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ATS BBR3 Instruction Manual

Bending beam rheometer 3
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INSTRUCTION MANUAL
BBR3
Bending Beam Rheometer 3
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
MAN - BBR3 - REV: Original

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  • Page 1 INSTRUCTION MANUAL BBR3 Bending Beam Rheometer 3 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 MAN - BBR3 - REV: Original...
  • Page 2 Information in this document is subject to change without 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: Table Of Contents

    Load Cell ............................15 Resistance Temperature Detector (RTD) ................... 15 Computer Control System Software ....................15 Mechanical Refrigeration Unit (Chiller) ....................16 Accessories ............................16 Specimen Molds .......................... 16 Confidence Beam ........................16 Non-Compliant Beams ......................... 17 MAN - BBR3 - REV: Original...
  • Page 4 D.4 Connecting Equipment ..........................25 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 ..........................
  • Page 5 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 ...................

  • Page 6: Introduction

    Retain all cartons and packing materials until the unit is operated and found to be in good condition. If damage has occurred during shipping, notify Applied Test Systems (ATS) and the carrier immediately. If it is necessary to file a damage claim, retain the packing materials for inspection by the carrier.
  • Page 7 Figure A.1 - ATS Sample Data Tag MAN - BBR3 - REV: Original | A. Introduction...

  • Page 8: Safety

    B. Safety B.1 For Owners, Operators, and Maintenance All ATS equipment is designed to be operated with the highest level of safety. This manual uses note, caution, and warning symbols throughout to draw your attention to important operational and safety information.
  • Page 9 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 damaged.

  • Page 10: System Overview

    Figure C.1 - Front of BBR3 Unit 1. Load Frame 6. Leveling Feet 2. Chiller 7. ZERO Regulator 3. USB Port 8. LOAD Regulator 4. Touch Screen Monitor 5. Power Indicator MAN - BBR3 - REV: Original | C. System Overview...

  • Page 11: Back Of Unit

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

  • Page 12: Load Frame

    1. LVDT Shaft 8. LVDT 2. Weight Pan 9. Air Bearing 3. Gaging Disk 10. Load Cell 4. Bearing Air Supply/Control 11. Load Nose 5. Lamps 6. Shroud 7. LVDT Housing MAN - BBR3 - REV: Original | C. System Overview...

  • Page 13: Tank Interior

    Figure C.5 - Gauge Kit 1. 100g Weights 5. Anvil Adapters 2. Step Disk 6. Non-Compliant Beam 3. 2g Weights 7. Crack Sealant (CS) Non-Compliant Beam 4. Load Nose 8. Confidence Beam MAN - BBR3 - REV: Original | C. System Overview...

  • Page 14: General Product Description

    Strategic Highway Research Program (SHRP) Test Method B-002, AASHTO Designation T313, AASHTO TP 87, BS EN14771, and ASTM D 6648 specifications. The BBR3’s design does not allow for it to perform any additional functions other than the intended functions specified in this manual.

  • Page 15: Environmental Conditions

    60 PSI inlet pressure (414 kpa) @ Class 3 Quality max particle of 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 floor and in an area that will not constitute a tripping hazard.

  • Page 16: Specimen Support

    Air Bearing The BBR3 incorporates an air bearing to provide frictionless loading performance. The air bearing control system requires a constant 60 – 65 psi (414 – 448 kPa) minimum clean and dry air supply, @ Class 3 Quality max particle of 5um.

  • Page 17: Linear Variable Differential Transformer (Lvdt)

    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.

  • Page 18: Accessories

    Load Cell Calibration Weights Four 100 gram and two 2 gram load cell calibration weights are supplied with the BBR3. These weights are placed on the load frame weight pan during load cell verification. The weights are also used to calibrate the load cell and ensure system compliance.

  • Page 19: Controls

    Figure C.9 - Internal Controls Internal Controls Five Internal Controls are located inside the LEFT panel of the BBR3 base unit, when viewed from the front (Figure C.9). These controls are factory set. 1. LINE PRESSURE REGULATOR - The line pressure regulator is positioned on the LEFT inside the panel. This pressure is set at 60 psi.

