ATS BBR3 Instruction Manual Download Page 17

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MAN - BBR3 - REV: Original | C. System Overview

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 as the test

load is applied.

Load Cell

The load cell is a precision strain gauge-type, with 500 gram (4903 mN) force capacity. It is constructed of stainless

steel to prevent corrosion or damage by the fluid during test procedures.

CAUTION: The load cell can be easily damaged, especially from side loading and excessive torque.

Use caution while handling the test frame when the loading shaft is attached. Remove loading shaft

before laying load frame on its side, especially before shipping.

Resistance Temperature Detector (RTD)

The RTD is a platinum measuring device that measures the cooling fluid bath temperature, is attached to the chiller,

and relays the information to the computer control system software. It is mounted in the BBR3 bath directly under the

test specimen supports.

Computer Control System Software

The computer control system software provides user control of the BBR3 system in a Windows® environment with

touchscreen access. The software provides pull- down menus, button selections, and data entry text boxes for easy

updates and access to information.

The base unit contains an integrated personal computer, designed to efficiently run the software. During operation,

the software collects and records the data from the various sensors on the load frame. During tests, the software

controls specimen loading and unloading. The software is organized so all the information required to conduct a

particular test is stored internally.

Mechanical Refrigeration Unit (Chiller)

The refrigeration unit (chiller) is an immersion cooler designed to act as a cooling source for sub ambient work in

liquid baths. It maintains the cooling fluid at a constant temperature using 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.

Refer to the separate manufacturer’s literature for more detailed information regarding safety, operation, and

maintenance of the refrigeration unit.

WARNING: Refrigeration unit (chiller) will cause the test bath to be extremely cold. Do not submerge

hand or arm in extremely cold test bath. Do not attempt to pull the drain plug when the test bath level

is high and the temperature is extremely cold. Extremely cold fluid may cause frostbite.

Summary of Contents for BBR3

Page 1: ...BR3 Bending Beam Rheometer 3 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: ...nit 6 Back of Unit 7 Load Frame 8 Tank Interior 9 Gage Kit 10 C 2 General Product Description 11 Major Components 11 Accessory Items 11 Product Specifications 12 Environmental Conditions 13 Load Frame 13 Specimen Support 14 Air Bearing 15 Linear Variable Differential Transformer LVDT 15 Load Cell 15 Resistance Temperature Detector RTD 15 Computer Control System Software 15 Mechanical Refrigeration...

Page 4: ...5 E Operation 28 E 1 Filling the Bath 28 E 2 Power Up the BBR3 28 E 3 Overview of Touchscreen and Menus 29 E 4 Editing Users and Permissions 29 E 5 Standardization Process 32 E 6 Verification Process 36 E 7 Test Setup 40 Test Name 41 Test Date 41 Saving Test Parameters 41 Copying a Test 41 Creating a New Test 42 Deleting a Test 42 Adding Report Images 42 Adding a Test Company 43 Standard or Data R...

Page 5: ...2 3 and 4 50 Digital Outputs 1 and 2 50 Digital Outputs 3 and 4 50 Cool PID Values 50 F Troubleshooting 52 F 1 Preface 52 F 2 Load Shaft Stuck or Stalled During Verification or Standardization 52 G Maintenance 55 G 1 Cleaning the BBR3 55 G 2 Changing the BBR3 Fluid Bath 55 APPENDIX A Warranty 56 APPENDIX B Wiring Diagram 57 APPENDIX C Declaration of Conformity 59 APPENDIX D Image Glossary 60 ...

Page 6: ...sions Administrator admin Basic Standardization Diagnostics User Edit Operator oper Basic Standardization Default Basic A 3 Warranty Information All new ATS systems are shipped with a warranty Units have a 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 4 After Sale Support If t...

Page 7: ...MAN BBR3 REV Original A Introduction 2 Figure A 1 ATS Sample Data Tag ...

