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Summary of Contents for ATS BBR3S
- Page 1 INSTRUCTION MANUAL BBR3S Bending Beam Rheometer 3S 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 Applied Test Systems (ATS) 154 East Brook Lane Butler, PA 16002 Telephone: +1.724.283.1212 For assistance with set-up or operation, contact the ATS Service Department. Please have this manual and product serial number readily available when you call. © Copyright Applied Test Systems 2023...
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Page 3: Table Of Contents
Table Of Contents Introduction ..........................6 A.1 – Unpacking ........................6 A.2 – Standard Users and Passwords ..................6 A.3 – Warranty Information ..................... 6 A.4 – After Sale Support ......................7 Safety ............................8 B.1 – For Owners, Operators, and Maintenance ..............8 B.2 –... - Page 4 D.3 Assembling the Load Nose .....................25 D.4 Connecting Equipment ....................28 Operation ..........................30 E.1 Filling the Bath ........................30 E.2 Power Up the BBR3S ......................30 E.3 Stirrer Motor ........................31 E.4 Overview of Touchscreen and Menus................31 E.5 Editing Users and Permissions ..................33 Operator Name Field ......................34 Password Field ........................34...
- Page 5 F.1 Preface ..........................55 F.2 Load Shaft Stuck or Stalled During Verification or Standardization ........55 Maintenance ..........................57 G.1 Cleaning the BBR3S .......................57 G.2 Changing the BBR3S Fluid Bath ..................57 APPENDIX A: Warranty ......................58 To obtain warranty service: ....................58 APPENDIX B: Declaration of Conformity...................59...
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Page 6: Introduction
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 calendar year from the date of shipment. Please see APPENDIX A of this manual for complete details on the... -
Page 7: After Sale Support
A sample data tag is illustrated below, and can be completed with the unit’s information for easy reference. Please be prepared to give a complete description of the problem to the ATS Service Department. i Figure A.4.1 - ATS Sample Data Tag... -
Page 8: Safety
Read and understand all instructions and safety precautions listed in this manual before installing or operating your unit. If you have any questions regarding the operation of the unit or instructions in this manual, contact the ATS Service Department at +1.724.283.1212. - Page 9 Handle the BBR3S carefully. Avoid dropping and jarring the BBR3S. Damage to the machine may result if dropping and jarring occurs. Dangerous high voltages present. Do not attempt to open the enclosure or gain access to areas where you are not instructed to do so. Refer any possible servicing to qualified service personnel only.
- Page 10 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 BBR3S. 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.
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Page 11: System Overview
System Overview C.1 Equipment Parts Front of Unit ii Figure C.1.1 - Front of BBR3S Unit 1. LOAD Regulator 5. Touch Screen Computer 2. Power Indicator 6. USB Port 3. ZERO Regulator 7. Leveling Feet 4. Load Frame 8. Chiller... -
Page 12: Back Of Unit
Back of Unit iii Figure C.1.2 - Back of BBR3S Unit 1. Network / Ethernet 5. Air Bearing Connections 2. USB Connection 6. Air Connector 3. Load Frame Electrical 7. Unit Power Cables 4. Chiller RTD Cable... -
Page 13: Load Frame
Load Frame iv Figure C.1.3 - Load Frame 1. LVDT Shaft 7. LVDT Housing 2. Weight Pan 8. LVDT 3. Gaging Disk 9. Air Bearing 4. Bearing Air Supply / Control 10. Load Cell 5. Lamps 11. Load Nose 6. Shroud... -
Page 14: Tank Interior
Tank Interior v Figure C.1.4 - Tank 1. RTD 2. Magnetic Stirrer 3. Drain Gauge Kit vi Figure C.1.6 - Gauge Kit (2) vii Figure C.1.5 - Gauge Kit 1. 2g Weights 6. Anvil Adapters 2. Load Nose 7. Non-Compliant Beam 3. -
Page 15: 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 BBR3S’s design does not allow for it to perform any additional functions other than those specified in this manual. -
Page 16: Product Specifications
Product Specifications Load Frame Construction Integral stainless steel, frictionless construction Loading Shaft Point In-line stainless steel with blunt point Variable test range from 0 to 4,500 mN (459 g) standard. Test Load System maintains required test load within +/- mN (0.5 g) throughout test cycle. -
Page 17: Environmental Conditions
Environmental Conditions The BBR3S 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 18: Specimen Support
pan for easy calibration of the load cell and the Linear Variable Differential Transformer (LVDT). Two low weight pan for easy calibration of the load cell and the Linear Variable Differential Transformer (LVDT). Two low voltage, sealed lamps are mounted in the base of the load frame in order to illuminate the specimen in the fluid bath. -
