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ATS BBR2S, Instruction Manual

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MAN - BBR2S - REV: Original | B. Safety

3

injuries that may occur while operating this equipment. 

WARNING:

 Injury to the operator could occur if operational procedures are not followed. Follow 

all steps or procedures as instructed and refer to accompanying documents. 

WARNING:

 Flammable vapors may be emitted from bath. Operate fluid bath in a well 

ventilated area. Do not smoke or use open flame near the bath. Refer to fluid manufacturer’s 

documentation for more detailed information specific to safety precautions for the bath fluid being 

used. 

WARNING:

 Do not submerge hand and arm in extremely cold test bath. Do not attempt to pull 

the drain plug when the fluid bath level is high and temperature is extremely cold. Extremely cold 

fluid may cause frost bite. 

WARNING:

 Use caution when handling air hoses during operation or when performing 

maintenance as contents will be under pressure. 

B.4 Cautions

The following statements are CAUTION statements. These statements alert the operator to conditions that may 

damage equipment. Operators must be aware of these conditions to ensure safe operation of this equipment.

CAUTION: 

Handle the load cell with care. The load cell will be damaged if the load frame is put 

on its side with the load nose attached, or if the load nose is over tightened. 

CAUTION: 

Handle the refrigeration hose with care. The refrigeration hose may be damaged if it 

is twisted or pulled, especially when the unit is cold. Do not move the refrigeration unit unless it 

has been turned off for at least 8 hours and has reached room temperature. 

CAUTION:

 Prevent damage to the cooling unit. Never operate the cooling unit if the ambient 

temperature is higher than 25

°

C.

CAUTION:

 The cooling unit should be placed in a well-ventilated area, on a stand at least six 

inches above the floor and not on the same surface as the BBR.

CAUTION:

 Carefully place the calibration weights on the load cell’s weight plan. If the Linear 

Variable Differential Transducer (LVDT) shaft is bumped, it may become inaccurate or even 

permanently damaged. 

Summary of Contents for BBR2S

Page 1: ...BBR2S Bending Beam Rheometer INSTRUCTION MANUAL This manual contains important operating and safety information Carefully read and understand the contents of this manual prior to the operation of this equipment www atspa com ...

Page 2: ...out notice and does not represent a commitment on the part of Applied Test Systems ATS Copyright Applied Test Systems 2018 For assistance with set up or operation contact the ATS service department Please have this manual and product serial number available when you call Telephone 1 724 283 1212 ...

Page 3: ...ont of Unit 4 Back of Unit 5 Gauge Kit 6 C 2 General Product Description 7 Major Components 7 Accessory Items 7 Product Specifications 7 Recommended Tools 8 Installation 8 Operation 8 Environmental Conditions 8 Load Frame 8 Specimen Support 9 Linear Variable Differential Transformer LVDT 9 Load Cell 10 Resistance Temperature Detector RTD 10 Computer Control System Software 10 Mechanical Refrigerat...

Page 4: ...3 Password Field 23 User Privilege Switches 23 Save Button 23 Copy Button 23 New Button 24 Delete Button 24 E 5 Standardization Process 24 E 6 Verification Process 27 E 7 Test Setup 31 Test Name 31 Test Date 31 Saving Test Parameters 31 Copying a Test 31 Creating a New Test 32 Deleting a Test 32 Adding Report Images 32 Adding a Test Company 32 Standard or Data Report 32 Deflection Plot and Load Pl...

Page 5: ...7 Digital Inputs 1 2 3 and 4 37 Digital Outputs 1 and 2 37 Digital Outputs 3 and 4 37 F Troubleshooting 38 F 1 Preface 38 F 2 Load Shaft Stuck or Stalled During Verification or Standardization 38 G Maintenance 40 G 1 General Maintenance 40 Appendix A Warranty 41 Appendix B Wiring Diagrams 42 Appendix C Image Glossary 44 ...

Page 6: ... warranty against defective parts and workmanship for one full year from the date of shipment Please see APPENDIX A of this manual for complete details on the warranty A 3 After Sale Support If there are any questions concerning the operation of the unit or software contact the ATS Service Department at 1 724 283 1212 Before calling please obtain the software revision number and the serial number ...

Page 7: ... have any questions regarding operation of the unit or instructions in this manual contact our Service Department Thoroughly understand the safety features and operation of the equipment This manual will provide operators with safety concerns and general procedures Be familiar with correct operating principals and use good judgment Also refer to the appropriate manuals for system component safety ...

