ATS BBR2S User manual
MAN - BBR2S - REV: Original
BBR2S
Bending Beam Rheometer
INSTRUCTION MANUAL
This manual contains important operating and safety information. Carefully read and
understand the contents of this manual prior to the operation of this equipment.
www.atspa.com
MAN - BBR2S - REV: Original
REVISED JULY 2018
Information in this document is subject to change without notice and does not represent a commitment on the part of
Applied Test Systems (ATS).
© Copyright Applied Test Systems 2018
For assistance with set-up or operation, contact the ATS service department. Please have this manual and product serial
number available when you call.
Telephone: +1-724-283-1212.
iMAN - BBR2S - REV: Original
Manual Contents
A. Introduction...................................................................................................................................1
A.1 Unpacking......................................................................................................................................................1
A.2 Warranty Information.....................................................................................................................................1
A.3 After Sale Support.........................................................................................................................................1
B. Safety.............................................................................................................................................2
B.1 For Owners, Operators, and Maintenance ....................................................................................................2
B.2 Safety Instructions.........................................................................................................................................2
B.3 Warnings .......................................................................................................................................................2
B.4 Cautions ........................................................................................................................................................3
C. System Overview..........................................................................................................................4
C.1 Equipment Parts ............................................................................................................................................4
Front of Unit.............................................................................................................................................4
Back of Unit .............................................................................................................................................5
Gauge Kit ................................................................................................................................................6
C.2 General Product Description.........................................................................................................................7
Major Components..................................................................................................................................7
Accessory Items......................................................................................................................................7
Product Specications.............................................................................................................................7
Recommended Tools ..............................................................................................................................8
Installation ...............................................................................................................................................8
Operation.................................................................................................................................................8
Environmental Conditions .......................................................................................................................8
Load Frame .............................................................................................................................................8
Specimen Support...................................................................................................................................9
Linear Variable Dierential Transformer (LVDT) .....................................................................................9
Load Cell ...............................................................................................................................................10
Resistance Temperature Detector (RTD)..............................................................................................10
Computer Control System Software .....................................................................................................10
Mechanical Refrigeration Unit ...............................................................................................................10
Accessories ..........................................................................................................................................10
Controls ................................................................................................................................................. 11
D. Installation................................................................................................................................... 12
D.1 Recommended Tools...................................................................................................................................12
ii MAN - BBR2S - REV: Original
Installation .............................................................................................................................................12
Operation...............................................................................................................................................12
D.2 Unpacking the BBR2S ................................................................................................................................12
D.3 Assembling the Load Nose .........................................................................................................................13
D.4 Connecting Equipment ................................................................................................................................15
D.5 BBR2S Software Installation.......................................................................................................................17
E. Operation.....................................................................................................................................20
E.1 Filling the Bath .............................................................................................................................................20
E.2 Power Up the BBR2S..................................................................................................................................20
E.3 Overview of Touchscreen and Menus.........................................................................................................20
E.4 Editing Users and Permissions..........................................................................................................................22
Operator Name Field.............................................................................................................................23
Password Field......................................................................................................................................23
User Privilege Switches ........................................................................................................................23
Save Button ...........................................................................................................................................23
Copy Button...........................................................................................................................................23
New Button............................................................................................................................................24
Delete Button.........................................................................................................................................24
E.5 Standardization Process .............................................................................................................................24
E.6 Verication Process.....................................................................................................................................27
E.7 Test Setup....................................................................................................................................................31
Test Name .............................................................................................................................................31
Test Date ..............................................................................................................................................31
Saving Test Parameters ........................................................................................................................31
Copying a Test.......................................................................................................................................31
Creating a New Test ..............................................................................................................................32
Deleting a Test.......................................................................................................................................32
Adding Report Images ..........................................................................................................................32
Adding a Test Company ........................................................................................................................32
Standard or Data Report .......................................................................................................................32
Deection Plot and Load Plot................................................................................................................32
Bath Values ...........................................................................................................................................33
Specimen Values...................................................................................................................................33
Test Times .............................................................................................................................................33
Report Language ..................................................................................................................................33
E.8 Run Test ......................................................................................................................................................33
Load Setup ............................................................................................................................................34
St ar t Test ...............................................................................................................................................35
Run Crack Sealant Test.........................................................................................................................35
iiiMAN - BBR2S - REV: Original
View Test ...............................................................................................................................................36
E.9 Diagnostics..................................................................................................................................................36
Analog Inputs AI1, AI2, and AI3 ...........................................................................................................37
Analog Outputs AO1 and AO2 ..............................................................................................................37
Digital Inputs 1, 2, 3, and 4 ...................................................................................................................37
Digital Outputs 1 and 2 .........................................................................................................................37
Digital Outputs 3 and 4 .........................................................................................................................37
F. Troubleshooting ..........................................................................................................................38
F.1 Preface .........................................................................................................................................................38
F.2 Load Shaft Stuck or Stalled During Verication or Standardization ............................................................38
G. Maintenance................................................................................................................................40
G.1 General Maintenance ..................................................................................................................................40
Appendix A: Warranty .................................................................................................................... 41
Appendix B: Wiring Diagrams .......................................................................................................42
Appendix C: Image Glossary .........................................................................................................44
MAN - BBR2S - REV: Original | A. Introduction 1
A. Introduction
A.1 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 (ATS) and the carrier immediately. If it is necessary to le a
damage claim, retain the packing materials for inspection by the carrier.
