing chamber and washing chamber drum reach high temperature while the unit is
operating. Use suitable personal protection devices (e.g. thermal gloves, etc.).
WARNING:
21/11/2013 68 Rev.2 EN
4.5.1 Start up and sample loading

1. Before starting the STANDARD BITUMEN EXTRACTION method, make sure that:
i. The manual valve on the centrifuge head is open (see Fig. 4-40)
ii. The manual valves of the recovery-distillation unit are closed (see Fig. 4-47)
Valve open
Fig. 4-40
Valves closed
Fig. 4-41
Rev.2 EN 69 21/11/2013
2. With the system ON, open the source of cooling water or turn on the chiller unit;
3. Check the level of the clean solvent in the tank (right-hand tank) referring to the
relevant level meter (make sure that the level is at least half of the level meter and
max. 2 cm below the black mark), otherwise wait for the end of the solvent recovery
cycle; take into consideration that for every WASHING cycle approx 2.7 liters of
solvent are used and that 1 cm of decrement on the level meter corresponds to 1 liter
of solvent;
4. Check the level of the solvent in the dirty solvent tank (it must be as low as possible)
and perform the cleaning cycle if needed (see chapter 4.3.2)
5. At the beginning of the daily working session, perform a process without sample
setting 2 WASHING cycles and 2 DRYING cycles to heat up the system (see chapter
4.5.2 to set the cycles); starting with a cold machine, the recovery of the dirty solvent
may not be fast enough to make available the proper quantity of clean solvent for the
extraction process; in this case the process maybe paused by the machine to recover
the solvent;
6. Prepare the sample reducing it into small pieces and heating in an oven at 140C in
order to eliminate any water (stop preheating it when constant weight is reached);
7. Allow the sample to cool a little bit below the boiling temperature of the in use
(121C for the perchloroethylene, 40C methylene chloride);
8. Weight the empty washing drum (including its cover);
9. Weight the sample, load it into the washing drum (max. 3,5 Kg), close and lock the
relevant cover;
Fig. 4-42
NOTE:
With the machine OFF, the electro-locks of the washing chamber door and of the
centrifuge door are locked. To unlock the doors, turn ON the machine and wait for the
end of the boot phase.
21/11/2013 70 Rev.2 EN
10. Insert the drum into the washing chamber making sure it matches the hexagonal
driving shaft into the chamber (slightly rotate it back and forth);
Fig. 4-43
11. Close the door and lock its latch.
Fig. 4-44
Rev.2 EN 71 21/11/2013
12. Line the inside lateral surface of the centrifuge cup with filter paper (code PV0005/2),
winding it counter-clockwise; this will enable simpler extraction of the filler and
avoid damaging of its internal surface (the rough surface of the paper must face
inside);
13. Weight the empty centrifuge cup (with filter paper);
Fig. 4-45
14. Grease the exterior of the cup and the o-ring on the bottom of the cup housing with
silicon grease, then fit the cup into the centrifuge pushing it fully down, close the
centrifuge door and lock its 2 latches.
Fig. 4-46
21/11/2013 72 Rev.2 EN
4.5.2 Process setup, start and possible actions during the process
1. On the MAIN MENU check that the STANDARD EXTRACTION process is
displayed, otherwise press the button to select it;
2. Manually input the desired number of washing cycles and drying cycles or select one
of the memorized programs by pushing the relevant icon on the screen; then press
the button START EXTRACTION on the screen.
Fig. 4-47
3. In the above example, the program number 2 has been selected; press now the green
START pushbutton on the front panel of the equipment to begin the extraction
process (the system checks that both washing chamber door and centrifuge door are
closed); refer directly to chapter 4.5.3 for details on the WASHING phase;
4. If instead the level of dirty solvent in the relevant tank is high (beyond the level of
the second level sensor located approx. at of the tank), the system will show the
following screen;
Fig. 4-48
Rev.2 EN 73 21/11/2013
a. Press the button to start the first phase of the extraction process
(typically WASHING) without waiting for the end of the distillation phase,
OR
distillated, the machine will automatically start the first phase of the extraction
process (typically WASHING);
WAIT
PRESS BUTTON
Fig. 4-49
NOTE:
The button appears only if there is a minimum level of clean solvent in the
relevant tank.
This message may appear at the beginning of the extraction or during the extraction.
It is suggested to allow the machine to complete the distillation phase and start the
first phase of the extraction process automatically; in fact, in case the test is started
with high level of dirty solvent (and therefore low level of clean solvent) it may
happen that the process be paused waiting for the completion of the distillation, thus
increasing the total time of the extraction process.
21/11/2013 74 Rev.2 EN
During the execution of the process, the system continuously monitors the level of
clean solvent in the relevant tank.
If the level of clean solvent goes below the limit, the solvent pump is stopped and the
following screen appears:
Fig. 4-50
Wait until the proper level of clean sample in the relevant tank is reached, the
process will be resumed automatically
Resume the process immediately by pressing the button on the screen;

