• Author / Uploaded
• Navi Morales

Citation preview

System Overview Safety Setup & Installation Operation Maintenance

Bending Beam Rheometer

ATS 62000 12/2004 Rev. 2.1

FOURTH EDITION, DECEMBER 2004 Information in this document is subject to change without notice and does not represent a commitment on the part of Applied Test Systems, Inc. The software described in this document is furnished under a license agreement or nondisclosure agreement. The software may be used or copied only in accordance with the terms of the agreement. It is against the law to copy the software on any medium except as specifically allowed in the license or nondisclosure agreement. Comments or suggestions pertaining to the contents of this manual can be sent to the address below: Editor/Technical Manuals Applied Test Systems, Inc. 348 New Castle Road Butler, PA 16001-2498. Information you supply may be used by ATS without obligation. Necessary changes will be made in future editions of this manual. © Copyright Applied Test Systems 2004 Windows and Excel are registered trademarks of the Microsoft Corporation For assistance with set-up or operation, contact ATS Field Services. Please have this manual and product serial number available when you call. Telephone: (724) 283-1212 – FAX (724) 283-6570

ATS 62000 12/2004 Rev. 2.1

ATS 62000 12/2004 BENDING BEAM RHEOMETER Table of Contents Section SECTION 1. A. B. C. D. E. F. G. H. I. J. K.

SET-UP AND INSTALLATION .................................................................................................24

OPERATION ................................................................................................................................32

SUMMARY OF BBR OPERATING PROCEDURES ...............................................................................................32 FILL THE BBR................................................................................................................................................32 POWER UP ......................................................................................................................................................32 SETUP TEST INFORMATION ............................................................................................................................33 VERIFY BBR..................................................................................................................................................34 CALIBRATE BBR............................................................................................................................................40 RUN TEST.......................................................................................................................................................45 DRAINING FLUID ............................................................................................................................................47 OBTAIN TEST DATA .......................................................................................................................................47 EXPORTING TEST RESULTS TO MICROSOFT EXCEL ........................................................................................47

SECTION 6. A. B.

CONTROLS ..................................................................................................................................21

UNPACKING BBR EQUIPMENT .......................................................................................................................24 ASSEMBLY .....................................................................................................................................................25 CONNECTING EQUIPMENT ..............................................................................................................................26 SOFTWARE INSTALLATION .............................................................................................................................28 INITIATE SOFTWARE ......................................................................................................................................31

SECTION 5. A. B. C. D. E. F. G. H. I. J.

SAFETY.........................................................................................................................................14

BASE UNIT .....................................................................................................................................................21 MECHANICAL REFRIGERATION UNIT .............................................................................................................22 TEMPERATURE CONTROLLER .........................................................................................................................22 COMPUTER .....................................................................................................................................................23

SECTION 4. A. B. C. D. E.

SYSTEM OVERVIEW...................................................................................................................4

FOR OWNERS, OPERATORS, AND MAINTENANCE PERSONNEL .......................................................................16

SECTION 3. A. B. C. D.

Page No.

GENERAL DESCRIPTION ...................................................................................................................................4 SPECIFICATIONS ...............................................................................................................................................5 RECOMMENDED TOOL LIST…………………………………………………………………………………………….6 ENVIRONMENTAL CONDITIONS………………………………………..……………………………………………….6 BASE UNIT .......................................................................................................................................................6 LOAD FRAME ...................................................................................................................................................6 COMPUTER CONTROL SYSTEM SOFTWARE ....................................................................................................10 MECHANICAL REFRIGERATION UNIT .............................................................................................................10 TEMPERATURE CONTROLLER .........................................................................................................................11 ACCESSORY ITEMS .........................................................................................................................................11 PRINCIPLES OF OPERATION ............................................................................................................................12

SECTION 2. A.

Title

MAINTENANCE..........................................................................................................................49

TROUBLESHOOTING .......................................................................................................................................49 CLEANING THE BBR…………………………………………………………………………………………56

1 of 57 BBR Manual Rev. 2.1

ATS 62000 12/2004 BENDING BEAM RHEOMETER List of Figures Figure Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16.

Title BBR Base Unit and Load Frame BBR Load Frame Assembly (Front) BBR Base (Front) Location of Safety Labels (FrontView) Location of Safety Labels (Side View) Location of Safety Labels (Rear View) Base Unit Control Panel Loading Shaft Installation BBR Cable Connections Positioning of Non-Compliant Beam and Calibration Weights for Load Positioning of Gaging Disk Positioning of Confidence Beam for Confidence Check Positioning of Non-Compliant Beam and Calibration Weights for Load Cell Calibration Positioning of Gaging Disk for LVDT Calibration Positioning of Non-Compliant Beam for Compliance Calibration Centering the LVDT

2 of 57 BBR Manual Rev. 2.1

Page No. 5 8 9 19 19 20 21 25 27 35 37 38 41 42 44 55

ATS 62000 12/2004 BENDING BEAM RHEOMETER

PREFACE Unpacking 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 and the carrier immediately. If it is necessary to file a damage claim, retain the packing materials for inspection by the carrier.

Warranty All new ATS, Inc. systems are shipped with a warranty. Units have a warranty against defective parts and workmanship for one full year from date of shipment.

After-Sale Support If you have any questions concerning the operation of your unit, contact our Service Department. Before calling, please obtain the serial number from the unit’s data tag (shown below)and the software revision number. Also, please be prepared to give a complete description of your problem to our Service Engineer.

3 of 57 BBR Manual Rev. 2.1

ATS 62000 12/2004 BENDING BEAM RHEOMETER

SECTION 1.

SYSTEM OVERVIEW

A. General Description ATS’s Bending Beam Rheometer (BBR) is designed to provide a state-of-the-art means for testing the flexural creep stiffness properties of asphalt binders in a temperature range from -40°C to 25°C. This testing is in accordance with the Strategic Highway Research Program (SHRP) Test, Method B-002, AASHTO Designation T313-02, and ASTM D 6648-01. The BBR's design does not allow for it to perform any additional functions other than the intended functions specified in this manual. The BBR is a fully integrated, modularized system consisting of the following: Major Components

•

Base unit

•

Load frame assembly

•

Personal computer

•

BBR software

•

Mechanical refrigeration unit

•

Temperature controller

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 BBR test control function and data acquisition is operated by a Windows®-based personal computer. During testing, the software controls the BBR load function, displays and records the load, 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.

4 of 57 BBR Manual Rev. 2.1

ATS 62000 12/2004 BENDING BEAM RHEOMETER

SECTION 1. SYSTEM OVERVIEW

Figure 1. BBR Base Unit and Load Frame B. Specifications 1. Base Unit Power Requirements Coolant Capacity Air Pressure Requirement

120 VAC, 60Hz or 230 VAC, 50 Hz 2 gallons (7.57 liters) 60 psi inlet pressure (414 kPa)

2. Computer System The computer system must meet the following minimum specifiations: Operating System Memory (RAM) Hard Disk Floppy Disk Drive Processor Display CD-ROM Drive PCI Slot

Windows® 95, 98, ME, NT 4.0, 2000, XP 64 Megabytes for Windows® 95, 98, ME 128 Megabytes for Windows® NT 4.0, 2000, XP 15 Megabytes free space 3.5” disk for BBR software installation Intel Celeron® 500 MHz or better Video Graphics Array (VGA) Required for software installation Required for add-on card

5 of 57 BBR Manual Rev. 2.1

ATS 62000 12/2004 BENDING BEAM RHEOMETER

SECTION 1. SYSTEM OVERVIEW 3. Mechanical Refrigeration Unit Refer to the manufacturer’s manual for specifications 4. Temperature Controller Refer to the manufacturer’s manual for specifications 5. Accessories Calibration Weights 50 grams (set of four), 2 grams (set of two) (Specifications subject to change without notice) C. Recommended Tool List The following tools are recommended for use during installation and operation of Bending Beam Rheometer. 1. Installation a. 7/16’’ Open-ended wrench b. 9/16’’ Open-ended wrench 2. Operation a. Metal tongs for the placement and removal of the specimen from the fluid bath. b. Protective eyewear and gloves for use during testing. D. Environmental Conditions The BBR 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 on the floor nearby. The mechanical refrigeration unit should be placed 6 inches above the floor and in an area that will not constitute a tripping hazard. E. Base Unit The BBR base unit is constructed primarily of stainless steel with a brushed finish cover and adjustable leveling feet. The base unit houses the cooling fluid bath, a set of precision air regulators, power switch, regulator control switch, magnetic stirrer unit, and the signal conditioning electronics. The tank is constructed of stainless steel and has a two gallon capacity (7.57 liters).

