ATS 2140-M Series User manual

WinCCS Lever Arm Tester
Series 2140-M, 2320-M, 2330-M, 2330-CC, 2410-M, 2410-CC

Revised March 2013

Contents
Preface           5
Unpacking          5
Warranty          5
Aer-SaleSupport         5
Terms          6
Secon1:Introducon         7
1.1GeneralDescripon        7
1.2ComputerSpecicaons       8
1.3WinCCSSystemOverview       9
Secon2:Safety          10
2.1ForOwners,Operators,andMaintenancePersonnel    10
2.2Warnings         11
2.3Cauons         11
Secon3:EquipmentSetupandInstallaon      12
3.1SafetyInstrucons        13
3.2LocaonofSafetyLabels       13
3.3UnpackingEquipment        15
3.4Specicaons         16
3.5HardwareInstallaon        17
3.6SowareInstallaon        19
3.7Setup          19
3.8Assistance/FieldSupport       19
Secon4:ManualOperaon        20
4.1Overview         20
4.2DrawheadOperaon        20
4.3ManualFrameControls,ClassicVersion     21
4.4ManualFrameControls,ModularVersion     22
4.5ManualControlviaComputer       22

Contents
Secon5:AssigningUserNames,Privileges,andPasswords   23
5.1AssigningUserNames        23
5.2Privileges         25
5.3Passwords         26
5.4MiscellaneousFuncons       26
Secon6:SystemSetup         27
6.1 SengSystemUnits        27
6.2FrameSetup         28
6.3GeneralSetup         42
6.4ThermocoupleCircuitBoardCalibraon     52
6.5ClockSpeed         52
Secon7:Operaon         53
7.1GeneralOverview        53
7.2TestSpecicaons        57
7.3Specimens         71
7.4Tesng          75
7.5StoppingaTest         79
7.6ViewTestData         80
7.7Maintenance         86
7.8Tools          90
7.9GraphingOpons        91
7.10Help          91
Secon8:Accessories         92
8.1Thermocouples         92
8.2Extensometers         96
AppendixA:SystemStatusDisplay       102
AppendixB:Glossary         106
AppendixC:DefaultValues        109
AppendixD:Warranty         114

5
Preface
Unpacking
Retainallcartonsandpackingmaterialsunltheunitisoperatedandfoundtobeingoodcondion.If
damagehasoccurredduringshipping,nofyAppliedTestSystems(ATS)andthecarrierimmediately.Ifit
isnecessarytoleadamageclaim,retainthepackingmaterialsforinspeconbythecarrier.
Warranty
AllnewATSsystemsareshippedwithawarranty.Unitshaveawarrantyagainstdefecvepartsand
workmanshipforonefullyearfromdateofshipment.PleaseseeAppendixD ofthismanualfor
completedetailsonthewarranty.
NOTE:Pleaseseethewarrantyinformaonincludedwiththecomputer.Itdetailsinformaonthatwill
ensurepropertransferofthecomputerwarrantyfromATStotheappropriatecompany.
Aer-Sale Support
Ifthereareanyquesonsconcerningtheoperaonoftheunitorsoware,contacttheATSService
Departmentat[phone].Beforecalling,pleaseobtainthesowarerevisionnumberandthe
serialnumberfromtheunit’sdatatag .Asampledatatagisshownbelowandcanbecompletedwiththe
unit’sinformaonforeasyreference.Pleasebepreparedtogiveacompletedescriponoftheproblem
toATSServiceEngineers.

Terms
Pleasenotethefollowingtermsusedthroughoutthismanual.
1.Extensometerframe:thehardwareaachedtothespecimenthatmeasurescreep
2.Extensometer:displacementtransducerorencoderaachedtotheboomoftheextensometer 
frame
3.°F:thissymbolisusedtonotedegreesFahrenheit
4.°C:thissymbolisusedtonotedegreesCelsius
AlsonotethatthismanualusesboththeUnitedStatescustomaryunitsofmeasurementandthe
InternaonalSystemofUnits(SIormetric)inthismanual.
6