Page 8: ...ements are CAUTION statements These statements alert the operator to conditions that may damage equipment Operators must be aware of these conditions to ensure safe operation of this equipment CAUTION Handle the load cell with care The load cell will be damaged if the load frame is put on its side with the load nose attached or if the load nose is over tightened CAUTION Handle the refrigeration ho...

Page 9: ...m Overview C System Overview C 1 Equipment Parts Front of Unit Figure C 1 BBR2S Front 5 3 1 2 7 6 4 1 Load Frame 2 Power Switch 3 Mode Select Switch 4 Stirrer Motor Controls 5 Zero Load Pressure Gauge 6 Zero Regulator 7 Load Regulator ...

Page 10: ...iew 5 Back of Unit 1 Incoming Air Connection 2 Air Connections to Load Frame 3 AC Power Connection 4 Chiller RTD Connects to Back of Chiller 5 USB Connection to BBR Computer 6 Load Frame Sensor Cables Figure C 2 BBR2S Rear View 1 2 6 3 4 5 ...

Page 11: ...iginal C System Overview Gauge Kit Figure C 3 BBR2S Gauge Kit 1 Step Disk 2 50 gram cal weights 4 3 2 gram weights 2 4 Non Compliant Beam 5 Confidence Beam 6 Load Shaft 7 Anvil Support Adapters 2 1 2 2 3 3 6 2 2 4 5 7 7 ...

Page 12: ...anical Refrigeration Unit Accessory Items Specimen Molds 5 Molds Confidence Beam Non Compliant Beam LVDT Calibration Gaging Disk Load Cell Calibration Weights 4 50 gram and 2 2 gram The BBR2S test control function and data acquisition is operated by a Windows based personal computer During testing the software controls the BBR2S load function displays and records the load deflection and temperatur...

Page 13: ...able corrosion resistance Each load frame is constructed from stainless steel plates and durable high strength PVC uprights that are designed to be dimensionally stable and provide accurate force control The load frame consists of an integral free floating loading shaft within an air bearing to permit specimen loads in the range of 0 to 1960 mN The air bearing also provides reliable and rapid load...

Page 14: ...t temperature fluid bath during the test The fluid in the bath provides a buoyant force that counterbalances the weight of the specimen Linear Variable Differential Transformer LVDT The LVDT is calibrated at between 0 and 6 mm and is mounted in the upper section of the load frame assembly A free floating core rod is attached directly to the load shaft It measures the displacement of the specimen a...

Page 15: ...immersion cooler designed as a cooling source for sub ambient work in liquid baths The unit rests on the floor and maintains the cooling fluid at a constant temperature by use of the unit s temperature controller and the magnetic stirrer located in the bath The single stage refrigeration system is equipped with one compressor A hose carries refrigerant through the cooling probe located in the bath...

Page 16: ...rols Two controls are located inside the right panel of the BBR2S base unit These controls are factory set the line pressure regulator is positioned on the right inside of the panel This pressure is set at 60 psi The bearing pressure regulator is located to the left of the line pressure regulator and is set at 15 to 20 psi Verify the settings if necessary Base Unit Controls The BBR2S base unit con...

Page 17: ...base unit and the refrigeration unit from the box and place them on a sturdy work surface WARNING Position the BBR2S in a well ventilated area Consider that flammable vapors may be emitted from the bath during operation Refer to fluid manufacturer s MSDS documentation for further information 2 Remove the load frame assembly and place it on a sturdy work surface near the base unit 3 Remove any pack...

Page 18: ...assembly by following the steps below 1 There are four screws securing the shroud to the load frame Figure D 1 Loosen the back two screws slightly and completely remove the front two screws This should allow you to remove the shroud from the frame 2 Remove the foam from inside of the load shroud Figure D 2 Unscrew the lower portion of the load shroud from the upper portion Figure D 3 Set the lower...

Page 19: ...fully screwing in the front two screws See Figure D 6 CAUTION Do not over tighten the load nose on the load cell or the load cell may become damaged The load cell is extremely sensitive to this twisting movement CAUTION The load cell can be easily damaged especially from side loading and excessive torque DO NOT place Load Frame on its side once the Load Nose is in place Improper handling will resu...

Page 20: ...ch that they will not snag or catch on anything in the surrounding environment 2 Connect the temperature sensor cable from the BBR base to the refrigeration unit 3 Connect the color coded electrical cables from the rear of the base unit to the rear of the load frame assembly 4 Connect all needed cables and equipment for the computer system 5 Connect the communication cable between the rear of the ...

Page 21: ...Incoming Air Connection 2 Air Connections to Load Frame Air Hose Zero Load Hose 3 AC Power Connection 4 Chiller RTD Connects to Back of Chiller 5 USB Connection to BBR Computer 6 Load Frame Sensor Cables 1 2 6 3 5 4 Figure D 10 BBR2S Connections ...