A.2 Warranty Information
All new ATS systems are shipped with a warranty. Units have a warranty against defective parts and workmanship
for one full year from the date of shipment. Please see APPENDIX A of this manual for complete details on the
warranty.
A.3 After Sale Support
If there are any questions concerning the operation of the unit or software, contact the ATS Service Department at
+1-724-283-1212.
Before calling, please obtain the software revision number and the serial number from the unit’s data tag. A sample
data tag is illustrated below, and can be completed with the unit’s information for easy reference. Please be
prepared to give a complete description of the problem to the ATS Service Department.
Figure A.1: ATS Sample Data Tag
MAN - BBR2S - REV: Original | B. Safety2
B. Safety
B.1 For Owners, Operators, and Maintenance
All ATS equipment is designed to be operated with the highest level of safety. This manual uses note, caution, and
warning symbols throughout to draw your attention to important operational and safety information.
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 the ATS
Service Department at +1-724-283-1212.
Read and follow these important instructions. Failure to observe these instructions can result in permanent damage
to the unit, signicant property damage, personal injury or death.
B.2 Safety Instructions
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.
Thoroughly understand the safety features and operation of the equipment. This manual
will provide operators with safety concerns and general procedures. Be familiar with correct
operating principals and use good judgment. Also refer to the appropriate manuals for system
component safety instruction manuals.
Obey all national and local electric code requirements.
Dangerous high voltages present. Do not attempt to open the enclosure or gain access to areas
where you are not instructed to do so. Refer servicing to qualied service personnel only.
Use caution when working with liquids at low temperatures. Protect skin by wearing protective
clothing, and follow safety, operation, and maintenance procedures described in the appropriate
instruction manuals.
B.3 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
MAN - BBR2S - REV: Original | B. Safety 3
injuries that may occur while operating this equipment.
WARNING: Injury to the operator could occur if operational procedures are not followed. Follow
all steps or procedures as instructed and refer to accompanying documents.
WARNING: Flammable vapors may be emitted from bath. Operate uid bath in a well
ventilated area. Do not smoke or use open ame near the bath. Refer to uid manufacturer’s
documentation for more detailed information specic to safety precautions for the bath uid being
used.
WARNING: Do not submerge hand and arm in extremely cold test bath. Do not attempt to pull
the drain plug when the uid bath level is high and temperature is extremely cold. Extremely cold
uid may cause frost bite.
WARNING: Use caution when handling air hoses during operation or when performing
maintenance as contents will be under pressure.
B.4 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 to ensure safe operation of this equipment.
CAUTION: Handle the load cell with care. The load cell will be damaged if the load frame is put
on its side with the load nose attached, or if the load nose is over tightened.
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 o for at least 8 hours and has reached room temperature.
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 oor and not on the same surface as the BBR.
CAUTION: Carefully place the calibration weights on the load cell’s weight plan. If the Linear
Variable Dierential Transducer (LVDT) shaft is bumped, it may become inaccurate or even
permanently damaged.