7
Secon1:Introducon
1.1 General Descripon
TheAppliedTestSystems(ATS)WinCCSsystemcombinesproprietaryhardwareandsowarewitha
directloadorleverarmtestertoprovidecomputerautomaonoftheenretestprocess.Usingarchived
testspecicaons,thesystemwill:
controlfurnacetemperature•
applytheappropriateload•
collectcreep,load,andtemperaturedata•
archivetestresultsinalogicalformat.•
Constantstressandstressrelaxaontesngisaccommodatedonsomemodels .Thesystemissupplied
withnewATSframesaswellasretroedintoexisngframesmadebyATSandothermanufacturers.
SERIES
2140 2320 2330 2410 2430 2510
MM X X X X X X
MS X X X X X X
CCM X NA X X X X
CCS X NA X X X X
SRM NA NA X NA NA NA
SRS NA NA X NA NA NA
X Thismodeltsthiscategory.
NA Notapplicableonthismodel.
MM WinCCSModularControlsMainTester
MS WinCCSModularControlsSecondaryTester
CCM WinCCSClassicControlsMainTester
CCS WinCCSClassicControlsSecondaryTester
SRM WinCCSClassicControlsMainTesterwithStressRelaxaonCapabilies
SRS WinCCSClassicControlsSecondaryTesterwithStressRelaxaonCapabilies
NOTE:AllSecondaryTesters(ModularandClassic)mustbepairedwithaMainTester.
NOTE:OnlyoneSecondaryTestercanbeconnectedtoaMainTester.

8
1.2 Computer Specicaons
Minimumcomputerspecicaonsincludethefollowing:
 Processor:2.8GHzorbeer
 OperangSystem:Microso®Windows®7Professional,32bit
 Memory:2GBorbeer
 HardDrive:250GBorbeer
 DVDDrive:16xorbeer
 RS422Card,DualPort
NOTE:EachRS422portiscapableofconnecngupto64testframes(or32pairsofframes).Acomputer
withaDualPortRS422cardiscapableofconnecngupto128testframes(or64pairsofframes).

9
1.3 WinCCS System Overview
1.3.1 Test Specicaons
Thetestspecicaoncontainsallthedetailsofthetest.Thesystemisdesignedtofollowguidelinesfor
severalregulangagencies.Userscansetspecicaonsaccordingtoeithertheseguidelinesortheirown
conguraons.Atestspecicaonissavedinthesystemeachmethatsetofparametersisappropriate.
1.3.2 Test Specimens
Thetestspecimenisspecictooneitemandthereforemusthaveauniquespecimennameforarchival
purposes.Associatedwiththespecimennameisalldata,includingphysicalsize,materials,etc.specic
tothatparcularitem.
1.3.3 Sequence of Events
Thetestisperformedinthefollowingsequenceofevents:
1.Selectorcreateaspecicaontobeusedtocontrolthetest.
2.Createaspecimenusingthesowareprocess.
3.SelectanIdletestframeandfollowtheStartaTestroune.
4.TheRunningTeststatewillchangetothePostTeststatewhenthetestiscompleteorstopped 
manually.
NOTE:ThePostTeststateallowstheoperatortorestartthetestorenterappropriatedata,suchas
elongaoninformaon,ontothetestcomments.Thetestdataisthenautomacallyarchived,andthis
testisnowclassiedasaPreviousTest.
5.TestresultscanbeviewedeitherbeforeoraerthePostTestprocedure.
NOTE:Alloftheabovefunconsaredescribedindetailinthismanual.

10
Secon2:Safety
AllATSequipmentisdesignedtobeoperatedwiththehighestlevelofsafety.ThismanualandATS
endeavortoeducatetheoperatoraboutsafetyissuessurroundingcertainpartsofthemachineryby
usingequipmentlabeling.Seepage13ofthismanualforthelocaonofsafetylabels.
2.1 For Owners, Operators, and Maintenance Personnel
Readandunderstandallinstruconsandsafetyprecauonslistedinthismanualbeforeinstallingor
operangtheunit.Ifthereareanyquesonsregardingoperaonoftheunitortheinstruconsinthis
manual,contacttheATSServiceDepartmentat[phone].
Inaddiontothesafetywarningslistedontheequipment,warningsarepostedthroughoutthis
manual.Readandfollowtheseimportantinstrucons.Failuretoobservetheseinstruconscanresultin
permanentdamagetotheunit,signicantpropertydamage,personalinjury,ordeath.

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2.2 Warnings
Thefollowingstatementsarewarningstatements.Unlikecauonstatements,warningstatementsalert
theoperatortocondionsthatmayinjurepersonnel.Operatorsmustbeawareofthesecondionsin
ordertopreventinjuriesthatmayoccurwhileoperangthisequipment.
WARNING:Disconnectpowerpriortoperformingmaintenance.Turnotheunitand
disconnectandlockoutbeforeperforminganymaintenanceprocedures.
WARNING:Hot/Burnsurface,usepersonalprotecvegearwhenoperangequipmentand
handlingmaterialsassociatedwiththetesngprocedure.
WARNING:Pinchhazard.
WARNING:Donotopenthepanel.
WARNING:Unpackandoperateonastablesurface.
2.3 Cauons
Thefollowingstatementsarecauonstatements.Thesestatementsalerttheoperatortocondionsthat
maydamageequipment.Operatorsmustbeawareofthesecondionsinordertoensuresafeoperaon
ofthisequipment.
CAUTION:Installaonofelectricaldevicesmustbeaccomplishedbycompetentpersonnel
anddoneinaccordancewithanycurrentlocalandnaonalcodes.Equipmentgroundingisa
MUSTforbothsafetyandproperoperaon.
CAUTION:Beforeenergizingtheelectricalpowertotheequipment,turnoallpower
switchesandplaceallcontrolsinanOFFposion.Checkthatthepowersourceissurge-
protectedandisoftheappropriatevoltageandamperage.Useappropriatepoweradapters
fortheregion.