6 of 57 BBR Manual Rev. 2.1

ATS 62000 12/2004 BENDING BEAM RHEOMETER

SECTION 1. SYSTEM OVERVIEW F. Load Frame The load frame (Figure 2 ) is an independent three-point loading device designed to apply a load of up to 1960 mN. The load frame may be operated in the supplied fluid bath, or it may be used in ambient conditions. The load frame is designed with space-saving design, rigid construction, and corrosion resistance. The load frame is constructed of 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 loading with an accuracy of ±5 mN. The load frame is constructed with a horizontal shelf that extends across the top of the base unit to provide supports to suspend the lower portion of the load frame in the fluid bath. The upper part of the load frame is covered by an access panel that permits the user to easily view the top of the loading shaft. This panel also provides access to the 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. The load frame is made up of an LVDT shaft, weight pan, air bearing, load shaft, load cell, and adapter (The interior of the load frame is shown in Figure 2). A hard plastic shroud is mounted to the load frame and serves to protect the load cell from splashing fluid and minimize the affect of fluid movement on the load nose. Section 1.0.0 through Section 1.0.5 describe other load frame assembly components. 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 Cell is in place. Doing so will result in damage to the Load Cell. 1. Specimen Support The bottom half of the load frame contains a pair of metal supports designed for alignment of the specimen (See Figure 2). The supporting points 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. The specimen supports and lower portion of the load frame are designed to be submerged in the constant-temperature fluid bath during the test. The fluid in the bath provides a bouyant force that counterbalances the weight of the specimen.

7 of 57 BBR Manual Rev. 2.1

ATS 62000 12/2004 BENDING BEAM RHEOMETER

SECTION 1. SYSTEM OVERVIEW LVDT Housing

LVDT LVDT Shaft

Weight Pan

Air Bearing

Lamps

Load Cell RTD

Load Shaft

Shroud

Specimen Support

Figure 2. BBR Load Frame Assembly (Front) 2. Air Bearing The BBR incorporates an air bearing to provide frictionless loading performance (Figure 2). The air bearing control system requires a constant 60 – 65 psi (414 – 448 kPa) minimum clean and dry air supply. The air pressure to the air bearing is controlled by a set of high-precision air regulators located on the front panel of the base unit (Figure 3). 8 of 57 BBR Manual Rev. 2.1

ATS 62000 12/2004 BENDING BEAM RHEOMETER

SECTION 1. SYSTEM OVERVIEW

AIR REGULATORS

Figure 3. BBR Base (Front) 3. 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 (Figure 2). A free-floating core rod is attached directly to the load shaft. The LVDT measures the displacement of the specimen as the test load is applied. CAUTION: 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.

9 of 57 BBR Manual Rev. 2.1

ATS 62000 12/2004 BENDING BEAM RHEOMETER

SECTION 1.

SYSTEM OVERVIEW

4. Load Cell The load cell is a precision strain gauge-type, with 500 gram (4903 mN) force capacity (Figure 2). The load cell 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. 5. Resistance Temperature Detector (RTD) The RTD is a platinum measuring device that measures the cooling fluid bath temperature and relays the information to the computer control system software(Figure 2). The RTD is mounted on the load frame directly under the test specimen supports. The RTD must be calibrated at two points. One point must be calibrated at 0°C and the second is at the testing temperature or beyond it (at least -10°C or lower). The RTD is factory-calibrated at 0°C and –30.0°C. No further adjustment should be made under normal operating conditions. G. Computer Control System Software The computer control system software provides user control of the BBR system in a Windows® environment with keyboard and/or mouse access to the functions. The software provides pull-down menus, button selections, and data entry text boxes for easy update and access to information. The software is designed to run on a standard IBM PC compatible computer which is connected to the base unit. 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 in the personal computer. This design allows future enhancements or new releases to be easily added to the existing system without the need for hardware additions or modifications. Procedures in this manual assume the operator has experience working in a Windows environment. Refer to Section 3.Section 3.D for a description of software menu items. H. Mechanical Refrigeration Unit The refrigeration unit is an immersion cooler designed as a cooling source for subambient work in liquid baths. 10 of 57 BBR Manual Rev. 2.1

ATS 62000 12/2004 BENDING BEAM RHEOMETER

SECTION 1. SYSTEM OVERVIEW The refrigeration 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. Refer to Section 3.B for more information about the refrigeration unit controls. Refer to the manufacturer's literature included with this manual for more detailed information regarding safety, operation, and maintenance of the refrigeration unit. WARNING: Refrigeration unit 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. I. Temperature Controller CAUTION: The controller has been configured, tuned, and calibrated specifically for use with the Bending Beam Rheometer. Do not reconfigure. The temperature controller is connected to the mechanical refrigeration unit. The temperature controller displays the process temperature and the set-point temperature. Refer to manufacturer’s literature for detailed information. Refer to Section 3.C for more information about using the controls, and refer to Section 5.C for instructions about how to change the set-point temperature. J. Accessory Items 1. Specimen Molds A specimen mold is used to create specimens. Each mold consists of five aluminum bars of various sizes, three mylar strips, and two holding rings. Five of these molds are supplied with the BBR. 2. The following accessory items are used to verify and calibrate the BBR. a. Confidence Beam The confidence beam is a thin stainless steel beam of a known stiffness. This beam is placed on the specimen supports of the load frame during the confidence check.

11 of 57 BBR Manual Rev. 2.1

ATS 62000 12/2004 BENDING BEAM RHEOMETER

SECTION 1.

SYSTEM OVERVIEW

b. Non-Compliant Beam The non-compliant beam is a length of stainless steel that has the same dimensions as a specimen. This beam is placed on the specimen supports when verifying and calibrating the load cell and when performing the compliance test. c. Calibration Gauging Disk The calibration gaging disk is used during LVDT calibration. The gaging disk has five positions containing high precision balls. The calibration positions include a zero gaging and four subsequent steps which decrease in increments of 1, 3, 5, and 6 mm. These steps are labeled on the disk using the letters A (1 mm), B (3mm), C (5mm), and D (6mm). This provides the 6 mm test range required by both ASTM and AASHTO Specifications. d. Load Cell Calibration Weights Four 50 gram and two 2 gram load cell calibration weights are supplied with the BBR. 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. K. Principles of Operation The personal computer performs two primary functions: (1) controls the load frame during the testing mode and (2) stores and analyzes data recorded during testing. The personal computer is used to control the test loads and gather data from the LVDT, load cell, and RTD. The general sequence of events for conducting a test using this system includes the following: 1. Fill the BBR - Fill the BBR with 2 gallons (7.57 liters) of fluid. Refer to Section 5.B for details. 2. Power Up - Apply power to various components Refer to Section 5.C for procedural steps. 3. Setup Test Information - Test information includes that information that defines a test, including plot scaling, test parameters, and specimen information. For details, refer to Section 5.D. 4. Verify BBR –At the start of each day, perform the steps described in Section 5.E for accurate test results. 5. Calibrate BBR - The BBR may need to be recalibrated if verification results indicate a problem. Refer to Section 5.F for procedural steps. 12 of 57 BBR Manual Rev. 2.1

ATS 62000 12/2004 BENDING BEAM RHEOMETER

SECTION 1.

SYSTEM OVERVIEW

6. Run Test - Run and monitor the test. The procedure described in this section uses the non-compliance beam as a "dummy" specimen before the specimen is used. Refer to Section 5.G for details. 7. Obtain Test Data - Test data may be obtained in the form of graphs, a summary, or a chart. Refer to Section 5.I for details. 8. Exporting Test Results To Excel - Test results can be exported into comma-separatedvariable (.CSV) files for direct access using Microsoft Excel®. Refer to Section 5.J for details.