Page 19: Air Bearing
The RTD is a platinum device that measures the cooling fluid bath temperature. It is connected to the chiller and relays the information to the computer control system software. It is mounted in the BBR3S bath directly under the test specimen supports. Computer Control System Software The computer control system software provides user control of the BBR3S system in a Windows®... -
Page 20: Accessories
Four 100 gram and two 2 gram load cell calibration weights are supplied with the BBR3S. 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 21: Controls
Controls Internal Controls Five Internal Controls are located inside the LEFT panel of the BBR3S base unit, when viewed from the front (Figure C.9). These controls are factory set. x Figure C.1.10 - Internal Controls 1. LINE PRESSURE REGULATOR – The line pressure is positioned on the LEFT inside the panel. -
Page 22: 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 BBR3S base unit as viewed from the front of the unit (see Figure C.1.11). xi Figure C.1.11 - Data Instruments 1. -
Page 23: Basic Unit Controls
supplies an amplified voltage output to the Data Acquisition Box. 4. (4.-6.) DC VOLT SOLID STATE RELAYS – Used to control the functions of the Bath Heater (4), Stirrer Motor (5), and Load Control Solenoid Valve (6). These modules are identical and interchangeable. -
Page 24: Recommended Tools
* Please refer to www.atspa.com – Instruction Manuals – Asphalt / Bitumen Testing; for BBR Training video. * To unpack and prepare the BBR3S for operation, complete the following steps. CAUTION: Use care when moving the base unit. The refrigeration unit is attached, and the refrigeration hose may be damaged if it is twisted or pulled, especially when the unit is cold. -
Page 25: Assembling The Load Nose
WARNING: Position the BBR3S 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. - Page 26 D.2). Set the lower portion aside. xiv Figure D.3.2 - Upper and Lower Portion of the Load Shroud 3. Retrieve the load nose from the BBR3S gauge kit. Place the load nose in the upper portion of the load shroud.
- Page 27 5. Once the load nose is secured, lift the upper portion of the shroud around it. Use the back two screws to guide it into place before tightening them and carefully screwing in the front two screws. See Figure D.5. xvii Figure D.3.5 - Upper Portion of Shroud CAUTION: Do not over tighten the loading shaft on the load cell, or the load cell may become damaged.
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Page 28: Connecting Equipment
D.4 Connecting Equipment 1. The following hoses and cables are shipped with the BBR3S. Use them for connecting the BBR3S equipment: • Two air hoses • Three color-coded electrical cables (integral to base) • RTD cable (integral to base) • Refrigeration Control Cable •... - Page 29 Refer to the data tag on the BBR3S base unit. 6. Connect printer if desired using the USB port located in the rear of the BBR3S base. NOTE: If at any point power is lost, disconnect all power sources and place all controls in an OFF position.
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Page 30: Operation
Please refer to individual specifications for more information. 1. The BBR3S with 1.5 gallons (5.5 liters) of fluid so the liquid is approximately 1 ½ to 2 inches from the top. Please refer to individual test specifications for fluid type. -
Page 31: Stirrer Motor
4. The BBR3S has loaded, a dialog window will appear on the screen. Press DISMISS. 5. Use the touchscreen to press the BBR3S software desktop icon to launch the program. -
Page 33: Editing Users And Permissions
NOTE: The “Exit” button on the bottom right of the screen will exit the BBR3S program and return to Windows. To return to the Main Menu screen from any other BBR3S software screen, press the “Main Menu” button in the upper right corner. -
Page 34: Operator Name Field
Operator Name Field Allows you to select a user to edit. Use the down arrow button to drop down a list of users saved on the system. Password Field Contains the current password for the selected user. If this field is left blank no password will be required to log in as this user, but this user will not be able to add a password in the future. -
Page 35: Standardization Process
deleted from the system. To prevent software lockout, the system will not allow you to delete the Default user. E.6 Standardization Process *Please refer to www.atspa.com for further video explaining the Standardization & Verification process (To access video, Downloads – Instruction Manuals –... - Page 36 After you set your temperature, press “Main Menu” to return to the main BBR3S screen. From the Main Screen, press the ‘Standardization” button to enter the Standardization Screen (Figure E.6.2). xxvi Figure E.6.2 - Standardization Screen NOTE: The standardization button will not be shown on the main menu unless the currently logged in user has the necessary permission to perform standardization.