this button appears once the minimum level of clean solvent in the relevant tank is
achieved.
Once the process is resumed, the paused cycle will be repeated from the beginning thus
increasing the total process time.
NOTE:
It is recommended to start the extraction process with the clean solvent tank full and the
dirty solvent tank empty.
The button on the MAIN MENU and on each of the screens of the phases
allows setting the power (in percentage) delivered to the heating resistor of the
recovery/distillation unit.
This may be required in case of processing of special bituminous mixtures that, with the
highest power, may cause the build up of foam inside the tank.
Rev.2 EN 75 21/11/2013
Pressing this button, the following pop up will appear on the screen:
Fig. 4-51
Select the power to be delivered to the heating resistor and press the button to
return to previous screen. From now on, the power delivered to the heating resistor will
be the selected one.
A red frame around the button indicates that the heating resistor is supplied.
The same button is also present on the screens of the three phases of the process. In this
case it will allow changing the power delivered to the heating resistor but will not indicate
the relevant status (red frame not shown).
Build up of foam inside the distillation/recovery tank may be indicated by the presence of
a solvent stream falling down from the upper part of the indicator of the dirty solvent
tank.
Stream of dirty solvent

falling down from here
Fig. 4-52
In this case reduce the power delivered to the heating resistor selecting one of the values
in the popup screen previously shown.
In case of lack of cooling water, the icon on the MAIN MENU will be the following
21/11/2013 76 Rev.2 EN
4.5.3 WASHING phase
The WASHING phase will take place if at least 1 washing cycle has been set. If the
washing cycles figure has been set to 0, the machine will directly proceed with the
DRYING phase.
During the WASHING phase, the asphalt sample will be separated into the main 4
components (bitumen, filler, aggregates and sand).
The machines performs the following steps during the WASHING phase:
1. The washing chamber is filled with solvent, the solvent is heated by the heating
resistors of the washing chamber in order to help separating bitumen and filler from
aggregates and sand. When the level of solvent is above the low limit, the ultrasounds
are activated. The washing drum is put into rotation by the washing chamber motor.
The operator can monitor the washing chamber behavior through the glass window
on the washing chamber door;
2. The mixture of solvent, bitumen and filler reaches the centrifuge which, rotating at
high speed, will spin bitumen and solvent that will be poured into the dirty solvent
tank, while the filler will be held by the filter paper in the cup;
3. During the whole washing phase, the cycle ends when the washing chamber is empty;
the system will show the following screen that allows monitoring (yellow lamp
means active component) :
a. The temperature into the washing chamber
b. The temperature of the washing chamber heating resistors
c. The number of cycles completed versus the total number of set washing cycles;
d. Total time elapsed from the beginning of the extraction process;
Fig. 4-53