13 of 57 BBR Manual Rev. 2.1

ATS 62000 12/2004 BENDING BEAM RHEOMETER

SECTION 2.

SAFETY

All Applied Test Systems Inc. equipment is designed to be operated with the highest level of safety. To maintain the safe operation of this tester, ATS endevours to educate the operator about safety issues surrounding certain parts of the tester. These safety issues are addressed through the use of labeling on the equipment. The following labels may appear on your test unit:

Burn Hazard Hot Surface

Electrical Shock/ Electrocution

Hand Crush Force From Above

Protective Earth (Ground)

European Directive CE Mark

General Danger

No Access For Unauthorized Persons

Read Operator’s Manual

14 of 57 BBR Manual Rev. 2.1

ATS 62000 12/2004 BENDING BEAM RHEOMETER

Safety Instructions

15 of 57 BBR Manual Rev. 2.1

ATS 62000 12/2004 BENDING BEAM RHEOMETER

SECTION 2.

SAFETY

A. For Owners, Operators, and Maintenance Personnel Read and understand all instructions and safety precautions listed in this manual before installing or operating your unit. If you have any questions regarding operation of the unit or instructions in this manual, contact our Service Department. In addition to the safety warnings listed below, warnings are posted throughout the manual. Read and follow these important instructions. Failure to observe these instructions can result in permanent damage to the unit, significant property damage, personal injury, or death. 1. Warnings The following statements are warning statements. Unlike caution statements, warning statements alert the operator to conditions that may injure personnel. Operators must be aware of these conditions in order to prevent injuries that may occur while operating this equipment. WARNING: Flammable vapors may be emitted from the bath. Operate fluid bath in a wellventilated area. Do not smoke or use an 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: Disconnect power prior to performing maintenance. Turn off the unit and disconnect the line cord from the power source before performing any maintenance procedures. 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 the temperature is extremely cold. Extremely cold fluid may cause frostbite. WARNING: Use caution when handling air hoses during operation or when performing maintenance as contents will be under pressure.

16 of 57 BBR Manual Rev. 2.1

ATS 62000 12/2004 BENDING BEAM RHEOMETER

SECTION 2.

SAFETY

2. 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 in order to ensure safe operation of this equipment. CAUTION: Installation of electrical devices must be accomplished by competent personnel and done in accordance with any current local and national codes. Equipment grounding is a MUST CAUTION: Before energizing the electrical power to the bending beam rheometer, turn off all power switches and place all controls in an OFF or neutral position. Check that your power source is of the appropriate voltage and is surge-protected. Use appropriate power adapters based upon your region. CAUTION: Handle the load cell with care. Exercise caution when handling the load cell and load frame. The load cell is extremely sensitive to twisting movement and side loads. Improper handling will result in irreversible load cell damage. 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 tempreture. CAUTION: Do not reconfigure the temperature controller. The temperature controller has been configured, tuned, and calibrated specifically for use with the Bending Beam Rheometer. Indiscriminate use of the calibration protocol will require the controller to be returned to ATS for reconfiguration.

17 of 57 BBR Manual Rev. 2.1

ATS 62000 12/2004 BENDING BEAM RHEOMETER

SECTION 2.

SAFETY

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. CAUTION: 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. CAUTION: Avoid damage to the Confidence Beam. Do not leave a load on the confidence beam for an extended period of time. This may cause the beam to bend and could result in inaccurate readings for future tests.

18 of 57 BBR Manual Rev. 2.1

ATS 62000 12/2004 BENDING BEAM RHEOMETER

SECTION 2.

SAFETY

EXTREME COLD FLAMMABLE (AT ROOM TEMP.)

Figure 4: Location of Safety Labels (Front View)

Figure 5: Location of Safety Labels (Side View)

(INSIDE PANEL)

19 of 57 BBR Manual Rev. 2.1

ATS 62000 12/2004 BENDING BEAM RHEOMETER

SECTION 2.

SAFETY

(SIDE PANEL) COMPRESSED AIR

(SIDE PANEL)

EXTREME COLD

Figure 6: Location of Safety Labels (Rear View)

20 of 57 BBR Manual Rev. 2.1

ATS 62000 12/2004 BENDING BEAM RHEOMETER

SECTION 3.

CONTROLS

A. Base Unit 1. External Controls The following controls are located on the front panel of the base unit. Refer to Figure .

ZERO AUTO

LOAD

MAGNETIC STIRRER

TORQUE SPEED

ZERO

PUSH ON

PUSH OFF

Power Switch provides power to the unit.

LOAD ZERO/LOAD PRESSURE

BENDING BEAM RHEOMETER Load Control Switch switches the air bearing pressure between the Zero and Load regulators during manual setup of the unit. The switch is also used to select the Automatic mode that will permit the computer to control the test loading sequence.

Torque knob controls the power of the magnetic stirring mechanism. Turn the knob clockwise to increase the power. Speed knob controls the speed of the magnetic stirring mechanism. Turn the knob clockwise to increase the speed.

Zero regulator provides means of lifting the loading shaft. Permits the operator to adjust the air bearing pressure to provide a zero or preload on the specimen.

Load regulator permits the operator to adjust the air bearing pressure to provide a test load on the specimen. Zero/Load Pressure Gauge indicates in psi how much air pressure that is applied to the air bearing by either the Zero regulator or the Load regulator.

Figure 7. Base Unit Control Panel

21 of 57 BBR Manual Rev. 2.1

ATS 62000 12/2004 BENDING BEAM RHEOMETER

SECTION 3. CONTROLS 2. Internal Controls Two controls are located inside the right panel of the BBR base unit. These controls are factory set. (The line pressure regulator is positioned on the right inside the panel. This pressure is set at 60 psi. The bearing pressure regulator is located to the left of the line pressure regulator, and the bearing pressure is set at 15 to 20 psi.) Verify the settings if necessary. B. Mechanical Refrigeration Unit The refrigeration unit’s power control is located on the front of the unit. The temperature setpoint is separately located on the temperature controller. C. Temperature Controller Four controls are on the temperature controller. CAUTION: This controller has been configured, tuned, and calibrated specifically for use with the Bending Beam Rheometer. Do not reconfigure. This loop key is not used during normal operating procedures. The UP arrow is used to scroll up when changing the set-point temperature. The DOWN arrow is used to scroll down when changing the set-point temperature. This MODE key is not used during normal operating procedures.

22 of 57 BBR Manual Rev. 2.1

ATS 62000 12/2004 BENDING BEAM RHEOMETER

SECTION 3. CONTROLS D. Computer Below is a list of menu items available in the BBR software. The Main Menu selections are listed at the top of each row in boldface. The other menu items are listed under the Main Menu items. File

• Load file – option to load an existing specimen data file.

• Save File – Save specimen test data (after a test is complete). Note that a file will not save over an existing file with the same name.

• Export – Used to create Microsoft Excel (.CSV) compatible data files

• Exit – This option also permits the user to exit the system.

Setup

• Test – Permits user to access the plot scaling information, test parameters, and specimen set-up information.

• Calibrate – Use this to calibrate the load cell, LVDT, compliance and RTD.

• Verify – Use this to verify the load cell, LVDT, and compliance..

Test

Reports

• Permits the user to • Permits the user to access the Test Setup and begin testing.

access one of three reports summarizing the current specimen test data.

• Plot Data – Displays the test information in a graphic format.

• Test Summary – displays the analysis of test data points.

• View Data – Displays the test time, deflection, load, and temperature.

23 of 57 BBR Manual Rev. 2.1

ATS 62000 12/2004 BENDING BEAM RHEOMETER

SECTION 4.

SET-UP AND INSTALLATION

A. Unpacking BBR Equipment To unpack and prepare the BBR for operation, complete the following steps.

NOTE:

When unpacking the BBR, locate the four calibration certificates and insert them in the back of this manual for future reference. These certificates will be used in Section 4.D Software Installation. 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.