Page 8: ...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 instruction manuals Use caution when working with liquids at low temperatures Protect skin by wearing protective clothing and follow safety operati...

Page 9: ...he cooling unit if the ambient temperature is higher than 25 degrees C 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 BBR3 Carefully place the calibration weights on the load cell s weight pan If the Linear Variable Differential Transducer LVDT shaft is bumped it may become inaccurate or even permanently...

Page 10: ...Overview 5 C System Overview C 1 Equipment Parts Front of Unit 1 Load Frame 2 Chiller 3 USB Port 4 Touch Screen Monitor 5 Power Indicator 6 Leveling Feet 7 ZERO Regulator 8 LOAD Regulator Figure C 1 Front of BBR3 Unit 1 2 3 4 5 6 7 8 ...

Page 11: ...AN BBR3 REV Original C System Overview Back of Unit 1 Air Connector 2 Connects to Chiller 3 Connects to Load Frame 4 Unit Power 5 Network Ethernet 6 USB Connection Figure C 2 Back of BBR3 Unit 1 2 3 4 5 6 ...

Page 12: ...System Overview 7 Load Frame 1 LVDT Shaft 2 Weight Pan 3 Gaging Disk 4 Bearing Air Supply Control 5 Lamps 6 Shroud 7 LVDT Housing 8 LVDT 9 Air Bearing 10 Load Cell 11 Load Nose Figure C 3 Load Frame 1 2 3 4 4 5 5 10 6 11 7 8 9 ...

Page 13: ...ior Gauge Kit 1 100g Weights 2 Step Disk 3 2g Weights 4 Load Nose 5 Anvil Adapters 6 Non Compliant Beam 7 Crack Sealant CS Non Compliant Beam 8 Confidence Beam Figure C 5 Gauge Kit 1 2 3 4 5 6 7 8 5 1 Spinner 2 RTD 3 Drain Figure C 4 Tank Interior 1 3 2 ...

Page 14: ... deflection and temperature data received from the unit When tests are not being performed the software permits access to test information including graphs raw data tables and test analysis The BBR3 is a fully integrated modularized system consisting of the following Major Components Base unit Load frame assembly BBR3 software Mechanical refrigeration unit Accessory Items Specimen Molds 5 molds Co...

Page 15: ... rating Air Pressure 60 PSI inlet pressure 414 kpa Class 3 Quality max particle of 5um Environmental Conditions The BBR3 is designed for use in an industry laboratory setting in an indoor and dry environment The base unit should be placed on a clean stable work surface with the connecting mechanical refrigeration unit nearby The mechanical refrigeration unit should be placed 6 inches above the flo...

Page 16: ...men These specimen supports have a 3 mm contact radius and are fixed 102 mm apart from each other They are designed to align samples that are approximately 127 00 mm x 12 70 mm x 6 35 mm Resting on each of the anvil s specimen supports are two anvil adapters see Figure C 7 During crack sealant testing these anvil adapters need to be removed by lifting STRAIGHT UP on the adapter and pulling it off ...

Page 17: ...nment with touchscreen access The software provides pull down menus button selections and data entry text boxes for easy updates and access to information The base unit contains an integrated personal computer designed to efficiently run the software During operation the software collects and records the data from the various sensors on the load frame During tests the software controls specimen lo...

Page 18: ...calibrating the load cell and when performing the compliance test The Crack Sealant Non Compliant Beam is the thicker of the two beams and is used only for Crack Sealant tests Step Disk The step disk is used during LVDT standardization and verifi cation It has five positions containing high precision balls The calibration positions include a zero gaging and four subse quent steps which decrease in...

Page 19: ... at 15 to 20 psi Verify the settings if necessary 3 DC POWER SUPPLY This supplies DC Power necessary to operate the computer touch screen display and other operating systems of the BBR3 A Green LED on the module indicates that the power output from the power supply is in the desired range 4 AMP CIRCUIT BREAKER Provides over current protection for the electronics of the BBR3 The circuit breaker han...