  • Page 20: Data Instruments

    The Data Instruments box and Signal Conditioner Modules, along with the 3 Solid State Relays, are all located on the RIGHT side of the BBR3 base unit as viewed from the front (see Figure C.10). 1. DATA ACQUISITION BOX - Digitizes the amplified voltages from the Load Cell and Signal Conditioner Modules and sends that information to the PC.

  • Page 21: Basic Unit Controls

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

  • Page 22: Installation

    1. Remove 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.

  • Page 23: Assembling The Load Nose

    Load Shroud 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 finger tight.
  • Page 24 (Figure D.7). Lift the lower portion of the shroud up and gently screw it in to the upper portion (Figure D.8). Figure D.8 - Attaching lower Figure D.9 - Attached Load Nose with Figure D.7 - Attaching lower portion of Load Shroud Shroud portion of Load Shroud MAN - BBR3 - REV: Original | D. Installation...

  • Page 25: Connecting Equipment

    D.4 Connecting Equipment The following hoses and cables are shipped with the BBR3. Use them for connecting the BBR3 equipment: • Zero/Load hose • Air bearing hose • Four color-coded electrical cables (integral to base) • Refrigeration control cable •...
  • Page 26 GRAY > Light WARNING: The cable for the lights should be connected to the load frame at all times while the BBR3 is in use. The electrical grounding for the load frame to the BBR3 chassis is done through the light cable.
  • Page 27 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. MAN - BBR3 - REV: Original | D. Installation...

  • Page 28: Operation

    Refer to individual specifications for more information. 1. Fill the BBR3 with 1.5 gallons (5.5 Liters), so the liquid is approximately 1 ½ to 2 inches from the top. Refer to individual test specifications for fluid type.
  • Page 29 Figure E.1 - BBR3 Software Screen map MAN - BBR3 - REV: Original | E. Operation...

  • Page 30: Editing Users And Permissions

    NOTE: The “Exit” button on the bottom right of the screen will exit the BBR3 program and return to Windows. To return to the Main Menu screen from any other BBR3 software screen, press the “Main Menu”...

  • Page 31: Standardization Process

    Before standardization, verify that the bath is set at your desired testing temperature. To do this, press the “Setup” button on the Main Screen. Enter your desired testing temperature in the “Temperature” field in the Bath section of MAN - BBR3 - REV: Original | E. Operation...
  • Page 32 Setup screen (Figure E.4). Figure E.4 - “Bath Temperature” Field on Setup Screen After you set your temperature, press “Main Menu” to return to the main BBR3 screen. From the Main Screen press the “Standardization” button to enter the Standardization Screen (Figure E.5).
  • Page 33 Select weight C from the gauge kit and place it on top of weight B. Wait five seconds and select the “Next” button. i. Select weight D from the gauge kit and place it on top of weight C. Wait five seconds and select the “Next” button. MAN - BBR3 - REV: Original | E. Operation...
  • Page 34 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 BBR3. c. Adjust the zero regulator to raise the load nose to its highest position.

  • Page 35: Verification Process

    E.6 Verification Process Verification of most BBR3 components will need to occur every 24 hours - this is usually done at the beginning of a day of testing. You will need a BBR3 gauge kit and a calibrated thermometer (see RTD) to perform a verification.
  • Page 36 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. MAN - BBR3 - REV: Original | E. Operation...
  • Page 37 If the temperatures differ more than ±0.1⁰C, press the “Standardization Required” button and then press “Next”. e. If the observed temperatures are within ±0.1⁰C press the “Verification Complete” button and then press “Next”. 9. Verifying the Load Shaft Alignment MAN - BBR3 - REV: Original | E. Operation...

  • Page 38: Test Setup

    Applied Test Systems Service Department at +1-724-283-1212. E.7 Test Setup Test setup is used to define a BBR3 test specification as well as the type of report it will generate. When you press the SETUP button the screen shown in Figure E.10 will display.

