ATS 2140-M Series Page 12 Instruction Manual Download

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Section 3: Equipment Setup and Installation

Read and understand all instructions and safety precautions listed in this manual before installing

or operating the unit. For questions regarding unit operation or installation, contact the ATS Service

Department at +1-724-283-1212.
In addition to the safety information listed here, there are cautions and warnings throughout this

manual. Failure to follow these instructions could result in permanent damage to the unit, significant

property damage, personal injury, or death.

Read Operator’s Manual

General Danger

Protective Earth (Ground)

Burn Hazard (Hot Surface)

Electrical Shock/Electrocution

Hand Crush Force From Above

European Directive CE Mark

No Access for Unauthorized Persons

Summary of Contents for 2140-M Series

Page 1: ...WinCCS Lever Arm Tester Series 2140 M 2320 M 2330 M 2330 CC 2410 M 2410 CC...

Page 2: ...Revised March 2013...

Page 3: ...2 3 Cautions 11 Section 3 Equipment Setup and Installation 12 3 1 Safety Instructions 13 3 2 Location of Safety Labels 13 3 3 Unpacking Equipment 15 3 4 Specifications 16 3 5 Hardware Installation 17...

Page 4: ...hermocouple Circuit Board Calibration 52 6 5 Clock Speed 52 Section 7 Operation 53 7 1 General Overview 53 7 2 Test Specifications 57 7 3 Specimens 71 7 4 Testing 75 7 5 Stopping a Test 79 7 6 View Te...

Page 5: ...Appendix D of this manual for complete details on the warranty NOTE Please see the warranty information included with the computer It details information that will ensure proper transfer of the comput...

Page 6: ...xtensometer displacement transducer or encoder attached to the bottom of the extensometer frame 3 F this symbol is used to note degrees Fahrenheit 4 C this symbol is used to note degrees Celsius Also...

Page 7: ...s retrofitted into existing frames made by ATS and other manufacturers SERIES 2140 2320 2330 2410 2430 2510 MM X X X X X X MS X X X X X X CCM X NA X X X X CCS X NA X X X X SRM NA NA X NA NA NA SRS NA...

Page 8: ...Microsoft Windows 7 Professional 32 bit Memory 2GB or better Hard Drive 250GB or better DVD Drive 16x or better RS422 Card Dual Port NOTE Each RS422 port is capable of connecting up to 64 test frames...

Page 9: ...tc specific to that particular item 1 3 3 Sequence of Events The test is performed in the following sequence of events 1 Select or create a specification to be used to control the test 2 Create a spec...

Page 10: ...l Read and understand all instructions and safety precautions listed in this manual before installing or operating the unit If there are any questions regarding operation of the unit or the instructio...

Page 11: ...NING Do not open the panel WARNING Unpack and operate on a stable surface 2 3 Cautions The following statements are caution statements These statements alert the operator to conditions that may damage...

Page 12: ...1 724 283 1212 In addition to the safety information listed here there are cautions and warnings throughout this manual Failure to follow these instructions could result in permanent damage to the uni...

Page 13: ...mpetent personnel and done in accordance with any current local and national codes Equipment grounding is a MUST for both safety and proper operation 3 Before supplying electrical power to the unit tu...

Page 14: ...14...

Page 15: ...w accepted moving practices to avoid damage to the tester NOTE Position the test frame and console to allow ample room for maintenance 3 If casters are supplied with the unit install them in the cabin...

Page 16: ...degrees to 40 degrees Celsius 4 Operating temperature of 3 degrees Celsius at the time of force application 5 Relative humidity no more than 80 percent at 31 degrees Celsius 50 percent at 40 degrees C...

Page 17: ...e weights 2 Install the locating dowels 3 Install bolts and tighten CAUTION Match the serial numbers on the test frames with the support blocks and lever arms when assembling multiple testers 4 Remove...

Page 18: ...diate These switches are pre installed by ATS b Adjust the nuts above the main proximity switch until the red light on the switch goes out which signals that the arm is level The red light will illumi...