Page 20: ...ose signals to the Solid State Relays to operate the stirrer motor bath heater and load control solenoid valve 2 LOAD CELL SIGNAL CONDITIONER MODULE Receives and conditions the output of the Load Cell and supplies an amplified voltage output to the Data Acquisition Box 3 LVDT SIGNAL CONDITIONER MODULE Receives and conditions the output of the LVDT Displacement Sensor and supplies an amplified volt...

Page 21: ...ovide a zero or preload on the specimen 3 LOAD REGULATOR Permits the operator to adjust the air pressure to provide a test load on the specimen 4 TOUCH SCREEN Operator interface that allows for all setup and running of tests all machine parameter entries and standardization 5 USB PORT Provides access for data downloads and software updates Users may also attach a mouse and or keyboard if desired F...

Page 22: ...move the base unit and the refrigeration unit from the box and place them on a sturdy work surface WARNING Position the BBR3 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 ...

Page 23: ...e D 2 Unscrew the lower portion of the load shroud from the upper portion Figure D 3 Set the lower portion aside 3 Retrieve the load nose from the BBR3 gauge kit Place the load nose in the upper portion of the load shroud 4 Position the shroud and load nose at the base of the load frame Lift the load nose and carefully screw it on to the threaded stud in the bottom of the load cell until it is fin...

Page 24: ...ng and excessive torque DO NOT place Load Frame on its side once the Load Nose is in place Improper handling will result in irreversible Load Cell damage 6 To re attach the lower portion of the load shroud place the lower portion of the shroud on a flat surface CAREFULLY lift the load frame and position it so that the load nose is directly above the lower portion of the shroud Figure D 7 Lift the ...

Page 25: ...ose Air bearing hose Four color coded electrical cables integral to base Refrigeration control cable Main electrical power cable s 7 9 8 6 4 5 6 3 2 1 1 LVDT hook up 2 Load Cell hook up 3 Light hook up 4 Network Ethernet 5 USB Connection 6 Chiller Communication Port 7 Back of Chiller Unit 8 AC Power Plug 9 Compressed Air 10 Air Bearing Lines 10 Figure D 10 Connecting the BBR3 ...

Page 26: ...he surrounding environment 2 Connect the chiller RTD cable from the rear of the base unit 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 the Chiller Communication Cable between the Chiller Communication Port on the rear of the BBR3 Chassis and the RS 485 Port on the rear of the Chiller 5 Plug the...

Page 27: ...controls in an OFF position Reconnect power sources and restart the system CAUTION Be aware of placement of all cables and hoses in relation to the surrounding area Surrounding area should provide no hazards resulting in involuntary disconnection of cables and hoses Disconnection will result in inaccurate test results ...

Page 28: ...information 1 Fill the BBR3 with 1 5 gallons 5 5 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 BBR3 1 Press the power button on the rear of the BBR3 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 rear o...

Page 29: ...ler PID s Set up Read Weight A Read Temperature 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 Privil...

Page 30: ...her BBR3 software screen press the Main Menu button in the upper right corner E 4 Editing Users and Permissions When you press the Edit Users button on the Main Screen the dialog shown in Figure E 3 is displayed The Edit Users button will not be shown on the main menu unless the currently logged in user has permission to edit users on the system Operator Name Field Allows you to select a user to e...

Page 31: ...Button Saves the current user This should be done any time you make any changes you want to keep If you exit this screen without pressing SAVE you will lose any changes you have made Copy Button Makes a copy of a selected user under a new name This is useful if you need to make a new user with similar permissions as a current user Press Save when complete New Button Creates a new user using defaul...

Page 32: ...tus 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 the component is ready for testing Prior to standardization verify that the information entered into the necessary fields matches the information provided on the Certificate of Conformance that ...