4. When all cycles of the WASHING phase have been completed, the machine will
automatically go to the RINSE phase.
Rev.2 EN 77 21/11/2013
4.5.4 RINSE phase
The RINSE phase will take place if at least 1 washing cycle has been set.
NOTE:
The number of RINSE cycles is fixed and can only be modified under the MANUAL
MODE ADVANCE SETTINGS menu (password protected), reserved to authorized
technical personnel (see chapter 6.1.2).
WARNING:
The aim of the RINSE phase is to clean the washing chamber and the circuits in order to
recover all residuals of bitumen and filler.
The machines performs the following steps during the RINSE phase:
1. Solvent is sprayed into the washing chamber and it is directly drained to recover all
material left;
2. The mixture of solvent, bitumen and filler coming from the washing chamber is
centrifuged in order to hold the filler on the filter paper and drain bitumen and solvent
into the dirty solvent tank;
5. This phase ends when the pause time after solvent spray is elapsed; during the whole
rinse phase, the system will show the following screen that allows monitoring:
c. Total time elapsed from the beginning of the extraction process;
Fig. 4-54
6. When the RINSE phase has been completed, the machine will automatically go to the
DRYING phase.
21/11/2013 78 Rev.2 EN
4.5.5 DRYING phase
The DRYING phase will take place if at least 1 drying cycle has been set.
The aim of the DRYING phase is to dry aggregates and sand in the washing drum and
filler in the centrifuge cup to prepare them for the weighing.
The machines performs the following steps during the DRYING phase:
1. The ball valve is closed in order to create a close circuit between condenser, washing
chamber and centrifuge;
2. The air pump is activated and the air is heated by the resistor of the washing chamber:
the air is withdrawn from the condenser, blown into the washing chamber and the
centrifuge then sent back to the condenser to obtain solvent from the vapors;
3. The cycle ends when the working time of the pump is elapsed; during the whole
drying phase, the system will show the following screen that allows monitoring:
c. The number of cycles completed versus the total number of set drying cycles
d. Total time elapsed from the beginning of the extraction process;
Fig. 4-55
4. When all cycles of the DRYING phase have been completed, the extraction process is
completed and the following steps take place:
a. The whole system is set to the atmospheric pressure by opening the relevant valve
b. The condenser is emptied
c. The washing chamber heating resistor is de-activated
d. The ball valve is open.
Rev.2 EN 79 21/11/2013
4.5.6 End of the extraction process
At the end of the last phase set for the process (RINSE or DRYING), the system will
show the following screen that indicates the total process time and allows to return to the
process setup screen.
Fig. 4-56
Remove the drum from the washing chamber and the cup from the centrifuge (both doors
will be automatically unlocked).
Press the button to return to the MAIN MENU and start a new process; the
number of cycles in the display will be the same as for the last process conducted.
In case, at the end of the test, the level of dirty solvent in the relevant tank is high (beyond
Fig. 4-57
21/11/2013 80 Rev.2 EN
a. Press the button to directly return to the MAIN MENU where it