Page 19: ...n the location desired before setup It is recommended to have this equipment installed by ATS Service Electrical power should be connected to the tester by a local electrician to adherence to local an...

Page 20: ...283 1212 prior to attempting this operation 4 2 Drawhead Operation Applied Test Systems drawheads are used for the initial loading of a specimen keeping the lever arm level They are designed to maint...

Page 21: ...il the screw comes out b Clean and apply multipurpose lithium grease c Replace the jack screw d Reassemble and adjust the limit switch 2 Lubricate jack worm gear annually with multipurpose lithium gre...

Page 22: ...ls Modular Version The drawhead can be jogged up and down when the frame is in the Idle state 4 5 Manual Control via Computer This function is used for troubleshooting only Contact ATS at 1 724 283 12...

Page 23: ...gh the setup process It is important to first create a user name and password for the administrator 1 The log in information upon initial setup is username for both the user name and password NOTE Do...

Page 24: ...user or operator name displayed 5 Enter the password and check boxes for all the privileges assigned to this user The administrator can also enter any account information at this time 6 Click OK to s...

Page 25: ...One administrator with full privileges is necessary Normally the ATS Service Department assigns an administrator login with full privileges To assign user privileges 1 Select Privileges from the User...

Page 26: ...customization under the Setup for User Name window The user can 1 Change the units displayed on the screen by clicking on the Units tab For example one operator can choose to view data in metric unit...

Page 27: ...Units tab 3 Choose the desired unit of measurement for each of the eight choices To use all English or all Metric units click the appropriate button 4 Click OK to save the choices and close the scree...

Page 28: ...own the shift key 1 Indicate the frame to be set up by entering the frame number name in the Frame Number pull down list NOTE Failure to select the proper frame is the single most common reason for se...

Page 29: ...oller on a common port must be set to a unique address which will be set by ATS personnel during setup ATS personnel will determine which address is used by the controller servicing the frame that is...

Page 30: ...ied during any test is checked against this information and tests which require loads outside the specified limits are not allowed to run This can protect the frame and load components from damage To...

Page 31: ...This fourth T C may be used to monitor room temperature or any other temperature of interest The temperature of this T C can be displayed on the temperature graph of any test run on this frame but it...

Page 32: ...m ratio Typical arm ratios are 20 1 16 1 10 1 5 1 and 3 1 Under the Frame Setup menu select the Arm Ratio tab 1 Enter the dividend of the ratio into the Add Ratio box For example if the arm ratio is 2...

Page 33: ...tached to the frame These settings must agree with the wiring configuration If the correct configuration is unknown refer to the installation drawings or consult ATS at 1 724 283 1212 The typical inst...

Page 34: ...otal of the three zones must still equal 300 For example if the bottom zone is 35 degrees low when the top zone reaches the setpoint value removing some of the power from the top zone and redistributi...

Page 35: ...anging this term Band Default 85 F This is the amount of swing allowed to the control parameters meaning the WinCCS control box varies the parameters during the control process as necessary For normal...

Page 36: ...ge can result to the tester load train extensometer or furnace On frames with motorized drawheads or elevators a manual control delay is essential If the motor has not stopped before the reverse motio...

Page 37: ...sion is specified by the timeout entry under the Miscellaneous tab While the specimen level value can be left unspecified the break value is normally set at 30 seconds Tare Values The tare value is th...

Page 38: ...hould not be changed without instructions from the ATS support contact Some tuning of individual frame types is routinely required and this will be done at the time of installation In the event that t...

Page 39: ...parameters of the load cell are specified by the manufacturer and are indicated on the data sheets supplied with the load cell NOTE In the event of load cell replacement this data should be updated T...

Page 40: ...es provide the use of two extensometers and the system will average the results for better creep data If one extensometer is used enter its description in the Left Center box Enter none in the Right b...

Page 41: ...ass is selected one is the default number of passes The user selects the number of steps The default number of steps is ten and will appear in a box under the number of passes There is also a choice o...

Page 42: ...der this tab can be entered during the test creation process entering information that is common across all tests in this default tab can save the operator time when creating a test Setting these para...