1. Remove the base unit and the refrigeration unit from the box, and place them on a sturdy work surface. WARNING: Position the BBR in a well-ventilated area. Consider that flammable vapors may be emitted from the bath during operation. Refer to fluid manufaturer's MSDS documentation for further information. 2. Remove the temperature controller and the load frame assembly. Place them on a sturdy work surface near the base unit. 3. Remove any packing materials from the unit. The following items should also be located and set aside:

•

Hard plastic case case containing a gaging disk, a non-compliant test beam, a confidence check beam, a six-piece weight set, and software.

•

Plastic bag containing loading shaft.

•

Plastic bag containing specimen mold.

4. Remove the monitor, the keyboard, and the computer chassis from their boxes, and place them on a work surface beside the base unit. 5. Inspect the base, the refrigeration unit, the computer system, and the load frame for any obvious damage that may have occurred during shipment.

NOTE:

If damage is found or suspected, notify the shipper and contact ATS Service Engineering immediately.

24 of 57 BBR Manual Rev. 2.1

ATS 62000 12/2004 BENDING BEAM RHEOMETER

SECTION 4. SET-UP AND INSTALLATION B. Assembly Assemble the loading shaft to the load frame assembly. (Refer to Figure 8). 1. Remove the screws that secure the shroud to the load frame. Remove and disassemble the shroud. CAUTION: Do not overtighten the loading shaft on the load cell, or the load cell may become damaged. The load cell is extremely sensitive to this twisting movement. 2. Carefully screw the loading shaft into the load cell and tighten the setscrew on the side of the load shaft. 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 Cell is in place. Improper handling will result in irreversable Load Cell damage. 3. Replace the upper shroud section using the screws removed in step 1. Replace the lower shroud by carefully re-screwing it onto the upper shroud.

Figure 8. Loading Shaft Installation 25 of 57 BBR Manual Rev. 2.1

ATS 62000 12/2004 BENDING BEAM RHEOMETER

SECTION 4. SET-UP AND INSTALLATION C. Connecting Equipment The following hoses and cables are shipped with the BBR. Use them for connecting the BBR equipment.

• Zero/Load hose • Air bearing hose • Temperature sensor cable (integral to base) • Four color-coded electrical cables (integral to base) • Communication cable (37-pin D-sub connector) • Refrigeration control cable (integral to temperature controller) • Main electrical power cable(s) 1. Connect the air hose ports on the rear of load frame assembly to the ports at the rear of base unit as shown in Figure 9. The air supply connections supply a minimum of 60psi of clean, dry air. Make sure the location of air hoses are such that they will not snag or catch on anything in the surrounding environment. (Continued on following page.)

26 of 57 BBR Manual Rev. 2.1

ATS 62000 12/2004 BENDING BEAM RHEOMETER

SECTION 4. SET-UP AND INSTALLATION

Air Supply Inlet Computer Connection Main Power

Base Drain Fitting

Figure 9. BBR Connections

NOTE:

If the refrigeration unit is turned on and connected to the base unit when the temperature controller is not connected (and operating), the refrigeration unit will operate at maximum cooling. 2. Connect the temperature controller’s sensor cable from the rear of the base unit to the temperature controller. Also, connect the refrigeration control cable from the temperature controller 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.

27 of 57 BBR Manual Rev. 2.1

ATS 62000 12/2004 BENDING BEAM RHEOMETER

SECTION 4. SET-UP AND INSTALLATION NOTE:

Refer to the computer Set-up Manual for proper connection and operation of computer unit. 4. Connect the monitor, keyboard, and mouse to the computer. 5. Connect the communication cable between the rear of the base unit and the computer chassis. 6. Plug the power cables from the base unit, the computer chassis and monitor, and the refrigeration unit into a surge-protected power source of appropriate voltage. Refer to the data tag on the BBR base unit.

NOTE:

If at any point power is lost, disconnect all power sources and place all 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.

D. Software Installation The control software is normally loaded onto the computer during testing at the ATS factory. However, if you are using your own computer, it will be necessary to install the software on your hard drive. The software must be installed on a computer with a hard disk containing at least 15 megbytes of free space. A 3.5-inch floppy drive and a CD-ROM drive is required to perform the installation. This installation consists of three basic steps. Install the hardware drivers, install the add-on hardware board, and install the ATS BBR control program. It is highly recommended that the hardware drivers be installed before the addon hardware board. This procedure includes installation of a hardware add-on board into a spare PCI slot inside the computer. The user should be familiar with this procedure and must understand basic Windows® operations such as locating and running programs listed under the Windows® Start button menu. 1. Hardware Driver Installation a. Turn the power on to the computer and wait for it to complete the Windows® start-up sequence.

28 of 57 BBR Manual Rev. 2.1

ATS 62000 12/2004 BENDING BEAM RHEOMETER

SECTION 4. SET-UP AND INSTALLATION b. Place the CD-ROM disk containing the hardware drivers into the CD-ROM drive. In most computers, the installation program will run automatically after a short period (typically between 5 and 30 seconds). If you do not see the installation program’s opening screen within 60 seconds, then you will need to invoke it manually. In this case, click on the Windows Start button and then on the item named Run. A Run dialog box should appear. Type into its text field ‘D:\setup.exe’ where ‘D’ is replaced by the drive letter for the CD-ROM drive. c. Wait until the animation stops and a Next button appears in the lower right corner of this program window. Click on the Next button. A new image appears containing several groupings of buttons. d. Locate the button labeled Install DriverLINX and click on it once. A new image appears containing several groupings of buttons. e. Locate the button labeled Install Drivers and click on it once. A second program window should appear which is the final hardware driver installation program. f. A series of dialog boxes will be presented; each containing a Next button and displaying various installation options. Adjusting these options may customize the installation, but it is recommended that the default entries be accepted by repeatedly clicking on the Next button until a dialog box appears with a Finish button. g. Click on the Finish button. The window for the second program should close and again display the first program. Click on the Exit button in this first program, and then on the Done button on the subsequent display. The window for this first program should close. If a dialog box asks, “Do you want to shut down your computer now?” click on the No button. h. Perform a normal Windows shutdown followed by turning off power to the computer. 2. Hardware Add-On Board Installation CAUTION: Before performing repairs or adjustments, the computer must be powered down. See Section D, 2, a, below. CAUTION: Static electricity on fingers and hands may damage electronic components in your computer or on your add-on card. Immediately before touching the new card, or any components inside your computer, discharge any static electricity on your hands by touching both hands on the metal chassis inside your computer case. 29 of 57 BBR Manual Rev. 2.1

ATS 62000 12/2004 BENDING BEAM RHEOMETER

SECTION 4. SET-UP AND INSTALLATION a. If the computer is powered up, perform a normal shutdown followed by turning off power to the computer. Do not disconnect the power cord from the computer base unit as this allows for the discharge of static electricity to ground. b. Open the computer base unit and locate an unused PCI slot, which has enough clearance to fit the full length of the add-on board without causing the add-on board to contact other hardware. If the slot opening cover on the back of the computer base unit for this particular slot is still in place, then remove it now. c. Place the add-on board’s gold-fingered tab, above the PCI slot connector, such that the front and back of the tab line up with the front and back of the slot connector opening in which it is to be placed. (‘Back’ refers to the side, which is toward the back of the computer base unit where the slot cover was removed). Work the tab into the connector by gently pressing it into the connector opening while wiggling the card slightly from front to back. Do not apply excessive force. This action is intended to separate two rows of connector springs. A small snapping sound will likely be heard when the tab finally separates the two rows of springs and hits the bottom surface of the connector. d. Make certain that the card is well seated in the connector, and then apply whatever mechanism is used to hold the card in place. (This is often a screw, which is applied just above the slot opening at the back of the computer.) e. Replace the cover on the computer base unit and reattach the power cord. f. Turn on power to the computer. Part way through the Windows start-up sequence, Windows should declare that it has found new hardware and is installing new software. The Windows NT product line (NT 4.0, 2000, and XP) should handle this installation with little user intervention. Follow any instructions and accept all of the defaults. The Windows 9x product line (95, 98, and ME) will display a configuration dialog box. Follow the instructions given. It will step the user through viewing and confirming the configuration. The configuration should not require any changes. g. Perform a normal Windows Restart sequence, or a Shutdown followed by a power-off/power-on sequence. The add-on board and its drivers should now be properly installed. 3. ATS BBR Control Program Installation a. Place the installation disk into the 3.5-inch floppy drive. b. Click on the Windows Start button and then on the Run option. c. Type ‘A:\setup.exe’ into the text box (where ‘A’ is replaced by the driver letter for the 3.5-inch floppy drive) and click on the OK button. 30 of 57 BBR Manual Rev. 2.1