will be possible to start a new process without waiting for the end of the
distillation phase,
OR
distillated, the machine will automatically return to the MAIN MENU where
it will be possible to start a new extraction process;
WAIT
PRESS BUTTON
Fig. 4-58
distillation phase and return to the MAIN MENU automatically.
Remove aggregate and sand from the washing drum and the filter paper with filler from
the centrifuge cup.
Remove the washing chamber drum and the centrifuge cup. To remove the latter, avoid
using pliers/grips, just hold it on the left-hand side and on the right-hand side with thumb
and forefinger. Use of tools may damage the cup.
WARNING:
WARNING:
Washing chamber drum and centrifuge cup are hot. Use personal protection devices (e.g.
thermal gloves, etc.) to avoid danger to the operator.
Before proceeding with another extraction process, refer to chapter 5.1 to clean the
washing chamber drum and the centrifuge cup.
Rev.2 EN 81 21/11/2013
4.5.6.1 Phase SKIP function
Pressing the button during any of the phases will cause the skipping to the next
phase at the end of the present cycle (e.g. if the machine is running one cycle of the
WASHING phase, at the end of that cycle it will go directly to the RINSE phase).
The system will require further confirmation before skipping to the next phase.
NOTE:
Once the SKIP function has been activated it is not possible to stop it.
21/11/2013 82 Rev.2 EN
4.5.6.2 QUIT the extraction process
The extraction process can be quit at any time by pressing the STOP (red) pushbutton on
the front panel of the equipment; the system will show the following screen:
Fig. 4-59
Pressing the button the machine will resume the running process (that was
continuing in the meantime).
Pressing the button will quit the present test and the system will return to the
MAIN MENU.
In case the extraction is stopped when there still is solvent in the washing chamber, the
system detects it and shows the following screen:
Fig. 4-60
Rev.2 EN 83 21/11/2013
WARNING:
WARNING:
21/11/2013 84 Rev.2 EN
4.6 Carry out a Fast extraction process
On the MAIN MENU, press the button to select the FAST BITUMEN
EXTRACTION method.
The difference with respect to the STANDARD BITUMENT EXTRACTION method is
that during the first washing cycle, it allows draining an aliquot of bitumen reach solvent
out from the dedicated valve on the recovery/distillation unit. After this, the extraction
process will proceed normally.
Once this method is selected, the system will show the MAIN MENU that has an
additional counter referred to the SPECIMEN SOACKING TIME.
Fig. 4-61
Before starting the FAST BITUMEN EXTRACTION process:

i. Wait for the end of the dirty solvent recovery phase;
ii. Close the manual valve on the centrifuge head;
Close valve
Fig. 4-62
iii. Place a container below the tap of the recovery-distillation unit and open the
manual valves to remove residuals of dirty solvent (see next Fig. 4-67);
Rev.2 EN 85 21/11/2013
iv. Close the manual valves of the recovery-distillation unit (see Fig. 4-63);
Valves closed
Fig. 4-63
After starting the extraction process, during the 1st washing cycle, once the SPECIMEN
SOAK TIME is elapsed, a dedicated popup screen will inform the operator to open the
valve on the centrifuge head and the valves on the recovery-distillation unit to drain the
solvent-bitumen mixture into the ampoule for further processing with a rotary evaporator.
Fig. 4-64
WARNING:
WARNING:
The solvent is hot. Use personal protection devices (e.g. thermal gloves, etc.) to avoid
danger to the operator.
21/11/2013 86 Rev.2 EN
Unscrew the retainer of the ampoule.
Fig. 4-65
Fit the ampoule in place and secure it to the tap by means of the retainer.
Fig. 4-66
Rev.2 EN 87 21/11/2013
Open first the air valve (upper one) then the bitumen valve (lower one).
Open air valve
Open bitumen valve
Fig. 4-67
Open the manual valve on the centrifuge.
Open valve
Fig. 4-68
21/11/2013 88 Rev.2 EN
When the ampoule is filled, close IMMEDIATELY air and bitumen valves
on the recovery-distillation unit and remove the ampoule.
Once done press the button on the display to proceed with the
extraction process.
WARNING:
Rev.2 EN 89 21/11/2013
4.7 Stopping the machine via the Emergency button

In case dangerous conditions are encountered during the execution of the process, it is
possible to stop the machine by pressing the EMERGENCY BUTTON.
EMERGENCY BUTTON
Fig. 4-69
Pressing this button will stop all the functions of the unit, except the display that will
remain active and will show the relevant error message.
Fig. 4-70
Releasing the emergency button (turn it clockwise) will bring the unit back to the start up
condition.
Press the button OK on the screen to return to the MAIN MENU.
21/11/2013 90 Rev.2 EN
4.8 Switching off the unit

At the end of the extraction process, make sure that the washing drum has been removed
from the washing chamber and that the cup has been removed from the centrifuge.
Also, if the unit is still restoring the level of the clean solvent, it is recommended to wait
for the end of this cycle before turning OFF the unit.
Fig. 4-71
At the end, turn the unit OFF via the MAINS SWITCH on the front panel.
MAINS SWITCH
Fig. 4-72
Rev.2 EN 91 21/11/2013
5. MAINTENANCE
As with all electrical equipment, this unit must be used correctly and maintenance and
inspections must be performed at regular intervals. Such precautions will guarantee the
safe and efficient functioning of the equipment.
Periodic maintenance consists of inspections made directly by the test operator and/or by
the authorized service personnel.
Maintenance to the equipment is responsibility of the purchaser and must be performed as

stated by this chapter.