Page 43: ...this screen Typically the minor alarm is set at 3 F for temperatures up to 1800 F 1000 C which adheres to the ASTM suggested excursion limit NOTE The minor alarm value is also the point where the syst...

Page 44: ...Under the Specimen Text tab enter the text fields desired Only the fields containing text will be shown to the operator when creating a test To view the application of these text fields select Create...

Page 45: ...Under the Test Specification Text tab enter the text fields desired Only the fields containing text will be shown to the operator when creating a test To view the application of these text fields sele...

Page 46: ...the Specimen Loading tab of the General Setup menu Stress Rupture Loading ASTM suggests that the preload should be no more than 10 percent of the total load Typically eight is the default value for th...

Page 47: ...t into the targeted value The Target Steps value is generally set at ten ASTM suggests that the preload should be no more than 10 percent of the total load Typically eight is the default value for thi...

Page 48: ...eck to be specified by the user It is an abbreviated version of the extensometer calibration setup from the Frame Setup menu Extensometer Linearization Normally a polynomial curve fit is used to reduc...

Page 49: ...chedule recalibration Be sure to call in advance to ensure the procedure is scheduled in enough time 6 3 7 Test Lockouts This section prevents the operator from starting tests when various system comp...

Page 50: ...to select the directory where the test reports should save each time a test runs Select the directory using the Browse button Debug This tab is used exclusively for troubleshooting purposes by ATS pe...

Page 51: ...weights 0 5lb 1 0lb 5 0lbs 10 0lbs 20 0lbs 30 0lbs The systems may also be supplied with metric weights 2 5N 5 0N 25N 50N 100N 150N To add weight values enter the value in pounds or Newtons into the...

Page 52: ...meter calibration 6 5 Clock Speed The clock speed on the WinCCS Circuit Board is checked during the manufacturing process See figures below to locate the clock on the WinCCS Circuit Board for both the...

Page 53: ...ion When an operator takes any action such as calibration test start up specification editing etc the identity of the operator is archived with a record of the action The operator identification is th...

Page 54: ...r logs in the system recognizes the identity and privileges of the new operator only NOTE System Units and the Status Display Option configuration are unique to the individual operator For example if...

Page 55: ...e Status Display icon located underneath the main menu bar in the upper left corner of the screen to access the System Status Display When the Status Display screen appears column headers and frame st...

Page 56: ...be unique and different Once a specimen name has been assigned it cannot be used for another test Each lab should develop a naming system that will best suit the record keeping practices in use Any nu...

Page 57: ...l automatically be saved and can be used at any time over multiple tests 1 Select Specifications and Create from the main menu 2 In the Test Specification field type the name of the test specification...

Page 58: ...down menus to select the appropriate Specimen Type and Test Type Review the entire list of options to ensure the correct selection is made 7 Use the Tab key to move through the remaining fields 8 Uni...

Page 59: ...se values are changed be sure to enter values that will protect the specimen and system hardware in case of control failure NOTE Tests are not interrupted for minor alarms however an entry is made in...

Page 60: ...the new setpoint 15 Click Next to proceed to the Power Failure screen 16 This screen relates to the load on the frame if a power failure brings the temperature below the major alarm level If the box...

Page 61: ...hoose either Multiple steps or Single steps from the pull down menu Typically multiple steps will be selected NOTE If Plastic Strain is to be separated from Creep data then the specimen must be loaded...

Page 62: ...to move to the Step Loads screen This screen is used for stress rupture testing If performing a creep test skip this screen by clicking Next See step 23 22 If performing a stress rupture test that re...

Page 63: ...Fail box is checked the test runs to completion but the report will note that the test failed 26 Check the Shutdown box to terminate the test 27 In the Life Hours field check the box and enter the num...

Page 64: ...ail or an elongation limit is desired make the appropriate selections 31 If necessary select the Separate Elongation Limit This limit allows the operator to measure an initial limit and then an additi...

Page 65: ...diate Creep Pass Fail screen 33 Use the Intermediate Creep Pass Fail field to establish criteria based on creep performance Define criteria from the Fail if pull down menu and click Add NOTE Any numbe...