Page 22: ...ompts to launch the Setup Wizard application to install the drivers Use default directories as destinations and accept all license agreements When installation has completed select Restart later and exit the setup application 2 Install the BBR2S operating software Locate the USB flash drive containing the BBR2S installation software which was included with your BBR On the flash drive locate the fi...

Page 23: ...e BBR Serial Number in the BBR2S Config File The Serial Number information for the BBR is stored in the BBR2S cfg file which is located inside of the config directory in the BBR2S program file directory in the ATS folder on the computer s C drive Figure D 11 shows the pathway to this file The file can be opened for editing or viewing using the Notepad application in Windows Figure D 12 shows how t...

Page 24: ...ne which says Serial Number 12 34567 8 Edit this line such that the 12 34567 8 is replaced with either the Serial Number of the BBR as shown on the nameplate on the back of the load frame or with whatever designation you prefer Save the changes to the file when exiting Notepad ...

Page 25: ...n 1 Fill the BBR2S with approximately 2 gallons 7 57 liters so the liquid is approximately 1 to 2 inches from the top Refer to individual test specifications for fluid type E 2 Power Up the BBR2S 1 Press the power button on the rear of the BBR2S base unit The power indicator light on the front of the unit will illuminate 2 Turn on the refrigeration unit chiller by flipping the power switch in the ...

Page 26: ...ID s Set up Read Weight A Zero Temp Enter Notes Run Test Read Weight B Read Weight C Read Weight D Finish Set up Read Weight A Read Weight B Read Weight C Read Weight D Finish Set up Read Gauge A Read Gauge B Read Gauge C Read Gauge D Finish Show Data Show Report Show Graph Set up Graph Deflection Set up Graph Load Set up Bath Set up Specimen Set up Test Times Report Images Need Privilage Need Pri...

Page 27: ... to the Standardization or Diagnostics screen No password is required Operator oper Allows the user to access all of the menu screens of the BBR2S except the Diagnostics screen The lower part on the screen shows values for machine temperature load and deflection It also has system status lights and controls for the machine NOTE The Exit button on the bottom right of the screen will exit the BBR2S ...

Page 28: ...ers on the system Diagnostics Allows this user to enter a diagnostic or maintenance screen NOTE Extreme caution should be used with this permission as there are no safety restrictions in this screen Standardization Allow this user to perform a standardization on the system Currently switches 3 4 and 5 do not add or remove any additional permissions Save Button Saves the current user This should be...

Page 29: ...dization Screen Figure E 4 NOTE The standardization button will not be shown on the main menu unless the currently logged in user has permission to perform standardization The BBR2S s system status lights located at the bottom right of the screen indicate whether or not a component requires standardization Red the component requires standardization Yellow the component requires verification Green ...

Page 30: ...he load frame RTD f Leave the thermometer in place for a minimum of two minutes and note the temperature reading of the bath to the nearest tenth of a degree within 0 1 C g Adjust the chiller setpoint temperature if necessary to obtain a bath temperature of 0 0 C h When the calibrated thermometer indicates a bath temperature of 0 0 C select ZERO in the Standardization menu then select NEXT i Chang...

Page 31: ...nt should be 2 5mN and repeatable within 10 from one standardization to another If it is not contact Applied Test Systems at 1 724 283 1212 3 Standardizing Deflection LVDT a Press the Deflection button on the Standardization Screen b With the load frame in the bath remove any beams from the supports and any weights from the BBR2S c Adjust the zero regulator to raise the load nose to its highest po...

Page 32: ...ization Screen b With the load frame mounted in the bath load the non compliant beam into test position c Slowly adjust the zero regulator to the lower loading nose until it gently makes contact with the beam 20mN 10mN Press the Next button e Select weight A from the gauge kit and place it on the weight pan Wait five seconds and press the Next button g Select weight B from the gauge kit and place ...

Page 33: ...ts and apply a 35mN load to the beam by turning the zero load regulator b Observe the reading of the LVDT Gently grasp the shaft and lift it upwards approximately 5mm by observing the reading of the LVDT c When the shaft is released it should immediately float downward and gently make contact with the beam d Remove any beams from the supports e Use the zero load regulator arrows to adjust the load...

Page 34: ...a 20mN load 10mN using the zero load regulator Add a 2g mass to the weight pan ii Verify the increased measured load is 20mN 5mN Add the second 2g weight to the weight pan Verify the increased measured load is 20mN 5mN iii If the measurements do not fall within these ranges standardization is required Press the Standardization Required button and press Next to move to the next section b Verify the...