WARNING:
CONTROLS will not be responsible for maintenance and service actions performed by
unauthorized people.
WARNING:
at least 5 minutes.
WARNING:
WARNING:
tools/buttons. These tools and buttons are for the use of maintenance people only. Never
leave them attached to the unit as this may endanger operator safety.
and locked.
21/11/2013 92 Rev.2 EN
WARNING:
failure, components may only be replaced by using original spare parts. It is in the
responsibility of the purchaser to ensure that fire prevention policies are properly
implemented according to the CE provisions.
WARNING:
Avoid pouring water, even accidentally, or other liquids into the device, as this could
cause short circuits. Before cleaning the device, disconnect it from the mains line.
WARNING:
WARNING:
WARNING:
Rev.2 EN 93 21/11/2013
5.1 Operators and Preventive maintenance
Action Who When

Check to ensure that there is no Operator Before every working session
external damage to the equipment,
which could jeopardise the safety of
use
Clean and grease (use silicon Operator Before every working session
grease) the housing of the
centrifuge cup to ensure simple
extraction of the cup
Clean and grease (use silicon Operator Before every working session
grease) the outer surface of the
centrifuge cup
Clean the washing drum using Operator Before every working session
compressed air
Check that the dirty solvent tank is Operator At the end of the working day
empty and bitumen has been
removed (otherwise see chapter
4.3.2 to empty it)
Perform a washing phase without Operator At the end of the working day
bitumen to keep the interior of the or every 10 extraction
unit clean (set WASHING CYCLE processes
= 1, DRYING CYCLE = 3)
Clean the chamber of the solvent Operator At the end of the working day
input line on the centrifuge (see or every 10 extraction
chapter 5.1.1) processes
Check the recovered solvent for pH Operator Every 50 extraction processes
value (use testing device code
PV5X110) and, if necessary,
correct it by using the solvent
stabilizator code PV5X120 using 20
cc of stabilizator every 100 liters of
recovered solvent (solvent in the
clean tank). Replace the solvent
when necessary.
General inspection Operator Weekly
Check status of the safety devices Operator Weekly
(refer to chapter 1.5 for their
identification)
Check status and functioning of the Operator Weekly
operator's commands
Check that all label and rating Operator Monthly
plates are intact and properly
attached
Perform the preventive CONTROLS Yearly
maintenance of the machine authorized
technical
personnel
21/11/2013 94 Rev.2 EN
5.1.1 Clean the chamber of the solvent input line on the centrifuge
1. With the machine in idle conditions, undo the knurled cap on the centrifuge
assembly;
Fig. 5-1
2. Remove the glass piece and clean the chamber from any residual;
Fig. 5-2
3. Re-position the glass piece and screw-in the knurled cap.
Rev.2 EN 95 21/11/2013
6. DIAGNOSTICS & TROUBLESHOOTING

The present chapter provides information on the diagnostic programs present in the
system and on the troubleshooting of the most common problems.
Depending on the problem encountered, the troubleshooting is carried out by dividing the
system into functional blocks.
WARNING:
at least 5 minute.
WARNING:
tools/buttons. These tools and buttons are for the use of maintenance people only. Never
leave them attached to the unit as this may endanger operator safety. After performing
maintenance/repair, make sure that all covers/doors are properly closed and locked.
WARNING:
WARNING:
CONTROLS has not to be held responsible for damages to the equipment and/or injuries
WARNING:
21/11/2013 96 Rev.2 EN
6.1 MANUAL MODE screen