4MAN - BBR2S - REV: Original | C. System Overview
C. System Overview
C.1 Equipment Parts
Front of Unit
Figure C.1: BBR2S Front
5
3
1
2
76
4
1. Load Frame
2. Power Switch
3. Mode Select Switch
4. Stirrer Motor Controls
5. Zero/Load Pressure Gauge
6. Zero Regulator
7. Load Regulator
MAN - BBR2S - REV: Original | C. System Overview 5
Back of Unit
1. Incoming Air Connection
2. Air Connections to Load
Frame
3. AC Power Connection
4. Chiller RTD (Connects to
Back of Chiller)
5. USB Connection to BBR
Computer
6. Load Frame Sensor Cables
Figure C.2: BBR2S (Rear View)
1
2
6
3
4
5
6MAN - BBR2S - REV: Original | C. System Overview
Gauge Kit
Figure C.3: BBR2S Gauge Kit
1. Step Disk
2. 50 gram cal. weights (4)
3. 2 gram weights (2)
4. Non-Compliant Beam
5. Condence Beam
6. Load Shaft
7. Anvil Support Adapters (2)
1 2 2
3
3
622
4
5
7 7
MAN - BBR2S - REV: Original | C. System Overview 7
C.2 General Product Description
The ATS Bending Beam Rheometer (BBR2S) has been designed to provide a state-of-the-art means for testing
the exural creep stiness properties of asphalt binders in a temperature range of -40°C to 25°C. This testing is
in accordance with the Strategic Highway Research Program (SHRP) Test, Method B-002, AASHTO Designation
T313, and ASTM D 6648. The BBR2S’s design does not allow it to perform any additional functions other than the
intended functions specied in this manual.
The BBR2S consists of the following:
Major Components
• Base Unit
• Load Frame Assembly
• Personal Computer
• BBR2S Software
• Mechanical Refrigeration Unit
Accessory Items
• Specimen Molds (5 Molds)
• Condence Beam
• Non-Compliant Beam
• LVDT Calibration Gaging Disk
• Load Cell Calibration Weights (4 50-gram and 2 2-gram)
The BBR2S test control function and data acquisition is operated by a Windows® based personal computer. During
testing, the software controls the BBR2S load function, displays and records the load, deection, 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.
Product Specications
Power Requirements 120 VAC, 60 Hz or 230 VAC, 50/60 Hz
Dimensions 24.125” W X 24.125” D X 23.25” H (w/ load frame)
Weight Approximately 270 lbs.
Coolant Capacity 2 gallons (7.57 liters)
Recommended Fluid Non-ammable ethylene glycol mixture
Test Standards ASTM D6648, BS EN 14771, AASHTO T313
8MAN - BBR2S - REV: Original | C. System Overview
Operating Temperature Ambient to -40°C
Recommended Tools
The following tools are recommended for use during installation and operation of the BBR2S.
Installation
• 9/16” Open-Ended Wrench
• Set of Hexagonal Wrenches
• Flat Bladed Screw Driver
Operation
• Metal Tongs for the placement and removal of the specimen from the uid bath.
• Protective eye wear and gloves for use during testing.
Environmental Conditions
The BBR2S is designed for use in an industry/laboratory setting in an indoor and dry environment. The Base Unit
should be placed on a clean, stable work surface with the connecting mechanical refrigeration unit nearby. The
mechanical refrigeration unit should be placed 6 in. above the oor and in an area that will not constitute a tripping
hazard.
Load Frame
The load frame 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 uid bath, or it may be used in ambient conditions. It features rigid
construction and a space saving design, as well as durable, corrosion resistance.
Each load frame is constructed from 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-
oating 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 uid 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 Dierential Transformer (LVDT). Two low
voltage, sealed lamps are mounted in the base of the load frame in order to illuminate the specimen in the uid bath.
The load frame is made up of an LVDT shaft, weight pan, air bearing, load shaft, load cell, and adapter. A hard,
plastic shroud is mounted to the load frame and serves to protect the load cell from splashing uid and minimize the
aect of uid movement on the load nose.
MAN - BBR2S - REV: Original | C. System Overview 9
Specimen Support
The bottom half of the load frame consists of an anvil with two metal supports designed for alignment of the
specimen. These specimen supports have a 3 mm contact radius and are xed 102 mm apart from each other. They
are designed to align samples that are approximately 127.00 mm x 12.70 mm x 6.35 mm.
Resting on each of the anvil’s specimen supports are two anvil adapters (see Figure C.5). During crack sealant
testing these anvil adapters need to be removed by lifting STRAIGHT UP on the adapter and pulling it o of the
guide pin. The load frame should be removed from the bath and allowed to warm to room temperature before
removing the anvil adapters. The anvil adapters should be installed on the anvil supports for testing of any regular
asphalt binder samples.