Page 35: ...ss the FINISH button without pressing any of the radio buttons a For this process you will need a strip of white paper 12 7 mm x approx 25 mm long and a strip of carbon paper of the same or similar dimensions b Place the white paper strip on the non compliant beam and secure with tape c Remove the load frame from the liquid bath and set it in an upright position on a flat surface WARNING Do not la...

Page 36: ...e the Test Name combo to select different test specifications already saved Just press the down arrow button to get a list Test Date Shows the last time that the currently selected test was saved Saving Test Parameters The Save button will save all the current screen data to the currently selected test specification This should be done any time you change anything that you want to keep If you exit...

Page 37: ...g seen in Figure E 8 which will allow you to select each image The best image size is listed on screen for each position and are as follows Report Header Left Image 200x100 Report Header Right Image 200x100 Report Footer Left Image 200x50 Report Footer Right Image 200x50 If the image entered is a different size it will be resized to fit but may appear distorted Adding a Test Company The Test Compa...

Page 38: ...imes The TEST TIMES are what set the sequence and sample rate the system uses when running this test specification NOTE Each stored data point is a running average of four data points Once you have entered your desired test parameters press SAVE and then EXIT Report Language This is the language used when generating a report It does not have to be the same language used in the operation of the mac...

Page 39: ...re stored with the run data and printed with the report Be sure you write these BEFORE you run a test for them to be included on the report If the BBR2S was sitting idle and the loading shaft was free hanging for more than one hour place the non compliant beam on the specimen support then manually exercise the load cell To do this place 100 gram of weight on the weight pan and remove it allowing t...

Page 40: ...ess Current deflection and load values are displayed on the graph 5 To abort the test press the STOP TEST button 6 When the test is complete the system will automatically generate a report and display it 7 If you have connected a printer to your BBR2S you can print the test summary report from this screen To do so select file and then print Run Crack Sealant Test 1 Before running this test you wil...

Page 41: ...d from this dialog The SHOW REPORT button will open the report that was generated for the selected test run Use the TIME switch to change between FULL GRAPH and ZOOM ZOOM will let you zoom in on the time scale and put a scroll bar under the graph to allow you to move the display back and forth You can also click on either end of any of the scales to change that value to zoom in on just part of the...

Page 42: ...Inputs 1 2 3 and 4 Raw values into the system Use a voltmeter to test the state at the input pin and verify that it matches the value shown on the diagnostics screen DI1 and DI2 are used to bring in the auto zero load switch DI3 and DI4 are not used at this time Digital Outputs 1 and 2 Raw values out of the system Use a voltmeter to test the state at the output pin and verify that it matches the v...

Page 43: ...eme caution when removing covers or panels Follow your company s electrical safety procedures thoroughly F 2 Load Shaft Stuck or Stalled During Verification or Standardization When the load shaft seems to be stuck or stalled during verification and standardization procedures the most likely cause is a misaligned LVDT To fix this issue perform the following steps 1 In order to determine if the LVDT...

Page 44: ...e lower end of the LVDT shaft while carefully adjusting the housing with the other hand Position the LVDT housing so the shaft is in the center of the LVDT housing CAUTION Never attempt to adjust the LVDT shaft If the shaft becomes damaged the load frame will not produce accurate results CAUTION The load cell can be easily damaged especially from side loading and excessive torque DO NOT place Load...

Page 45: ... 1 General Maintenance When cleaning the surface of the BBR2S first disconnect all power sources and place all controls in an OFF position Use a very mild cleaning agent and be careful not to allow the cleaning agent to enter and contaminate the fluid bath ...

Page 46: ...duct must be returned to the Applied Test Systems factory or an authorized 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 Applied Test Systems must be promptly notified in writing of the defect 2 Upon receipt of written authorization said defective equipme...

Page 47: ...MAN BBR2S REV Original Appendix B Wiring Diagrams 42 Appendix B Wiring Diagrams ...

Page 48: ...MAN BBR2S REV Original Appendix B Wiring Diagrams 43 ...

Page 49: ...er portion of Load Shroud 15 Figure D 8 Attaching lower portion of Load Shroud 15 Figure D 9 Attached Load Nose with Shroud 15 Figure D 10 BBR2S Connections 16 Figure D 11 Pathway to the File 18 Figure D 12 File After Opening Notepad 18 Figure E 1 BBR2S Software Screen map 21 Figure E 2 Main Menu Screen 22 Figure E 3 Edit Users dialog 23 Figure E 4 Standardization Screen 24 Figure E 5 Step disk po...

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