The MANUAL MODE menu is reserved to CONTROLS authorized technical personnel.
It contains functions and settings that affect the functioning of the whole equipment.
Altering these settings may lead to damage to the equipment and endanger the operator
safety.
Do not access this menu unless specifically authorized by CONTROLS technical

personnel.
WARNING:
Access to the MANUAL MODE menus is allowed to CONTROLS authorized technical
On the SETUP screen, press the button to access MANUAL MODE menu.
Fig. 6-1
Rev.2 EN 97 21/11/2013
It requires entering the password 111 and pressing the button ; the system will
show the following screen:
Fig. 6-2
Here follows a detailed description of the menus available under the MANUAL MODE
menu.
21/11/2013 98 Rev.2 EN
6.1.1 MANUAL I/O screen
Press the button to access the MANUAL I/O screen; the system will show:
Fig. 6-3
This screen allows to manually operate the main devices of the machine. It can be used
for troubleshooting purposes.
Active component is indicated on the screen by the activation of the relevant lamp that
becomes yellow.
Refer to the other chapters of the present manual to identify the component being
operated.
WARNING:
The manual activation of the different components is not monitored by the machine.
Therefore damages may result in case wrong operation (e.g. activation of the solvent
pump in absence of solvent). CONTROLS will not be held responsible for damage to
Press the button to return to the MANUAL MODE screen.
Rev.2 EN 99 21/11/2013
6.1.2 ADVANCED SETTING screen
Press the button to access the ADVANCED SETTINGS screen; the system
will show:
Fig. 6-4
WARNING:
This screen allows setting the functioning parameters (timings, number of RINSE cycles
and temperatures) of the main devices of the machine and reading the actual WASHING
CHAMBER TEMPERATURE and RESISTOR WORKING TEMPERATURE.
21/11/2013 100 Rev.2 EN

The next table lists the default parameters set up for the 2 allowed solvents:
Also, there are two thermal switches on the heating resistors of the dirty solvent tank;
both are set as follows depending on the solvent in use:
Perclhoroethylene: 130C
Methylene chloryde (Dichloromethane): 60C
Next picture shows the position of the knobs if the 2 thermal switches (accessible through
a panel on the rear side of the machine).
Fig. 6-5
Rev.2 EN 101 21/11/2013

Pressing the button , the system will show a popup that allows setting the
parameters dedicated to the behavior of the machine during the 1st washing cycle of the
FAST BITUMENT EXTRACTION method.
Fig. 6-6
Press the button to return to the previous menu screen.
21/11/2013 102 Rev.2 EN

6.1.3 SYSTEM COUNTERS screen
Press the button to access the SYSTEM COUNTERS screen and the date of
solvent check/regeneration (this date can be updated in the SYSTEM INFORMATION
screen, see chapter 4.3.3.3):
Fig. 6-7
Press the button to return to the MANUAL MODE screen.
This menu allows setting a number of functioning parameters of the system and
performing procedures reserved to CONTROLS authorized service organisation.
WARNING:
CONTROLS has not to be held responsible for damage to the equipment and/or injuries
Rev.2 EN 103 21/11/2013

6.2 ERROR MESSAGES

In case that error conditions are detected, the machine will show an error message screen
with yellow background.
Fig. 6-8
The following table provides troubleshooting tips for each error condition listed; when
electrical components are mentioned , refer to the electrical diagram of chapter 7
Error message Possible causes/checks