  • Page 39: Saving Test Parameters

    The REPORT IMAGES button allows you to select images that are printed on the report that this test generates. When pressed it will display the dialog seen in Figure E.11, which will allow you to select each image. Figure E.11 - Add images to test dialog MAN - BBR3 - REV: Original | E. Operation...

  • Page 40: Adding A Test Company

    Bath Values The BATH values set the current Temperature and Stir Speed and are saved with the test specification to set the values when it is run. MAN - BBR3 - REV: Original | E. Operation...

  • Page 41: Specimen Values

    When you press the TEST button the run screen shown in Figure E.14 will display. Figure E.14 - Run Test main screen The BBR3’s system status lights, located at the bottom right of the screen, indicate whether or not a component is ready for testing.

  • Page 42: 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).

  • Page 43: Start Test

    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 BBR3, you can print the test summary report from this screen. To do so, select file and then print.

  • Page 44: View Test

    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. MAN - BBR3 - REV: Original | E. Operation...

  • Page 45: Diagnostics

    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. The BBR3 does not currently use any of the digital inputs. MAN - BBR3 - REV: Original | E. Operation...

  • Page 46: Digital Outputs 1 And 2

    High speed pulse outputs. Use a scope to test the output pin and verify that it matches the frequency and duty cycle entered in the diagnostics screen. DO3 is not used in the current BBR3, DO4 is used to control the bath heater.

  • Page 47: Troubleshooting

    Listed within this section are the most common troubleshooting errors that operators may encounter when using the BBR3. Users may follow the steps provided to work through these basic errors. Any additional issues or system errors should be brought to the attention of the Applied Test Systems Service Department immediately by calling +1-724-283-1212 or emailing service@atspa.com.
  • Page 48 Figure F.1 - LVDT Shaft 2. If the LVDT shaft appears to be centered in the LVDT, re-secure the cover and contact ATS for assistance. 3. If you determine that the shaft is misaligned, attempt to center it by performing the steps below.

  • Page 49: Maintenance

    G. Maintenance G.1 Cleaning the BBR3 1. When cleaning the surface of the BBR3, first disconnect all power sources and place all controls in an OFF position. 2. Use a very mild cleaning agent to wipe down the outside of the unit.

  • Page 50: Appendix A: Warranty

    The aforementioned provisions do not extend the original warranty period of any article that has been either repaired or replaced by Applied Test Systems. Applied Test Systems reserves the right to change published specifications. MAN - BBR3 - REV: Original | Appendix A: Warranty...

  • Page 51: Appendix B: Wiring Diagram

    Appendix B: Wiring Diagram BRN_#16AWG BRN_#16AWG BRN_#16AWG GRN_YEL_#16AWG BLU_#16AWG BLU_#16AWG BLU_#16AWG U:\Eng Drawing Files\2-xxxx\2-91xx\2-9131-R0-SH1.dwg CAD DWG FILE DATE REVISION MAN - BBR3 - REV: Original | Appendix B: Wiring Diagrams...
  • Page 52 U:\Eng Drawing Files\2-xxxx\2-91xx\2-9131-R0-SH2.dwg CAD DWG FILE DATE REVISION MAN - BBR3 - REV: Original | Appendix B: Wiring Diagrams...

  • Page 53: Appendix C: Declaration Of Conformity

    154 East Brook Lane Butler, PA 16002 Office: (724) 283-1212 Cell: (724) 996-0145 Fax (724) 283-6570 rcarroll@atspa.com www.atspa.com 154 East Brook Lane � Butler, PA 16002 USA � +1-724-283-1212 www.atspa.com MAN - BBR3 - REV: Original | Appendix C: Declaration of Conformity...

  • Page 54: Appendix D: Image Glossary

    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 Communication Port..........21 Figure E.1 - BBR3 Software Screen map .........................24 Figure E.2 - Main Menu screen ..........................25 Figure E.3 - Edit Users dialog ...........................25...
  • Page 55 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 MAN - BBR3 - REV: Original | Appendix D: Image Glossary...

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