ATS BBR3S User 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
INSTRUCTION MANUAL
BBR3S
Bending Beam Rheometer 3S

2
REVISED NOVEMBER 2023
Information in this document is subject to change without notice and does
not represent a commitment on the part of:
Applied Test Systems (ATS)
154 East Brook Lane
Butler, PA 16002
USA
Telephone: [phone]
For assistance with set-up or operation, contact the ATS Service
Department. Please have this manual and product serial number readily
available when you call.
© Copyright Applied Test Systems 2023

3
Table Of Contents
Introduction ................................................................................................................................ 6
A.1 – Unpacking ..................................................................................................................... 6
A.2 – Standard Users and Passwords .................................................................................... 6
A.3 – Warranty Information..................................................................................................... 6
A.4 – After Sale Support ......................................................................................................... 7
Safety ........................................................................................................................................ 8
B.1 – For Owners, Operators, and Maintenance..................................................................... 8
B.2 – Cautions & Warnings..................................................................................................... 8
System Overview ......................................................................................................................11
..............................................................................................................................................11
C.1 Equipment Parts .............................................................................................................11
Front of Unit .......................................................................................................................11
Back of Unit .......................................................................................................................12
Load Frame ................................................................................................................13
Tank Interior .......................................................................................................................14
Gauge Kit...........................................................................................................................14
C.2 Product Description.........................................................................................................15
Major Components.............................................................................................................15
Accessory Items.................................................................................................................15
Product Specifications........................................................................................................16
Environmental Conditions ..................................................................................................17
Load Frame .......................................................................................................................17
Specimen Support .............................................................................................................18
Air Bearing .........................................................................................................................19
Linear Variable Differential Transformer (LVDT) .................................................................19
Load Cell............................................................................................................................19
Resistance Temperature Detector (RTD) ...........................................................................19
Computer Control System Software ...................................................................................19
Mechanical Refrigeration Unit (Chiller)...............................................................................19
Accessories .......................................................................................................................20
Controls .............................................................................................................................21

4
Data Instruments................................................................................................................22
Basic Unit Controls ............................................................................................................23
D.1 Recommended Tools ......................................................................................................24
Installation..........................................................................................................................24
Operation...........................................................................................................................24
D.2 Unpacking the BBR3S ....................................................................................................24
D.3 Assembling the Load Nose .............................................................................................25
D.4 Connecting Equipment....................................................................................................28
Operation ..................................................................................................................................30
E.1 Filling the Bath ................................................................................................................30
E.2 Power Up the BBR3S......................................................................................................30
E.3 Stirrer Motor ....................................................................................................................31
E.4 Overview of Touchscreen and Menus..............................................................................31
E.5 Editing Users and Permissions........................................................................................33
Operator Name Field .........................................................................................................34
Password Field ..................................................................................................................34
User Privilege Switches .....................................................................................................34
Save Button .......................................................................................................................34
Copy Button .......................................................................................................................34
New Button ........................................................................................................................34
Delete Button .....................................................................................................................34
E.6 Standardization Process .................................................................................................35
E.7 Verification Process.........................................................................................................40
E.8 Test Setup.......................................................................................................................44
Test Nam e ..........................................................................................................................45
Test Date............................................................................................................................45
Saving Test Parameters .....................................................................................................45
Copying a Test ...................................................................................................................45
Creating a New Test...........................................................................................................45
Deleting a Test ...................................................................................................................46
Adding Report Images .......................................................................................................46
Adding a Test Company .....................................................................................................46
Standard or Data Report ....................................................................................................46
Deflection Plot and Load Plot .............................................................................................48
Bath Values........................................................................................................................48

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Specimen Values ...............................................................................................................48
Test Times..........................................................................................................................48
E.9 Run Test..........................................................................................................................48
Load Setup ........................................................................................................................49
Start Test............................................................................................................................51
Run Crack Sealant Test – Optional ....................................................................................51
View Test ...........................................................................................................................52
E.10 Diagnostics ...................................................................................................................53
Analog Inputs AI 1, AI 2, and AI 3.......................................................................................54
Analog Outputs AO1 and AO2............................................................................................54
Digital Inputs 1, 2, 3, and 4 ................................................................................................54
Digital Outputs 1 and 2.......................................................................................................54
Digital Outputs 3 and 4.......................................................................................................54
Cool PID Values.................................................................................................................54
Troubleshooting ........................................................................................................................55
F.1 Preface ............................................................................................................................55
F.2 Load Shaft Stuck or Stalled During Verification or Standardization ..................................55
Maintenance .............................................................................................................................57
G.1 Cleaning the BBR3S.......................................................................................................57
G.2 Changing the BBR3S Fluid Bath.....................................................................................57
APPENDIX A: Warranty ............................................................................................................58
To obtain warranty service:....................................................................................................58
APPENDIX B: Declaration of Conformity...................................................................................59
APPENDIX C: Image Glossary .................................................................................................60

6
Introduction
A.1 – Unpacking
Retain all cartons and packing materials until the unit is in operation. If
damage has occurred during shipping, notify Applied Test Systems (ATS) and the
carrier immediately. If it is necessary to file a damage claim, retain ALL the
packing materials for inspection by the carrier.
A.2 – Standard Users and Passwords
Every BBR3S is programmed with the three standard user settings. Each
setting has a corresponding password and set of user restrictions. Please refer to
the table below to login and operate your new equipment.
User Name
Password
Permissions
Administrator
admin
Basic
Standardization
Diagnostics
User Edit
Operator
oper
Basic
Standardization
Default
Basic
A.3 – Warranty Information
All new ATS systems are shipped with a warranty. Units have a warranty
against defective parts and workmanship for one calendar year from the date of
shipment. Please see APPENDIX A of this manual for complete details on the
warranty.