EMERGENCY BUTTON Release the emergency button;
PRESSED Check the contacts of the emergency button 1SB1
on the front panel;
Check the safety module fuse 1FU2 in the
electrical panel;
Check the Safety relay unit 1A1 in the electrical
panel;
Check the PLC controller 5D1 in the electrical
panel.
WASHING CHAMBER Make sure the washing chamber door is properly
DOOR OPEN closed;
Check the washing chamber door latch 4SQ1;
Check relay 7KA1 in the electrical panel;
panel.
CENTRIFUGE DOOR OPEN Make sure the centrifuge door is properly closed;
Check the centrifuge door latch 4SQ2;
Check relay 7KA3 in the electrical panel;
panel.
CENTRIFUGE MOTOR Make sure the centrifuge cup is properly fitted into
INVERTER ALARM the centrifuge;
Check fuses 2FU1 in the electrical panel;
Check motor inverter 6U1 in the electrical panel;
Check centrifuge motor 2M1.
21/11/2013 104 Rev.2 EN

Error message Possible causes/checks

WASHING CHAMBER Check temperature sensor 10PT1;
OVER-TEMPERATURE Check analog module 5A2 in the electrical panel.
WASHING CHAMBER Check static relay 7KS1 in the electrical panel;
RESISTOR OVER- Check temperature sensor 10PT2;
TEMPERATURE Check thermal switch 3S1.
VACUUM PUMP MOTOR Recycle vacuum pump motor breaker 2QF2 in the
BREAKER TRIPPED electrical panel;
Check vacuum pump motor 3MS1;
Check contactor 11KM1 in the electrical panel;
panel.
SOLVENT PUMP MOTOR Recycle solvent pump motor breaker 2QF1 in the
BREAKER TRIPPED electrical panel;
Check solvent pump motor 3M1;
Check contactor 7KM1 in the electrical panel;
panel.
WRONG ELECTRICAL Swap 2 phases in the power cord plug (refer to
PHASE SEQUENCE chapter 3.5.1;
Check the phase sequence relay 1U1 in the
electrical panel;
panel.
Rev.2 EN 105 21/11/2013

7. SCHEMATICS AND DRAWINGS

1. Electrical panel schematics
2. Electrical components identification
3. Electrical panel layout
4. Front panel layout
21/11/2013 106 Rev.2 EN

Rev.2 EN 107 21/11/2013

21/11/2013 108 Rev.2 EN

Rev.2 EN 109 21/11/2013

21/11/2013 110 Rev.2 EN

Rev.2 EN 111 21/11/2013

21/11/2013 112 Rev.2 EN

Rev.2 EN 113 21/11/2013

21/11/2013 114 Rev.2 EN

Rev.2 EN 115 21/11/2013

21/11/2013 116 Rev.2 EN

Rev.2 EN 117 21/11/2013

21/11/2013 118 Rev.2 EN

ELECTRICAL COMPONENT IDENTIFICATION
COMPONENT FUNCTION
1QS1 Mains switch
1FU1 24V Power supply fuse Fusibile 2AF
1GD1 24V 2 Power supply
1HL1 LINE lamp
1U1 Phase sequence relay
1SB1 EMERGENCY BUTTON
1FU2 Safety module fuse 2AT
1A1 Safety module
2FU1 Centrifuge motor inverter fuse 6AF
2M1 Centrifuge motor
2FU2 Washing chamber fuse 2AF
2GD1 24V 5A power supply
2MD2 Washing chamber motor
2QF1 Breaker solvent pump motor
2QF2 Breaker vacuum pump motor
3M1 Solvent pump motor
3MS1 Vacuum pump motor
3FU1 Washing chamber heating resistor fuse 8AT
3S1 Washing chamber thermal
3EH1 Washing chamber heating resistor
3FU2 Dirty solvent tank upper heating resistor fuse 12AT
3S2 Dirty solvent tank upper heating resistor thermal switch
3EH2 e 3EH3 Dirty solvent tank upper heating resistor
3FU3 Dirty solvent tank lower heating resistor fuse 8AT
3S3 Dirty solvent tank lower heating resistor thermal switch
3EH4 Dirty solvent tank lower heating resistor
4SQ1 Electro-lock washing chamber door
4SQ2 Electro-lock centrifuge door
4M1 Ball valve
4YV1 Condenser discharge electrovalve (EV7)
4YV2 Vent electrovalve (EV4)
5U1 Touch screen display unit
5D1 PLC controller
5A2 Analog module for PLC
6SB1 START push button
6SB2 STOP push button
6BF1 Washing chamber optical level sensor
6SL3 Clean solvent tank low level sensor
6S1 Cooling water pressure switch
6SL1 Dirty solvent tank high level sensor
6SL2 Dirty solvent tank low level sensor
6U1 Centrifuge motor inverter
7KA1 Washing chamber door locking relay
7KA2 Washing chamber motor reverse rotation relay
7KS1 Washing chamber heating resistor relay
7KA3 Centrifuge door locking relay
7KA6 Ultrasound activation relay
Rev.2 EN 119 21/11/2013