ATS 62000 12/2004 BENDING BEAM RHEOMETER

SECTION 4. SET-UP AND INSTALLATION d. Follow the instructions in the installation program. e. After software installation is complete, the Windows Start button menu will contain a folder in the Programs section named “ATS BBR n.nnW”, where n.nn is the version number. Inside this folder is a program named “Calibration Constants”. Locate the envelope containing the four calibration certificates found in Section 4.A. Then run the “Calibration Constants” program. f. From the Step Gage Disk certificate, enter the values for Steps A through D from the column entitled “Displacement from Zero Setup”. Also, enter the serial number of the Step Gage Disk. g. From the Calibration Weights certificate, enter the values for weights A through D from the column entitled “Measured”. Also, enter the serial number of the weight set. h. From the Confidence Test Beam certificate, enter the values for thickness and width from the column entitled “Actual”. Also, enter the serial number for the beam. i. From the base unit’s data tag field labeled “NO”, enter the unit’s serial number using only the first two groups of digits. This should be in the form yy-zzzz, where yy is the year of purchase, and zzzz is the ATS order number. j. Enter the ID code you intend to use to differentiate between different BBR machines. k. Double-check you entries and click on the Save button. l. Once the calibration certificate data has been saved, close the “Calibration Constants” program. E. Initiate Software Click on Windows Start button, then Programs, then on the group ATS BBR x.xxW, and finally on the program shortcut ATS BBR x.xxW (where the x.xx is the program version number).

31 of 57 BBR Manual Rev. 2.1

ATS 62000 12/2004 BENDING BEAM RHEOMETER

SECTION 5.

OPERATION

A. Summary of BBR Operating Procedures The following procedures instruct the operator how to perform typical tests using ATS's BBR. The main steps are described below. Refer to appropriate specifications for proper detailed procedures.

• Fill the BBR • Power Up • Setup Test Information • Verify BBR • Calibrate BBR • Run Test • Drain Fluid (maintenance or replacement only) • Obtain Test Data • Exporting Test Results To Microsoft Excel WARNING: During operation and testing never use bare hands to place objects in fluid bath. Wear protective clothing and adequate eye protection during test procedures and use metal tongs for object placement and removal. Extremely cold fluid may cause frostbite. B. Fill the BBR Fill the BBR with two gallons (7.57 liters) of fluid, so the liquid is approximately 1 inch from the top. Refer to individual test specifications for fluid type. WARNING: Possible eye and/or skin irritant. Wear protective clothing and adequate eye protection during test procedures. Hazards can differ from fluid type to fluid type. Refer to fluid manufacturer's MSDS documentation for more detailed information. C. Power Up In order to apply power, perform the steps below. 32 of 57 BBR Manual Rev. 2.1

ATS 62000 12/2004 BENDING BEAM RHEOMETER 1. Press the Power button on the BBR base unit. The Power button will illuminate. 2. Turn on the refrigeration unit. 3. Adjust the temperature controller by pressing the up and down arrow keys, so it displays the desired test temperature. 4. Turn on the computer. D. Setup Test Information Prior to starting a new test, the operator may choose to verify the test settings. Three primary screens control testing. Refer to the list below; refer to individual procedures for more information

• Plot Scaling • Test Parameters • Specimen Parameters 1. Setup Plot Scaling The Plot Scaling screen allows the operator to select maximum and minimum scaling for deflection, load, and temperature graphs. a. Select Setup from the Main Menu. b. Select Test from the Setup Menu. c. Select Plot Scaling from the Test Menu. d. The Plot Scaling screen appears. e. Make any necessary changes to the Plot Scaling parameters. To restore factory default plot scaling, select the Factory button. Select Save under User Defaults in order to save the current plot scaling. Select Restore under User Defaults to restore the user default plot scaling. f. Select Ok to return to the principle display. 2. Setup Test Parameters Unless test specifications change or the operator chooses to perform a test according to different specifications, this procedure is not necessary to perform. Test parameters reflect current test specifications. For this reason, these parameters are not commonly changed.

NOTE:

Only perform these steps when the test parameters change. a. Select Setup from the Main Menu. b. Select Test from the Setup Menu.

33 of 57 BBR Manual Rev. 2.1

ATS 62000 12/2004 BENDING BEAM RHEOMETER c. Select Test Parameters from the Test Menu. The Test Parameters screen displays the current Test Parameters such as loading time, load values, and temperature time.

NOTE:

The test parameter defaults are shown. They are set to the current test specifications parameters. d. If desired, change the data in the appropriate data fields. e. Select OK to return to the principle display.

3. Specimen Information Specimen parameters provide the software with information about the specimen to be tested.

NOTE:

Perform these steps when the project ID, specimen number, specimen dimensions, and/or operator name change, or if you wish to add a note to the test report. a. Select Setup from the Main Menu. b. Select Test from the Setup Menu. c. Select Specimen Information from the Test Menu. d. The Specimen Information screen displays the current information. This information includes sample information, dimensions, operator name, and notes/comments. e. Enter the data in the appropriate data fields. f. Select OK to return to the principle display.

E. Verify BBR The following verification procedures must be performed when the BBR is to be operated at a different temperature and upon initial installation. These procedures are designed to test the various functions and safety features of the BBR to ensure it is fully operational and ready for testing.

• Verify Load Cell • Verify LVDT • Confidence Check • Verify RTD 1. Verify Load Cell The purpose of this procedure is to verify that the load cell is within the acceptable calibration range. During this procedure, refer to Figure 10 for placement of the calibration weights and non-compliant beam. 34 of 57 BBR Manual Rev. 2.1

ATS 62000 12/2004 BENDING BEAM RHEOMETER

SECTION 5.

OPERATION

CAUTION: 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.

NOTE:

The unit may not display actual weight values until after the first calibration is performed. Two 2-gram weights are provided to allow performance of the load cell sensitivity test as per ASTM D6648.

Figure 10. Positioning of Non-Compliant Beam and Calibration Weights for Load a. Place the Load Control switch on the base unit in the Zero position. b. Select Setup from the computer's Main Menu. c. Select Verify from the Setup Menu. d. Select Load (Load Cell) from the Verify Menu. Press Enter. The Load Cell Verification Screen appears. 35 of 57 BBR Manual Rev. 2.1

ATS 62000 12/2004 BENDING BEAM RHEOMETER

SECTION 5.

OPERATION

e. Follow the instructions in the Load Cell Verification window and refer to Figure as necessary. Select OK for more instructions. At any time, if it is necessary to repeat a step, select the Back button to return to the previous step. CAUTION: Carefully place the calibration weights on the weight pan. Do not bump the LVDT shaft with the weights or damage may result. f. After all four weights have been placed on the weight pan, the system will display a Load Cell Verification Results screen. g. Review the Load Cell Verification Results information. Each weight reading should be within ± 0.2 grams of the known load value. If the results are not within the allowable tolerance, perform the verification check again. If the results are still not within the allowable tolerance after performing the check at least three times, perform the load cell calibration steps described in Section 5.F.1 of this manual. h. Exit the Load Cell Verification Results screen, and follow the instructions displayed in the Verification -Complete window. i. Begin the deflection (LVDT) verification procedure at the prompt, or return to the principle display. If starting the deflection (LVDT) verification procedure now, skip steps a - c of Section 5.E.2. 2. Verify LVDT The purpose of this verification procedure is to verify that the LVDT is within the acceptable calibration range. During this procedure, refer to Figure 10 for placement of the gaging disk.