12
Secon3:EquipmentSetupandInstallaon
Readandunderstandallinstruconsandsafetyprecauonslistedinthismanualbeforeinstalling
oroperangtheunit.Forquesonsregardingunitoperaonorinstallaon,contacttheATSService
Departmentat[phone].
Inaddiontothesafetyinformaonlistedhere,therearecauonsandwarningsthroughoutthis
manual.Failuretofollowtheseinstruconscouldresultinpermanentdamagetotheunit,signicant
propertydamage,personalinjury,ordeath.
 ReadOperator’sManual
 GeneralDanger
 ProtecveEarth(Ground)
 BurnHazard(HotSurface)
 ElectricalShock/Electrocuon
 HandCrushForceFromAbove
 EuropeanDirecveCEMark
 NoAccessforUnauthorizedPersons

13
3.1 Safety Instrucons
1.Readandfollowallwarningandcauonstatementsinallrelatedequipmentmanuals  
beforeaempngtooperatethismachine.Ifindoubtaboutanystatementorsequence,  
contactATSService.
2.Installaonofelectricaldevicesmustbeaccomplishedbycompetentpersonnelanddonein 
accordancewithanycurrentlocalandnaonalcodes.EquipmentgroundingisaMUSTfor 
bothsafetyandproperoperaon.
3.Beforesupplyingelectricalpowertotheunit,turnallpowerswitchesandcontrolsinanOFF 
orNEUTRALposion.
4.Matchallserialnumbersontestframes,supportblocks,andleverarmswhenassembling  
mulpletesters.
5.Alternateweightslotsat180degreestopreventp-overwhenstackingweights.
3.2 Locaon of Safety Labels

14

15
3.3 Unpacking Equipment
Carefullyunpacktheequipmentandinspectitfordamageduringshipment.Retainallcartonsand
packagingmaterialsunltheunitisoperatedandfoundtobeingoodcondion.Ifdamagehasoccurred
duringshipping,nofythecarrierandATSimmediately.Ifitisnecessarytoleadamageclaim,retain
thepackingmaterialsforinspeconbythecarrier.
UnpackingandSetup
1.Carefullyremovetheshippingcrateandpackingmaterials.Donotdiscardthepacking  
materialsunlallitemsontheinvoicehavebeenaccountedfor.
2.Useanoverheadcraneorforklitoremovethetestframeandcontrolconsolefromthepallet 
andposionitinthedesiredlocaon.
NOTE:Usemovingblanketsbetweenunitcomponents,andfollowacceptedmovingpraccestoavoid
damagetothetester.
NOTE:Posionthetestframeandconsoletoallowampleroomformaintenance.
3.Ifcastersaresuppliedwiththeunit,installtheminthecabinetbasewhenitisliedothepallet.
4.Adjusttheisolatormountsonthetestframetoapproximatelylevel,ensuringevensupport.
CAUTION:Donotallowtheisolatormountpadstoslideontheoorwhilemovingthetester.
Theyarenotdesignedtoacceptsideloading.Damagetothepadsmayresult.
5.Ifapplicable,connectthecablesbetweentheloadframeandthecontrolconsole.
6.Connectelectricalpowertothecustomerpowerterminalblock.PropergroundingisaMUST.
NOTE:Followalllocalandnaonalcodes,andbesuretousethecorrectvoltageandamperage.Referto
equipmentdatatagfortheindividualunitinformaon.
CAUTION:TurnallpowerswitchestoOFFandplaceallcontrolsinaneutralposionbefore
supplyingpowertothemachine.

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3.4 Specicaons
EnvironmentalCondions
1.Indooruseonly.
2.Maximumaltudeof2000meters.
3.Storagetemperatureof5degreesto40degreesCelsius.
4.Operangtemperatureof±3degreesCelsiusatthemeofforceapplicaon.
5.Relavehumiditynomorethan80percentat31degreesCelsius,50percentat40degreesCelsius.
6.MainSupply±10percentof230VACor±10percentof115VAC,dependingontheunit.
7.1Prang:1PXO.
Series 2320 Tester