- Page 37 EXACTLY AS DESCRIBED. Failure to perform all steps of the standardization procedure may result in incorrect or erratic operation of the BBR3S. 1. Standardizing the Temperature (RTD) NOTE: Before standardization, verify that the bath is set at your desired testing temperature.
- Page 38 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 BBR3S. Locater Pin Weight Pan xxvii Figure E.6.3 - Step Disk Positioned Under Locater Pin c.
- Page 39 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 “B” position. Gently lower the load nose until the pin rests lightly on the “A”...
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Page 40: Verification Process
Verification of most BBR3S components will need to occur every 24 hours – this is usually done at the beginning of a day of testing. You will need a BBR3S gauge kit and a calibrated thermometer (see RTD) to perform a verification. - Page 41 2. Verify the information entered in the Confidence Beam Serial # section matches the information on the certification of conformance form that was shipped with the BBR3S. Make corrections if necessary. 3. Press the verification button to begin the verification sequence.
- Page 42 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 Conformance form, as well as on the main Verification screen.
- Page 43 xxx Figure E.7.3 - System Verification a. Ensure the load frame is in the bath. b. Place Confidence Beam on the sample supports. c. Apply 100g mass to the weight pan. d. Press “Record” e. Apply the second 100g to the weight pan and press “Record”. f.
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Page 44: Test Setup
Service Department at +1.724.283.1212. E.8 Test Setup Test setup is used to define a BBR3S 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 45: Test Name
The name of the currently selected test specification. The only limit to the number of tests that can be stored is the size of the disk drive in the BBR3S. Since a test specification takes about 1K of storage space, it would be nearly impossible to run out of space on the drive. -
Page 46: Deleting A Test
Deleting a Test The “Delete” button will delete a saved test. Once pressed, a pop up will require you to verify that you want to delete the test. If you answer YES, the test cannot be recovered. Adding Report Images The “Report Images”... - Page 47 xxxiii Figure E.8.3 - Standard Report xxxiv Figure E.8.4 - Data Report...
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Page 48: Deflection Plot And Load Plot
Deflection Plot and Load Plot DEFLECTION PLOT and LOAD PLOT set the graph limits when a test is running. They are stored with the test specification and are used each time that test specification is run. 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. -
Page 49: Load Setup
BEFORE you run a test for them to be included on the report. If the BBR3S 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. - Page 50 xxxvi Figure E.9.2 - Load Control Switch in the Zero Position 3. Adjust the zero regulator (see Figure E.16) until the loading shaft contacts the non-compliant beam with a minimal force of 35 ± 10 mN. xxxvii Figure E.9.3 - Zero Regulator &...
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Page 51: 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 BBR3S, you can print the test summary report from this screen. To do so, select file and then print. -
Page 52: View Test
WARNING: Load frame should be removed from the bath and allowed to warm to room temperature before removing the anvil adapters. 2. Raise the loading shaft. Remove the non-compliant beam and place the specimen in the test position. Gently lower the loading shaft, so it contacts the specimen. -
Page 53: Diagnostics
xxxix Figure E.9.5 - View Test Screen E.10 Diagnostics When you press the ‘Diagnostics” button the screen in Figure E.19 will be shown. xl Figure E.10.1 - Diagnostics Screen You should not have permission for this screen unless you are experienced with the machine and what it does. -
Page 54: Analog Inputs Ai 1, Ai 2, And Ai 3
These are 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 BBR3S does not currently use any of the digital inputs. -
Page 55: Troubleshooting
F.1 Preface Listed within this section are the most common troubleshooting errors that operators may encounter when using the BBR3S. 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 56 LVDT can be viewed from above. See Figure F.1. 2. If the LVDT shaft appears to be centered in the LVDT, re-secure the cover and contact ATS for assistance. View LVDT Shine Light xli Figure F.2.1 - LVDT Shaft 3.
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Page 57: Maintenance
4. Use Personal Protective Gear (PPG) to reach into the room temperature bath and pull up on the lever attached to the BBR3S plug. Once the plug is loose enough, pull it out. -
Page 58: Appendix A: Warranty
APPENDIX A: Warranty Your Applied Test Systems product has been manufactured and inspected by experienced craftsmen. Applied Test Systems warrants, for the original purchaser, each product to be free from defects in material and workmanship for a period of thirteen (13) months from date of shipment or twelve (12) months from date of installation –... -
Page 59: Appendix B: Declaration Of Conformity
APPENDIX B: Declaration of Conformity... -
Page 60: Appendix C: Image Glossary
APPENDIX C: Image Glossary...
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