Page 33: ...g Leave the thermometer in place for a minimum of two minutes and note the temperature reading to the nearest tenth of a degree within 0 1 C h Record this temperature in the field and select the Finish button 2 Standardizing the Load Load Cell a Select the Load button from the Standardization Screen b With the load frame in the bath load the non compliant beam into test position c Using the zero r...

Page 34: ... g Place a 100g weight on the weight pan wait five seconds and press Next h Manually raise the load nose by lifting the weight pan and gently rotate the step disk to the A position Gently lower the load nose until the pin rests lightly on the A step Wait five seconds and press Next i Manually raise the load nose again and gently rotate the step disk to the B position Gently lower the load nose unt...

Page 35: ... it on top of weight C Wait five seconds and select the Next button m Select Finish to record the calibration contestant NOTE The calibration constant should be less than or equal to 5μm N and repeatable within 10 from one standardization to another If it is not contact Applied Test Systems at 1 724 283 1212 E 6 Verification Process Verification of most BBR3 components will need to occur every 24 ...

Page 36: ...ange press Standardization Required and then press Next 5 Verify the LVDT a With the loading frame mounted in the bath at the test temperature remove all beams from the supports b Place the step gauge disk in any position and apply the provided 100g mass to the weight pan c Compare the measured displacement to the known gauge disk location This information can be found on the Certification of Conf...

Page 37: ...ecord e Apply the second 100g mass to the weight pan and press Record f The modulus reported should be within 10 of the modulus of the Confidence Beam as listed on the verification conformance form g If the measurement is within 10 press OK then the Verification Complete button h If the measurement is more than 10 press OK and then the Standardization Required button i Press the Next button to mov...

Page 38: ...ve the carbon paper and measure the distance from the center of the carbon imprint to each sample support using vernier calipers h If the difference between the two measurements is 1 0mm or less press the Verification button followed by the Finish button i If the difference between the two measurements is more than 1 0mm press Standardization Required and contact the Applied Test Systems Service D...

Page 39: ...you want If you exit this screen without pressing SAVE you will lose any changes you have made Creating a New Test The New button will create a new test using default test specification values Remember to press Save once you have created a new test even if you have not changed anything so that it is saved Deleting a Test The DELETE button will delete a saved test Once pressed a pop up will require...

Page 40: ...n the report that this test will generate Standard or Data Report The Standard Report check box lets you select a standard report or a data report The data report is most often used to chart in Excel or another similar program to generate additional calculations or graphs Deflection Plot and Load Plot DEFLECTION PLOT and LOAD PLOT set the graph limits when a test is running They are stored with th...

Page 41: ...p your test When you press the TEST button the run screen shown in Figure E 14 will display The BBR3 s system status lights located at the bottom right of the screen indicate whether or not a component is ready for testing Red the component requires standardization Yellow the component requires verification Green the component is ready for testing The SPECIMEN NAME is any text you wish to make it ...

Page 42: ...hree or four seconds between loading and unloading Repeat this at least four times allowing three or four seconds between each time Load Setup 1 Load the non compliant beam on the specimen supports 2 The load control switch is located on the Run Test main screen to the right of the BBR3 s system status lights Using the touchscreen move the switch to the zero position Figure E 15 3 Adjust the zero ...

Page 43: ...Gently lower the loading shaft so it contacts the specimen Make sure the load display is 35 10 mN If it is not adjust the zero regulator 3 Press the START TEST button 4 The horizontal graph allows the operator to monitor test progress 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 automaticall...

Page 44: ...y generate a report and display it View Test View Test is used to look at test data for tests that have already been run and saved When you press the VIEW TEST button the screen shown in Figure E 18 will display The TEST DATA sections allows users to select different test runs already saved Press the down arrow button to show a list Once a data set has been selected the data is displayed in the gr...