NOTE:

When positioning the gaging disk, the weight pan pin must rest in the middle of the ball of the gaging disk. Grooves at each step on the gaging disk align the disk for more accuracy. a. Select Setup from the Main Menu. b. Select Verify from the Setup Menu. c. Select Deflection (LVDT) from the Verify Menu. d. Follow the instructions displayed in the LVDT Verification window. Select OK for more instructions. Refer to Figure 10 as necessary. At any time if it is necessary to repeat a step, select the Back button to return to the previous step.

36 of 57 BBR Manual Rev. 2.1

ATS 62000 12/2004 BENDING BEAM RHEOMETER

SECTION 5. OPERATION

Figure 11. Positioning of Gauging Disk

NOTE:

To prevent inaccurate readings, make sure the bottom of the gaging disk mounting area, locating pin, and indicator pin are dirt-free. e. After the gauging disk rotates completely, an LVDT Verification Results screen is displayed. f. Review the LVDT Verification Results information. Each deflection reading should be within 5 μm of the known deflection value. If the results are not within the allowable tolerance, perform the verification procedure again. If the results are still not within the allowable tolerance after performing the check at least three times, perform the LVDT calibration steps described in Section 5.F.2 of this manual. g. Exit the LVDT Verification Results screen and follow the instructions displayed on the Verification – Complete window.

37 of 57 BBR Manual Rev. 2.1

ATS 62000 12/2004 BENDING BEAM RHEOMETER

SECTION 5. OPERATION h. Begin the confidence check verification procedure at the prompt, or exit to the principle display. If starting the confidence check verification procedure now, skip steps a - c of Section 5.E.3. 3. Confidence Check The purpose of this procedure is to check the operation of the system. At the end of the test, the confidence beam must fall within the acceptable stiffness range. During this procedure, refer to Figure 12 for placement of the confidence beam.

Figure 12. Positioning of Confidence Beam for Confidence Check a. Select Setup from the Main Menu. b. Select Verify from the Setup Menu. c. Select Confidence Check from the Verify Menu. d. At the prompt, load the confidence beam in the test position, mounted on the specimen supports (Figure 12). Press Enter after positioning the confidence beam. 38 of 57 BBR Manual Rev. 2.1

ATS 62000 12/2004 BENDING BEAM RHEOMETER

SECTION 5. OPERATION e. Follow the instructions displayed in the Confidence Test Setup window. f. Select Start to begin. Three horizontal graphs indicate check progress. g. When the test is completed, press any key to continue. A Test Summary Report displays. h. Review the information on the Test Summary Report window. Verify that the measured stiffness value is within the allowable range displayed. If the value is not within the allowable range, perform the confidence check verification procedure again. If the value is still not within the allowable range after performing the confidence check at least three times, perform the compliance check procedures described in Section 5.F.3 of this manual. WARNING: Do not leave a load on the confidence beam for an extended period of time. This may cause the beam to bend and could result in inaccurate readings for future tests. i. If desired, print the information on the Test Summary Report window before exiting. 4. Verify Resistance Thermometer Device (RTD) The purpose of this procedure is to check that the measured bath temperature is the same temperature displayed on the monitor. In order to perform this procedure, the fluid bath temperature must be stabilized and the temperature must be displayed on the monitor. a. Select Test from the Main Menu. The Test Setup screen will appear. b. Allow the load frame base and RTD temperature (displayed on the screen) to stabilize. c. Insert an ASTM certified thermometer calibrated to 0.1°C in the cooling fluid up to the immersion line. The temperature displayed on the monitor and the temperature reading from the thermometer should agree to within 0.1°C. The bulb of the thermometer should be placed as close as possible to the area in which the loading shaft makes contact with the specimen. If the readings do not agree, perform the calibrate RTD - Zero and calibrate RTD - Span procedure described in Section 5.F.4 and Section 5.F.5 of this manual.

NOTE:

RTD calibration is factory-set and should not require further calibration under normal operation. Make sure the certified thermometer reading is correct before recalibrating the RTD.

39 of 57 BBR Manual Rev. 2.1

ATS 62000 12/2004 BENDING BEAM RHEOMETER

SECTION 5. OPERATION F. Calibrate BBR The following calibration procedures should only be performed if the verification procedures described in Section 5.E do not fall within the allowable range.

• Calibrate Load Cell • Calibrate LVDT • Calibrate Compliance • Calibrate RTD-Zero • Calibrate RTD-Span

NOTE:

If any of the following calibration steps are unsuccessful, refer to Section 6 of this manual. This Maintenance section provides tips that may help you identify and correct a problem. 1. Calibrate Load Cell Perform this procedure if the results of the load cell verification procedure described in Section 5.E.1 do not fall within the allowable range.

NOTE:

When performing the first calibration during installation, the unit may not display actual weight values until after the first calibration is complete. During this procedure, refer to Figure 10 for placement of the non-compliant beam and the calibration weights. a. Select Setup from the Main Menu. b. Select Calibrate from the Setup Menu. c. Select Load (Load Cell) from the Calibrate Menu. d. Follow the instructions in the Load Cell Calibration window. Refer to Figure 10 if necessary. Select OK for more instructions. At any time, if it is necessary to repeat a step, select the BACK button to return to the previous step. CAUTION: Carefully place the calibration weights on the weight pan. If the LVDT shaft is bumped, it may be damaged.

40 of 57 BBR Manual Rev. 2.1

ATS 62000 12/2004 BENDING BEAM RHEOMETER

SECTION 5. OPERATION

Figure 13. Positioning of Non-Compliant Beam and Calibration Weights for Load Cell Calibration e. After all four weights are placed on the weight pan, the system will display a Load Cell Calibration Results screen. f. Review the Load Cell Calibration Results information. Each weight reading should be within ± 0.2 grams of the known load value. If the results are acceptable, select Save to save the calibration data. g. Exit the Load Cell Calibration Results screen, and follow the instructions displayed in the Calibration - Complete window. h. Begin the deflection (LVDT) calibration procedure at the prompt or return to the principle display. If starting the procedure now, skip steps a - c of Section 5.F.2. 2. Calibrate LVDT Perform this procedure if the results of the LVDT verification procedure described in Section 5.F.2 do not fall within the allowable range.

41 of 57 BBR Manual Rev. 2.1

ATS 62000 12/2004 BENDING BEAM RHEOMETER

SECTION 5. OPERATION NOTE:

When performing the first calibration during installation, the unit may not display actual deflection values until after the first calibration is complete. CAUTION: Carefully lift and lower weight pan when placing gaging disk in position. If the LVDT shaft is bumped, it may be damaged. During this procedure, refer to Figure 14 for placement of the gaging disk. a. Select Setup from the Main Menu. b. Select Calibrate from the Setup Menu. c. Select Deflection (LVDT) from the Calibrate Menu. d. Follow the instructions displayed in the LVDT calibration window. Select OK for more instructions. Refer to Figure 14 as necessary. At any time, if it is necessary to repeat a step, select the Back button to return to the previous step.

NOTE:

To prevent inaccurate readings, make sure the bottom of the gaging disk mounting area, locating pin, and indicator pin are dirt-free.

Figure 14. Positioning of Gauging Disk for LVDT Calibration

42 of 57 BBR Manual Rev. 2.1

ATS 62000 12/2004 BENDING BEAM RHEOMETER

SECTION 5. OPERATION e. After the gauging disk rotates completely, an LVDT Calibration Results screen is displayed. Each deflection reading should be within five μm of the known deflection value. If the results are acceptable, select Save to save the calibration results. f. Exit the LVDT Calibration Results screen, and follow the instructions displayed on the Calibration - Complete window. g. Begin the compliance calibration procedure at the prompt, or exit to the principle display. If starting the Confidence Check Compliance Calibration procedure at this point, skip steps a - c of Section 5.F.3. 3. Compliance Calibration The purpose of this procedure is to check the system compliance and obtain a compliance number, which will be used to compensate for deflection error introduced by deflection of the load cell. The load cell body deflects more or less depending upon the amount of applied load. Refer to Figure 10 for placement of the non-compliant beam and the calibration weights. a. Select Setup from the Main Menu. b. Select Calibrate from the Setup Menu. c. Select Compliance from the Calibrate Menu. d. Follow the instructions displayed on the Compliance Calibration window. Select OK for more instructions. Refer to Figure 10 as necessary. e. Review the Compliance Calibration Results information. f. Save the compliance calibration results data. Select EXIT. g. Follow the instructions displayed on the Calibration - Complete window. h. Return to the principle display.