The specimen supports and lower portion of the load frame are designed to be submerged in the constant-
temperature uid bath during the test. The uid in the bath provides a buoyant force that counterbalances the weight
of the specimen.
Linear Variable Dierential Transformer (LVDT)
The LVDT is calibrated at between 0 and 6 mm and is mounted in the upper section of the load frame assembly. A
free-oating core rod is attached directly to the load shaft. It 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 LVDT shaft
is bumped, it may become inaccurate or even permanently damaged.
Load Cell
The load cell is a precision strain gauge-type, with 500 gram (4903 mN) force capacity. It is constructed of stainless
steel to prevent corrosion or damage by the uid 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.
Figure C.5 - Load Frame with Anvil Adapters
Figure C.4 - Load Frame without Anvil Adapters
10 MAN - BBR2S - REV: Original | C. System Overview
Resistance Temperature Detector (RTD)
The RTD is a platinum measuring device that measures the cooling uid bath temperature and relays the
information to the computer control system software. It 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
at the testing temperature or beyond it (at least -10°C or lower). The RTD is factory-calibrated at 0°C and -36.0°C. No
further adjustment should be made under normal operating conditions.
Computer Control System Software
The computer control system software provides user control of the BBR2S system in a Windows® environment with
keyboard and/or mouse access to these functions. The software provides pull-down menus, button selections, and
data entry text boxes for easy updates and access to information.
The software is designed to run on a standard PC 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 of the information required to conduct a
particular test is stored in the PC. This design allows future enhancements or new releases to be easily added to the
existing system without the need for hardware additions or modications.
Mechanical Refrigeration Unit
The refrigeration unit is an immersion cooler designed as a cooling source for sub-ambient work in liquid baths.
The unit rests on the oor and maintains the cooling uid 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 the manufacturer’s literature 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 into the 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 uid may cause frostbite.
Accessories
• Specimen Molds: Used to create specimens. Each mold consists of ve aluminum bars of various
sizes, three mylar strips, and two holding rings. Five of these molds are supplied with the BBR2S.
• Condence Beam: A thin, stainless steel beam of known stiness. This beam is placed on the
specimen supports of the load frame during the condence check.
• Non-Compliant Beam: A length of stainless steel that has the same dimensions as the specimen.
This beam is placed on the specimen supports when verifying and calibrating the load cell and when
performing the compliance test.
• Step Disk: The step disk is used during LVDT standardization and verication. It has ve 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
MAN - BBR2S - REV: Original | C. System Overview 11
the letters A (1 mm), B (3mm), C (5mm), and D (6mm). This provides the 6mm test range required by
both ASTM and AASHTO Specications.
• Load Calibration Weights: Four 50 gram and two 2 gram load cell calibration weights are supplied
with the BBR2S. These weights are placed on the load frame weight pan during load cell verication.
The weights are also used to calibrate the load cell and ensure system compliance.
Controls
• Internal Controls: Two controls are located inside the right panel of the BBR2S base unit. These
controls are factory set (the line pressure regulator is positioned on the right inside of the panel. This
pressure is set at 60 psi. The bearing pressure regulator is located to the left of the line pressure
regulator and is set at 15 to 20 psi. Verify the settings if necessary.
• Base Unit Controls: The BBR2S base unit controls can be seen in Figure C.1.
• Mechanical Refrigeration Unit: The refrigeration unit’s power control is located on the front of the
unit. The temperature set-point is located on the temperature control on the front of the unit (see
manufacturer’s literature for set-up).
MAN - BBR2S - REV: Original | D. Installation12
D. Installation
D.1 Recommended Tools
The following tools are recommended for use during installation and operation of Bending Beam Rheometer.
Installation
• 9/16’’ Open Ended Wrench
• Set of Hexagonal Wrenches
• Flat Bladed Screw Driver
Operation
• Metal tongs for the placement and removal of the specimen from the uid bath.
• Protective eye wear and gloves for use during testing.
D.2 Unpacking the BBR2S
To unpack and prepare the BBR2S for operation, complete the following steps.
CAUTION: Use care when moving the base unit. The refrigeration unit is attached, and the
refrigeration hose may be damaged if it is twisted or pulled, especially when the unit is cold.
1. Remove the base unit and the refrigeration unit from the box, and place them on a sturdy work surface.
WARNING: Position the BBR2S in a well-ventilated area. Consider that ammable vapors may
be emitted from the bath during operation. Refer to uid manufacturer’s MSDS documentation
for further information.