Page 66: ...oints during the test either as creep at a specified run time or as run time to a specific creep value Use the Report pull down menu to choose the type then enter the appropriate time or creep value a...

Page 67: ...at requires modification For example click on Condition to change add or delete a test condition The Condition window will then appear for editing 4 Click OK when finished NOTE The revision field shou...

Page 68: ...screen or printed by selecting Specifications then View To see specific specifications or conditions select the Test Specification or Test Condition from the pull down menu NOTE Once the specification...

Page 69: ...he list avoiding possible operator confusion 1 Select Specifications then Delete 2 When the Select a Test Specification to Delete screen appears use the pull down menu to select the appropriate specif...

Page 70: ...new specification that is very similar to an existing one 1 Select Specifications then Copy 2 Select the existing specification from the pull down menu 3 Click OK 4 Assign the copy a new file name an...

Page 71: ...NOTE Each specimen name must be unique and cannot be used for any other test 3 Use the pull down menu to select the Test Specification and the Test Condition 4 The remaining data field will show the d...

Page 72: ...ed Make sure they are correct or the results will be in error 6 Click Next to proceed to the Comments screen 7 Enter any comments about the test or specimen here If there are no comments skip this ste...

Page 73: ...check the Release for Test box to certify that s he has reviewed the details of the test and is satisfied that they are correct The user logged in at that time will be automatically entered in this se...

Page 74: ...t have the privileges necessary for editing specimens 7 3 4 Viewing a Specimen The specimen information can be viewed and printed in report form at any time 1 From the main menu select Specimens then...

Page 75: ...tus Display is the main display used by the operator during normal operation of the system Machine states and alarm conditions are displayed on the status display screen Refer to Appendix B for a comp...

Page 76: ...Test menu will appear b From the main menu select Specimens then Start The Start a Test menu will appear c Click the Frame icon on the main menu d Double click on the Status Display line for the frame...

Page 77: ...ill be much more accurate if using calibrated thermocouples Further using a single batch for all thermocouples will be more convenient and present less chance of an error 11 Verify that the informatio...

Page 78: ...propriate preload amount in pounds and adjust the value if it does not agree with ASTM or applicable standards NOTE The system will automatically populate the values listed under Creep Loading Informa...

Page 79: ...k Yes The test will be terminated 2 Click the Frame icon on the main menu a Select the appropriate frame from the Frame Services menu b Click Stop the Test from the options c Verify that the system sh...

Page 80: ...ways to view a test currently running 1 From the main menu select View then Running Test a When the Select Frame to View screen appears select the desired frame b Click OK and the Report Graphing Opt...

Page 81: ...perly locate data To view a completed test 1 Select View from the main menu then Previous Tests The Select Archived Test to View screen will appear 2 Use the Directory pull down menu to select Tests 3...

Page 82: ...boxes for the data to be shown in the report a If the Short Form box is checked only the following information will be included in the report Specimen Information Test Condition Test Results Intermed...

Page 83: ...nts are collected during a creep test users can choose which data points are reported NOTE This will not change the archived data the function is used primarily to make reports more concise 4 Proceed...

Page 84: ...is and Legend Types These can be selected based on user preference vi Data Average This creates a running average of the points on the graph The default setting is five which means that every five dat...

Page 85: ...h by clicking Browse 6 Modify the file name if desired in the Save As text box 7 Specify the Save In destination for the file by using the Browse button 8 Select OK to complete the export process 7 6...

Page 86: ...bar CAUTION DO NOT PERFORM MAINTENANCE FUNCTIONS WITHOUT ATS SERVICE PERSONNEL Diagnostic Displays This function is reserved for ATS Service Personnel Furnace Logging The furnace logging option allows...

Page 87: ...ol can damage the machine Upon selecting manual control the following warning will appear Reset Frame to IDLE This option is another troubleshooting feature that may be used in the event of a computer...

Page 88: ...ing the appropriate box on the bottom of the screen b Frame Status This relates other information pertaining to the frame flags alarms etc c Furnace Data This relates information pertaining to the fur...