COMPONENT FUNCTION
7KM1 Solvent pump activation replay
7KA8 Electrovalve EV7 activation relay (Condenser discharge electrovalve)
7KA9 Electrovalve EV4 activation relay (Vent electrovalve)
7KS2 Dirty solvent tank upper resistor activation relay
7KS3 Dirty solvent tank lower resistor activation relay
10PT1 Washing chamber temperature sensor (PT100)
10PT2 Washing chamber heating resistor temperature sensor (PT100)
11KM1 Vacuum pump activation relay
11KA3 Ball valve activation relay
11KA6 Washing chamber motor activation relay
11HL1 ALARM lamp
21/11/2013 120 Rev.2 EN

Rev.2 EN 121 21/11/2013

21/11/2013 122 Rev.2 EN

Notes:
Rev.2 EN 123 21/11/2013

Notes:
21/11/2013 124 Rev.2 EN

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4. USE OF THE EQUIPMENT 36

4.4 ERROR messages ............................................................................................................. 67

6. DIAGNOSTICS & TROUBLESHOOTING 96

7. SCHEMATICS AND DRAWINGS 106

This Manual is published by CONTROLS.

This method allows the complete analysis of an asphalt sample.

Main features of the equipment are:

The typical operating cycle of the machine is as follows:

The following models are available:

This manual is applicable for units having firmware release as follows:

1.1 Icons appearing in the manual

1.2 Manual revision history

Revision/Date Change description

1.3 Symbols used

Emergency stop switch

Harmful or irritating substances (see the solvent safety sheet)

Conformity to the CE Directive

1.4 Intended use and improper use

1.5 Safety information

CONTROLS will not to be held responsible for:

The unit is not designed to be used in an explosive atmosphere.

Installation and any technical intervention must only be performed by qualified

Personnel Area with residual risks

1.6 Environmental risks and disposal

INFORMATION TO THE OWNER OF THE EQUIPMENT

Improper disposal of the product is subject to penalties as foreseen by the local

2.1 Functional block diagram

2.2 Identification plate

2.3 Commands and controls

2.4 Technical specifications

The information in this chapter is intended for authorized service-trained personnel.

3.2 Unpacking and inspection

Here follows the procedure for the unpacking of the equipment.

3.2.1 How to remove the equipment from the shipping crate

Model Net weight

Follow the instructions below to remove it from the shipping crate:

2. Open the shipping crate;

3.3 Positioning of the unit and space requirements

The unit must be placed on a flat and level surface.

Soft material to remove

3.4 Electrical requirements

3.5 External connections

3.5.1 Electrical connection

3.5.2 Cool water line connections

3.5.3 Connection to the air

Quick fit for

3.5.4 Filling the clean solvent tank

4. USE OF THE EQUIPMENT

4.1 Operating phases

The whole extraction process is performed automatically by the machine; default

Here follows a brief description of each phase:

DYRTY SOLVENT RECOVERY PHASE

WASHING PHASE and RINSE PHASE (STANDARD EXTRACTION METHOD)

1st WASHING CYCLE FOR FAST EXTRACTION METHOD

DIRTY SOLVENT TANK CLEANING PHASE

4.2 Switching on the equipment