2. Remove the load frame assembly and place it on a sturdy work surface near the base unit.
3. Remove any packing materials from the unit. The following items should also be located and set aside:
• Case containing the step disk, a non-compliant test beam, a non-compliant test beam, a condence check
beam, a six-piece weight set, (2) anvil supports, and load nose.
• USB-A to USB-B cable which connects between the BBR base unit and BBR computer.
• Plastic bag containing crack sealant specimen mold pieces.
• Air hoses and magnetic stirrer.
• Envelope containing certications of verication, manual CDs for chiller, and NI drivers CD.
MAN - BBR2S - REV: Original | D. Installation 13
4. Remove the computer system from its box, and place it on a work surface beside the base unit.
5. Inspect the base unit, refrigeration unit, the computer system, and the load frame for any obvious damage that
may have occurred during shipping.
NOTE: If damage is found or suspected, notify the shipper and contact ATS immediately by
calling +1-724-283-1212.
D.3 Assembling the Load Nose
Assemble the loading shaft to the load frame assembly by following the steps below.
1. There are four screws securing the shroud to the load frame (Figure D.1). Loosen the back two screws slightly,
and completely remove the front two screws. This should allow you to remove the shroud from the frame.
2. Remove the foam from inside of the load shroud (Figure D.2). Unscrew the lower portion of the load shroud from
the upper portion (Figure D.3). Set the lower portion aside.
3. Retrieve the load nose from the BBR2S gauge kit. Place the load nose in the upper portion of the load shroud.
Four Screws
Figure D.1 - Load frame screw location
Figure D.2 - Foam Inside Load Shroud Figure D.3 - Unscrew the Lower Portion
of the Load Shroud
MAN - BBR2S - REV: Original | D. Installation14
4. Position the shroud and load nose at the base of the load frame. Lift the load nose and carefully screw it on to the
threaded stud in the bottom of the load cell until it is nger tight. When complete, secure the load nose in place by
tightening the set screw on the side of the load nose (see Figure D.4 and D.5).
WARNING: Do not over tighten the load nose, or damage to the load cell may occur.
5. Once the load nose is secured, lift the upper portion of the shroud around it. Use the back two screws to guide it
into place before tightening them and carefully screwing in the front two screws. See Figure D.6.
CAUTION: Do not over tighten the load nose on the load cell, or the load cell may become
damaged. The load cell is extremely sensitive to this twisting movement.
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 Nose is in place. Improper
handling will result in irreversible Load Cell damage.
6. To re-attach the lower portion of the load shroud, place the lower portion of the shroud on a at surface.
CAREFULLY lift the load frame, and position it so that the load nose is directly above the lower portion of the
Figure D.6 - Upper portion of shroud
attached to Load Cell
Figure D.5 - Tightening the Set
Screw
Figure D.4 - Set Screw Location on
Load Nose
MAN - BBR2S - REV: Original | D. Installation 15
shroud (Figure D.7). Lift the lower portion of the shroud up and gently screw it in to the upper portion (Figure D.8).
D.4 Connecting Equipment
The following hoses and cables are shipped with the BBR2S. Use them for connecting the BBR2S equipment and
refer to Figure D.10 on p.16.
• Zero/Load Hose (Item 2)
• Air Bearing Hose (Item 2)
• Temperature Sensor Cable (integral to base) (Item 4)
• Four Color-Coded Electrical Cables (integral to base) (Item 6)
• Communication Cable (USB-A to USB-B) (Item 5)
• Main Electrical Power Cable(s) (Item 3)
1. Connect the air hose ports on the rear of the base unit. The air supply connections supply a minimum of 60psi
of clean, dry air. Make sure the location of the air hoses are such that they will not snag or catch on anything in the
surrounding environment.
2. Connect the temperature sensor cable from the BBR base to the refrigeration unit.
3. Connect the color-coded electrical cables from the rear of the base unit to the rear of the load frame assembly.
4. Connect all needed cables and equipment for the computer system.
5. Connect the communication cable between the rear of the base unit and the computer system.
6. Plug the power cables from the base unit, the computer system, and the refrigeration unit into a surge-protected
power source of appropriate voltage. Refer to the data tag of the BBR2S 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.
Figure D.7 - Attaching lower
portion of Load Shroud
Figure D.8 - Attaching lower
portion of Load Shroud
Figure D.9 - Attached Load Nose with
Shroud
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