Page 89: ...to the equipment CAUTION Do not overload the machine Observe rated capacity on data tag CAUTION Do not overload load train components Elevated temperatures lower their capabilities A load train is no...

Page 90: ...ph Fix Creep Data Anomalies This function allows the system to recognize an anomaly in the creep graph and delete it The creep graph will then more accurately portray creep without discontinuous data...

Page 91: ...The Multiple Creep Graph option allows users to select multiple creep tests It then superimposes the creep data allowing users to view multiple graphs simultaneously This graph is useful when compari...

Page 92: ...assume a perfect NIST Thermocouple Typically the thermocouple is tested at several temperatures over the useful range of the thermocouple wire type and a chart is provided as a calibration record see...

Page 93: ...use a unique name for each batch c Enter the appropriate information d Enter the Temperature and Offset Correction in the appropriate window e Click Add f Repeat these steps for each temperature point...

Page 94: ...ermocouple out of the bottom of the furnace adjacent to the pull rod Allow an extra 2 in 50 mm of wire on the specimen end 2 Attach a Male Thermocouple Connector to the Junction Box end of thermocoupl...

Page 95: ...95 Once these steps are completed the thermocouples will be properly attached to the specimen...

Page 96: ...s 5 Install Crosshead Halves taking care to properly engage the specimen groove or v ridge 6 Reinstall Crosshead Clamping Nuts and lightly tighten 7 Adjust location of Extensometer Rod Guide if needed...

Page 97: ...gage length between extensometer inserts 6 Install Crosshead Halves taking care to properly engage the specimen groove or v ridge 7 Reinstall Crosshead Clamping Nuts and lightly tighten 8 Adjust loca...

Page 98: ...Crosshead Halves taking care to properly engage the specimen groove or v ridge 6 Reinstall Crosshead Clamping Nuts and lightly tighten 7 Adjust location of Extensometer Rod Guide if needed The Extens...

Page 99: ...ensometer Calibration and Verification Both involve using a micrometer to increment the LVDT in precise amounts through its range of operation but they differ in the way the signal is handled by the s...

Page 100: ...e e When the process is completed the status display screen will return to normal f To review the calibration report and graph select View Calibration Report from the Extensometers pull down on the Ca...

Page 101: ...rame Services menu select the Extensometer Calibration from the Report Graph menu that appears and click OK 8 2 5 4 Viewing Calibration Summary A review of the calibration status of a frame can be acq...

Page 102: ...here assumes that three thermocouples are in use and the temperature of the uppermost thermocouples is displayed here The middle and lower thermocouples are likewise shown in the adjacent columns Powe...

Page 103: ...for the NVRAM needs replacing Break The frame s break detect switch is active Cal Ver The frame is currently having the extensometer calibrated or verified Com The host PC is unable to communicate wit...

Page 104: ...ements in a zone may be open 2 In unusual circumstances a wiring error in the thermocouple connections or the furnace zone control relays could result in the thermocouple or zone relay being associate...

Page 105: ...ne alarm lead to persistent TLow or THigh alarms If TLow occurs frequently during the soak cycle it may be that the Integral Algorithm is not active enough Increasing the I term of the furnace setup m...

Page 106: ...art up The frame is requested to start all parameters are downloaded to the frame controller Post Test The test is complete and ready to be removed Ramp The furnace is ramped from the current temperat...

Page 107: ...tween the zones as much as possible and was not able to control temperature uniformity ISO Thermal Temperature Range Error Shutdown The temperature measurement subsystem ambient temperature sensor is...

Page 108: ...hardware error has occurred in the temperature measurement subsystem of the frame controller Test Reloaded or Restarted Indicates that a test which had been previously removed and post tested has been...

Page 109: ...109 Appendix C Default Values This appendix includes all the default values typically seen on a WinCCS tester...

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Page 114: ...zed repair center Applied Test Systems shall not be liable for any labor transportation or installation costs that may arise in connection with the product or return To obtain warranty service 1 Appli...

Page 115: ...154 East Brook Lane Butler PA 16002 USA 1 724 283 1212 www atspa com...

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