Page 45: ...nu unless the currently logged in user has permission for this screen Analog Inputs AI1 AI2 and AI3 Raw voltages into the system You should be able to use a voltmeter to test the voltage at the input pin and it should match what is shown here AI1 is deflection AI2 is load and AI3 is not used on a mechanical chiller system Analog Outputs AO1 and AO2 Raw voltages out of the system Use a voltmeter to...

Page 46: ...eater Cool PID Values If you have mechanical cooling you will see the Cool PID values which set the PID information for each range of the mechanical chiller WARNING These values have been set at the factory by Applied Test Systems and SHOULD NOT BE CHANGED without consulting with the Applied Test Systems Service Department The Cool PID values are as follows T sets the temperature for that set of v...

Page 47: ...ectrical shock use extreme 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 t...

Page 48: ...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 49: ...nect the provided hose to the drain in the underside of the bath Place the other end of the hose in a bucket large enough to hold the amount of fluid within the unit 3 Carefully remove the load frame Do not place the load frame on its side when the load cell is in place as it can be easily damaged 4 Use personal protective gear PPG to reach into the room temperature bath and pull up on the lever a...

Page 50: ...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 51: ...WN BY DATE ENGINEER JOB NO DWG NO CAD DWG FILE REV SHEET NO 12 05 2016 U Eng Drawing Files 2 xxxx 2 91xx 2 9131 R0 SH1 dwg 1615464 ELECTRICAL WIRING DIAGRAM MAIN POWER DAQ POWER ENTRY MODULE LOAD FRAME SP SCIENTIFIC FC50 CHILLER BRN_ 16AWG BLU_ 16AWG RED_ 16AWG BLK_ 16AWG RED_ 16AWG GRY_ 20AWG GRY_ 20AWG BLU_ 20AWG BLU_ 20AWG BLU_ 20AWG GRY_ 20AWG WHT_RED_ 22AWG WHT_BLK_ 22AWG RED_ 20AWG BLK_ 20AW...

Page 52: ...CKED BY DRAWN BY DATE ENGINEER JOB NO DWG NO CAD DWG FILE REV SHEET NO 12 05 2016 U Eng Drawing Files 2 xxxx 2 91xx 2 9131 R0 SH2 dwg 1615464 ELECTRICAL WIRING DIAGRAM 24VDC RED_ 20AWG RED_ 20AWG RED_ 20AWG RED_ 20AWG RED_ 20AWG RED_ 22AWG RED_ 20AWG RED_ 20AWG RED_ 22AWG BLK_ 20AWG RED_ 16AWG RED_ 16AWG BLK_ 20AWG BLK_ 20AWG 38 15 47 50 17 19 20 21 22 51 27 8 7 45 35 36 36 30 46 33 34 34 17 19 20...

Page 53: ...ve 98 37 EEC on the Approximation of the Laws the member States Relating to Machinery ECM Council Directive 2014 30 EU EN61326 1 Electromagnetic Compatibility Council Directive 2006 95 EC EN 61010 1 2010 General Electrical L ow Voltage Equipment The technical Construction File required by these directives is maintained at corporate headquarters of Applied Test Systems 154 East Brook Lane Butler Pe...

Page 54: ... D 6 Upper portion of shroud attached to Load Cell 19 Figure D 7 Attaching lower portion of Load Shroud 19 Figure D 8 Attaching lower portion of Load Shroud 19 Figure D 9 Attached Load Nose with Shroud 19 Figure D 10 Connecting the BBR3 20 Figure D 11 Load Frame Hook Ups 21 Figure D 12 Chiller Communication Cable in RS 485 Port 21 Figure D 13 Chiller Communication Cable in BBR3 Chiller Communicati...

Page 55: ...est main screen 36 Figure E 15 Load Control Switch in the Zero Position 37 Figure E 16 Zero Regulator Load Regulator 37 Figure E 17 BBR3 anvil adapters 38 Figure E 18 View Test main software screen 39 Figure E 19 Diagnostics main software screen 40 Figure F 1 LVDT Shaft 43 Figure G 1 BBR3 plug 44 ...

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