43 of 57 BBR Manual Rev. 2.1

ATS 62000 12/2004 BENDING BEAM RHEOMETER

SECTION 5. OPERATION

NON-COMPLIANT BEAM

Figure 15. Positioning of Non-Compliant Beam for Compliance Calibration 4. Calibrate RTD-Zero RTD calibration is factory-set and should not require further calibration under normal operation. Make sure the certified thermometer reading is correct before recalibrating the RTD. The purpose of this calibration is to set the RTD temperature Zero at the first temperature point described in Section 1.C.5. When performing this procedure, be sure to calibrate the RTD-Zero before calibrating the RTD-Span.

NOTE:

During initial set-up the unit may not display the actual temperature until after the first calibration is complete. a. Prepare a bath, allowing the bath temperature to stabilize at 0°C. Use a certified thermometer to confirm the temperature.

44 of 57 BBR Manual Rev. 2.1

ATS 62000 12/2004 BENDING BEAM RHEOMETER

SECTION 5. OPERATION NOTE:

NOTE:

The base unit and the refrigeration unit should be given enough time to reach the test temperature. If the temperatures of the test bath and refrigeration unit have not been given ample time to stabilize prior to test operations, the BBR may give inaccurate or inconsistent readings. The bath must be stirred continuously to ensure temperature uniformity. b. Place the load frame in the bath and allow the temperature to stabilize for at least one hour. c. Select Setup from the Main Menu. d. Select Calibrate from the Setup Menu. e. Select Zero Temperature (RTD) from the Calibrate Menu. f. Follow the instructions displayed on the RTD-Zero Calibration screen. Select OK. g. Select YES to indicate Zero is based on the current bath temperature.

5. Calibrate RTD-Span The purpose of this calibration is to set the RTD temperature span at the second temperature point described previously in Section 1.Section 1.C.5. a. Adjust the temperature to -30°C, and allow the fluid bath to temperature stabilize for at least one hour. Use a certified thermometer calibrated to the nearest 0.1°C to check the temperature, and note the reading to the nearest 0.1°C. b. Select Setup from the Main Menu. c. Select Calibrate from the Setup Menu. d. Select Span Temperature (RTD) from the Calibrate Menu. e. Follow the instructions displayed on the RTD-Span Calibration window. Select OK for more instructions and prompts. G. Run Test Now that the calibration information has been verified, tests may be conducted. Steps 1 8 of the procedure below describe testing set-up using the non-compliant beam which is the size of a specimen. 1. Select Test from the Main Menu. The Test Setup screen will appear.

45 of 57 BBR Manual Rev. 2.1

ATS 62000 12/2004 BENDING BEAM RHEOMETER

SECTION 5. OPERATION NOTE:

If the unit 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. Place two 50 gram weights on the weight pan and remove them, allowing three or four seconds between loading and unloading. Repeat this at least four times, allowing three or four seconds between each time. 2. Load the non-compliant beam on the specimen supports. 3. Place the Load Control switch in the Zero position. 4. Adjust the zero regulator on the base unit until the loading shaft is slightly above the non-compliant beam. Select LOAD to tare the load channel. 5. Adjust the zero regulator until the loading shaft contacts the non-compliant beam with a minimal force of 10 - 30 mN, preferably 25 mN. 6. Turn the Load Control on the base unit to the Load position. 7. Adjust the Load regulator on the base unit until the load display reading is 980 mN ± 5 mN. 8. Turn the Load Control switch on the base unit to the Zero position.

NOTE:

Re-check the zero or pre-load pressure and load pressure once or twice to make sure the values are consistent. NOTE: Allow the specimen temperature to stabilize in the cooling fluid bath at the required test temperature according to the specifications. 9. 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. Make sure the load display is between 10-30 mN, preferably 25 mN. If it is not, adjust the zero regulator. 10. Turn the Load Control switch in the Automatic position. 11. Select START. 12. Three horizontal graphs allow the operator to monitor test progress. Current deflection, load, and temperature values are displayed to the left of the corresponding graphs.

NOTE:

To abort the test, press ESCape key. 13. When the test is complete, press any key to show a Save Data File box and a Test Summary Report. The report can only be printed after saving the file. 14. Save the file in the desired directory.

46 of 57 BBR Manual Rev. 2.1

ATS 62000 12/2004 BENDING BEAM RHEOMETER

SECTION 5. OPERATION 15. The Test Setup Screen will appear again. If desired, select Exit to return to the principle display. 16. To obtain test data, perform the steps described in Section 5.J. H. Draining Fluid WARNING: Do not attempt to pull the drain plug when the fluid level is high and the temperature is extremely cold. Extremely cold fluid may cause frostbite. When the bath fluid becomes unusable, connect drain hose to the drain fitting under the bottom of the base unit and remove the fluid by opening the drain located on the inside of the base unit. Refer to Figure 9. 1. Make sure that the drain hose connected to the drain fitting will empty into a proper receptacle. 2. Carefully locate the black rubber drain plug inside the fluid bath. 3. Remove the plug using either metal tongs or a pair of pliers and the fluid will drain out. Do not remove plug with bare hands. 4. Refer to fluid manufacturer's MSDS and other documentation for information on proper disposal. I. Obtain Test Data Perform the following steps in order to obtain a summary of the test data or to view the data. 1. Select Reports from the Main Menu. 2. Select any of the menu options as listed below: Plot Data - View the data plotted during the test. Test Summary - View a Test Summary Report. This report may be printed if desired. View Data - View a chart of Test Data including time, deflection, load, and temperature. This report may be printed if desired.

NOTE:

If necessary, specimen data can be imported into Microsoft Excel. Refer to Section 5.J. for details.

J. Exporting Test Results to Microsoft Excel The specimen data may be exported into a flat ASCII (human-readable) data file and may be imported into other databases and spreadsheet programs such as Microsoft Excel. The 47 of 57 BBR Manual Rev. 2.1

ATS 62000 12/2004 BENDING BEAM RHEOMETER

SECTION 5. OPERATION process for exporting the raw specimen data can be accomplished by using the following procedure: 1. Select File from the Main menu. 2. Select Export from the File menu. 3. In the resulting Save As dialog box, select or create a directory into which the file is to be saved. 4. Type a file name, which ends with ‘.csv’ (without the quotes, for example: Test2.csv). 5. Click on the Save button. 6. On computers, which have Microsoft Excel® installed, the file may be accessed in Excel by double-clicking the file.

48 of 57 BBR Manual Rev. 2.1

ATS 62000 12/2004 BENDING BEAM RHEOMETER

SECTION 6.

MAINTENANCE

A. Troubleshooting The purpose of this Troubleshooting section is to describe the kind of problem the operator may experience and describe what the operator should or should not do in order to correct it. Below are descriptions of common problems and solutions. A flowchart is located beside each problem. This chart summarizes the descriptions found in each section. Do not attempt to correct the problem by reading the flowchart alone. Read each description and contact an ATS Service Engineering Representative for assistance if necessary. WARNING: To prevent electrical shock, use extreme caution if you need to remove covers. Follow your company’s electrical safety procedures. 1. If the bath temperature is not the same as the temperature set on the temperature controller, perform the following steps. Refer to the flow chart on the next page. a. Attempt to diagnose the problem by determining if the temperature difference is by a few degrees (small error) or by many degrees (larger error). b. For small errors, follow steps Section 1.A.1.c.1 through Section 1.A.1.c.14 to correct a calibration problem. For larger errors, skip step c and follow steps Section 1.A.1.d.1 through Section 1.A.1.d.8 to correct a configuration problem. c. If a small error occurs, perform the steps below. CONTROLLER RECALIBRATION PROCEDURE 1) Prepare the fluid bath, and apply power to the base unit and the temperature controller. Verify that the temperature controller displays a temperature reasonably close to what the present bath temperature may be. Adjust the stirrer for maximum speed. 2) Set the temperature set point for 0° C. Allow the bath temperature to stabilize. 3) Use a certified thermometer calibrated to the nearest 0.1°C to measure the actual bath temperature.