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3.5 Hardware Installaon
AllhardwareisbuiltattheATSfactory.Ifhardwareinstallaonisrequiredonsite,pleasecontactthe
ServiceDepartment.ONLYPERFORMTHOSEOPERATIONSTHATAPPLYTOTHEUNITRECEIVED.
NOTE:ELECTRICALPOWERMUSTBECONNECTEDPRIORTOARRIVALOFATSSERVICE.
3.5.1 Lever Arm Assembly Installaon
1.Posiontheknife-edgesupportblockassemblyontopofthetestframesothattheserial  
numberontheblockisfacingtheweights.
2.Installthelocangdowels.
3.Installboltsandghten.
CAUTION:Matchtheserialnumbersonthetestframeswiththesupportblocksandlever
armswhenassemblingmulpletesters.
4.Removeorpivottheleverarmsafetyguardstotheside.
5.Checkthattheknife-edgeandV-blockmangsurfacesarefreeofdirtorrust.
6.InstalltheleverarmtothetesterwiththeV-blocksmatedtotheknife-edges.
NOTE:Takecarenottodamageknife-edgesorproximityswitch.
7.EnsurethattheleverarmV-blocksarecenteredonthepedestalblockknife-edgesfronttoback. 
Theleverarmshouldpivotfreely.
8.Installthesafetyguardsandghtenbolts.

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9. Checkposionandoperaonoftheproximityswitchactuator(orshutdownswitchactuator, 
ifequipped).
10.Forautomacbeamlevelingontesterdrawheads:
 a.Aachtheautomacbeamleveloangactuatorstotheleverarmabovetheproximity 
switches.
 NOTE:Theswitchatthefrontofthemachineisknownasthemainswitch,whiletheswitchat 
 thebackofthemachineistheintermediate.Theseswitchesarepre-installedbyATS.
 b.Adjustthenutsabovethemainproximityswitchunltheredlightontheswitchgoesout, 
whichsignalsthatthearmislevel.TheredlightwillilluminateONLYwhentheleverarm 
 islowontheweightpanside.
 c.Tosettheintermediateswitch,adjustthenutsaboveunltheredlightgoesout.This 
 shouldbewhentheweightpansitsonthebaseandthereisabout1-2cmofslackinthechain.
 TheredlightwillilluminateONLYwhentheleverarmthereisexcessiveslackinthechain.
NOTE:Agreenlightshowsthattheswitchesarelevel.

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3.6 Soware Installaon
AllsowareisinstalledonthecomputersattheATSfactory.Ifsowareinstallaonisrequiredonsite,
pleasecontacttheServiceDepartment.
3.7 Setup
Pleasehavealloftheequipmentunpackedandplacedinthelocaondesiredbeforesetup.Itis
recommendedtohavethisequipmentinstalledbyATSService.Electricalpowershouldbeconnectedto
thetesterbyalocalelectriciantoadherencetolocalandnaonalcodes.
NOTE:ELECTRICALPOWERMUSTBECONNECTEDPRIORTOARRIVALOFATSSERVICE.
3.8 Assistance/Field Support
IfthereareanyproblemswhilesengupanyATSequipment,pleasecontacttheATSService
Departmentat[phone].

20
Secon4:ManualOperaon
4.1 Overview
Whileinmostinstancestheframeiscontrolledbythesystemduringtesng,itisnecessarytoprovide
fullmanualcontrolfortestsetupandfortroubleshoongpurposes.
TherearetwobasicversionsoftheWinCCShardware,ModularandClassic.Manualcontrolis
accomplishedinvariouswaysdependingontheversionofWinCCShardwareused .
Inaddion,manualcontrolisprovidedthroughthecomputerunderthemaintenanceroune.
NOTE:Whenundermanualcontrolviacomputer,mostsafetyinterlocksaredisabled.Thisisnecessaryto
allowfortroubleshoongpurposes.
Ifanoperatorisnotthoroughlyfamiliarwiththeuseofthesecontrols,consultATSat[phone]
priortoaempngthisoperaon.
4.2 Drawhead Operaon
AppliedTestSystemsdrawheadsareusedfortheinialloadingofaspecimen,keepingtheleverarm
level.Theyaredesignedtomaintainleverarmposioning,evenduringspecimenelongaon,providing
moreaccuratetestresults.
4.2.1 Automac Drawhead Controls
1.JogUp:Usedtojogthedrawheadupinmanualmode.
NOTE:SystemmustbeinIdlestatetoswitchtomanualmode.
2.JogDown:Usedtojogthedrawheaddowninmanualmode.
NOTE:SystemmustbeinIdlestatetoswitchtomanualmode.
3.DrawheadSpeed:Usedtovarythespeedofthedrawhead.
NOTE:Thedrawheadistypicallysetatornearzeroduringtestsandsetathigherspeedswhen 
jogging.
4.2.2 Drawhead Cauons
Observeallcauonslistedinthetesngmachineinstruconmanual.
Observeleverarmwhenloading.Donotallowcounterweightendofarmtoboomoutonthe
frame.