NOTE:

When placing the thermometer in the bath, be sure to position it beside the temperature probe located on the bottom of the load frame. 4) On the temperature controller, hold down the key for approximately 10 seconds, until AcCd and 01 alternately flash on the SV screen. 5) Press the

key to level 04. Now AcCd and 04 will alternately flash.

49 of 57 BBR Manual Rev. 2.1

ATS 62000 12/2004 BENDING BEAM RHEOMETER

SECTION 6. MAINTENANCE 6) Press the

key until CAL.H appears.

7) Use the and keys to control the PV reading. Change the temperature display, so it agrees with the thermometer reading. 8) Exit this menu by pressing the

button.

9) Use the and keys to adjust the temperature set point to -30° C. Allow the temperature to stabilize. SYMPTOM Bath Temperature is different than Controller Temperature This problem may be detected while performing RTD-Zero and RTD-Span Calibration Procedures

DIAGNOSE PROBLEM Determine if the temperature difference is by a few degrees (small error) or by many degrees (large error).

SMALL ERROR

LARGE ERROR

Problem may be related to the calibration.

Problem may be related to the configuration.

RE-CALIBRATE CONTROLLER

CHECK CONFIGURATION

Perform re-calibration procedure.

Perform check configuration procedure. Re-configure if necessary.

CONTACT ATS

CONTACT ATS

If the temperature is still different, contact ATS

If the temperature is still different, contact ATS.

50 of 57 BBR Manual Rev. 2.1

ATS 62000 12/2004 BENDING BEAM RHEOMETER

SECTION 6. MAINTENANCE 10) Use a certified thermometer calibrated to the nearest 0.1°C to measure the actual bath temperature.

NOTE:

When placing the thermometer in the bath, be sure to position it beside the temperature probe located on the bottom of the base unit. key for approximately 10 11) On the temperature controller, hold down the seconds, until AcCd and 01 alternately flash on the SV screen. 12) Press the

key to level 04. Now AcCd and 04 will alternately flash.

13) Press the

key until CAL.L appears.

14) Use the and keys to control the PV reading. Change the temperature display, so it agrees with the thermometer reading. 15) Exit this menu by pressing the

button.

d. Check the configuration of the temperature controller if a large error occurs. The procedure is described below. CAUTION: Indiscriminate use of the configuration protocol will require the controller to be returned to ATS for reconfiguration. Do not attempt to retune. Tuning is pre-set at ATS. CHECK CONFIGURATION PROCEDURE 1) Hold down the key for approximately 10 seconds, until AcCd and 01 alternately flash on the SV screen. 2) Press the

key to level 05. Now AcCd and 05 will alternately flash.

3) Press the key once, so SnSr appears. SnSr and d should alternately flash. If SnSr and some letter other than d flash alternately, use the and keys to scroll through the other selections and select d. 4) Press the key until Unit appears. Unit and C should alternately flash. If Unit and F flash alternately, use the and keys to select C. 5) Exit this menu by pressing the

button.

6) Return to Loop 1 by pressing the alternately flash. 7) Use the 8) Press the

button once. AcCd and 05 should

key to return to Loop 1. key.

e. The bath temperature should now match the control temperature. 51 of 57 BBR Manual Rev. 2.1

ATS 62000 12/2004 BENDING BEAM RHEOMETER

SECTION 6. MAINTENANCE 2. When performing RTD-Zero and RTD-Span Calibration, if the bath temperature is not the temperature displayed on the computer monitor, perform the steps below. Refer to the flow chart below. SYMPTOM Bath Temperature is different than Computer Temperature This problem may be detected while performing RTD-Zero and RTD-Span Calibration Procedures

DIAGNOSE PROBLEM Determine if the temperature difference is consistent or inconsistent

CONSISTENT ERROR

INCONSISTENT ERROR

Indicates possible calibration problem

Indicates possible hardware problem

RECALIBRATE RTD

CONTACT ATS

Refer to Sections 5.D.4 and 5.D.5 of this manual

If the problem continues, contact ATS

a. Attempt to diagnose the problem by determining if the temperature difference is a consistent error or an inconsistent error. b. To correct consistent errors, attempt to recalibrate the RTD. RTD-Zero and RTDSpan procedures are described in Section 5.F.4 and Section 5.F.5 of this manual. If these procedures have already been completed unsuccessfully, contact ATS Service Engineering for assistance. An inconsistent error indicates a possible hardware problem. Contact ATS Service Engineering Department for assistance. 3. When performing the Confidence Check and the Compliance Calibration, if the results are consistently outside the acceptable range, perform the steps below. 52 of 57 BBR Manual Rev. 2.1

ATS 62000 12/2004 BENDING BEAM RHEOMETER

SECTION 6. MAINTENANCE a. Verify the data entered in the Calibration Certificate Data Entry window. In order to view this screen, exit the BBR software and run the Calibration Constants program from the ATS BBR program group in the Windows start button menu. b. From the Windows start button menu, select Programs, ATS BBR, and Calibration Constants. c. The data on this screen must match the data found on three of the certificates shipped with your machine. One certificate is titled Step Gage Disk-Rheometer; the second certificate is titled Compliance Test Beam-Rheometer; the third is titled Calibration Weight-Rheometer. d. If the information on the Calibration Certificate Data Entry window does not match the information found on the certificates listed above, enter the new information. If the information on the window and the certificates is the same, the confidence beam may be bent. e. Contact ATS if the problem cannot be corrected by entering accurate information on the Calibration Certificate Data Entry window. SYMPTOM During Confidence Check and Compliance Calibration, results are out of range.

VERIFY DATA ENTRY Check Calibration Certificate Data Entry information.

RE-ENTER DATA

POSSIBLE PROBLEM

If necessary, re-enter the data according to Certificates.

Bent Confidence Beam

CONTACT ATS If the problem continues, contact ATS

53 of 57 BBR Manual Rev. 2.1

ATS 62000 12/2004 BENDING BEAM RHEOMETER

SECTION 6. MAINTENANCE 4. When the load shaft appears to be stuck or stalled during Verification and/or Calibration procedures, perform the steps described below. Refer to the following flowchart and Figure 16. SYMPTOM During Load Cell Verification and Calibration, results are out of range

VERIFY LVDT ALIGNMENT Perform LVDT Alignment Check procedure

ALIGN LVDT

OTHER PROBLEM

Perform LVDT alignment procedure

Contact ATS

a. When the load shaft seems to be stuck or stalled during verification and calibration procedures, the most likely cause is a misaligned LVDT. In order to determine if the LVDT is misaligned, the LVDT must be viewed from above. 1) Remove the front cover on the load frame assembly. 2) Shine a flashlight at the lower end of the LVDT shaft. Refer to Figure 16. This light reflects up the shaft, so the LVDT can be viewed from above. b. If the LVDT shaft appears to be centered in the LVDT, re-secure the cover and contact ATS for assistance. If you determine that the shaft is misaligned, attempt to center it by performing the steps below. 1) Loosen the four retainer screws using a 3/32-inch Allen wrench. 2) Continue to shine the flashlight on the 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.

54 of 57 BBR Manual Rev. 2.1

ATS 62000 12/2004 BENDING BEAM RHEOMETER

SECTION 6. MAINTENANCE 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 Frame on its side when the Load Cell is in place. Doing so will result in damage to the Load Cell.

Figure 16. Centering the LVDT

55 of 57 BBR Manual Rev. 2.1

ATS 62000 12/2004 BENDING BEAM RHEOMETER

SECTION 6. MAINTENANCE B. Cleaning the BBR When cleaning the surface of the BBR, first disconnect all power sources and place all controls in an OFF position. Use a very mild cleaning agent and when cleaning be careful not to allow cleaning agent to enter and contaminate the fluid bath.

56 of 57 BBR Manual Rev. 2.1

ATS 62000 12/2004 BENDING BEAM RHEOMETER

57 of 57 BBR Manual Rev. 2.1