7
NO.
AMP VAC
PH HZ
DWG
i Figure A.4.1 - ATS Sample Data Tag
A.4 – After Sale Support
If there are any questions concerning the operation of the unit or software,
contact the ATS Service Department at [e-mail].
Before emailing, 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.

8
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
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 the 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, significant property
damage, personal injury or death.
B.2 – Cautions & Warnings
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 manuals.
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.
Obey all national and local electric code requirements.

9
Handle the BBR3S carefully. Avoid dropping and jarring the BBR3S.
Damage to the machine may result if dropping and jarring occurs.
Dangerous high voltages present. Do not attempt to open the enclosure or
gain access to areas where you are not instructed to do so. Refer any
possible servicing to qualified service personnel only.
Injury to the operator could occur if operational procedures are not
followed. Follow all steps or procedures as instructed and refer to
accompanying documents.
Flammable vapors may be emitted from bath. Operate fluid bath in a well-
ventilated area. Do not smoke or use an open flame near the bath. Refer
to fluid manufacturer’s documentation for more detailed information
specific precautions for the bath fluid being used.
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
temperature is extremely cold. Extremely cold fluid may cause frost bite.
Use caution when handling air hoses during operation or when performing
maintenance as contents will be under pressure.
Handle 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.
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 temperature.

10
Prevent damage to the cooling unit. Never operate the cooling unit if the
ambient temperature is higher than 25°C.
The cooling unit should be placed in a well-ventilated area, on a stand at
least six inches above the floor and not on the same surface as the
BBR3S.
Carefully place the calibration weights on the load cell’s weight pan. If the
Linear Variable Differential Transducer (LVDT) shaft is bumped, it may
become inaccurate or even permanently damaged.
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.
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.
FLAMMABLE CHEMICALS may be located within enclosure. Exposure
may result in severe injury. Refer to maintenance manual before servicing.

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System Overview
C.1 Equipment Parts
Front of Unit
1. LOAD Regulator
5. Touch Screen Computer
2. Power Indicator
6. USB Port
3. ZERO Regulator
7. Leveling Feet
4. Load Frame
8. Chiller
4
8
6
5
2
3
1
7
ii Figure C.1.1 - Front of BBR3S Unit

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6
4
3
7
1
2
5
iii Figure C.1.2 - Back of BBR3S Unit
Back of Unit
1. Network / Ethernet
5. Air Bearing Connections
2. USB Connection
6. Air Connector
3. Load Frame Electrical
Cables
7. Unit Power
4. Chiller RTD Cable

13
6
5
1
3
3
2
4
10
7
8
11
9
iv Figure C.1.3 - Load Frame
Load Frame
1. LVDT Shaft
2. Weight Pan
3. Gaging Disk
4. Bearing Air Supply / Control
5. Lamps
6. Shroud
7. LVDT Housing
8. LVDT
9. Air Bearing
10. Load Cell
11. Load Nose

1. RTD
2. Magnetic Stirrer
3. Drain
2
1
3
1
2
3
4
*6
7
5
*
*
Optional with Crack Sealant Test
v Figure C.1.4 - Tank
vii Figure C.1.5 - Gauge Kit
vi Figure C.1.6 - Gauge Kit (2)
Tank Interior
Gauge Kit
1. 2g Weights
2. Load Nose
3. 100g Weights
4. Step Disk
5. Non-Compliant Beam
6. Anvil Adapters
7. Non-Compliant Beam
8. *Crack Sealant (CS) Non-
Compliant Beam

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C.2 Product Description
The ATS Bending Beam Rheometer 3S (BBR3S) 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 0 to -40°C. This testing is in accordance with the
Strategic Highway Research Program (SHRP) Test Method B-002, AASHTO
Designation T313, AASHTO TP 87, BS EN14771, and ASTM D 6648 specifications. The
BBR3S’s design does not allow for it to perform any additional functions other than
those specified in this manual.
The BBR3S test control function and data acquisition is operated by a Windows®-based
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.
The BBR3S is a fully integrated, modularized system consisting of the following:
Major Components
•Base Unit
•Load Frame Assembly
•BBR3S Software
•Mechanical Refrigeration Unit
Accessory Items
•Specimen Molds (5 Molds)
•Confidence Beam
•Step Disk
•Load Cell Calibration Weights (4) 100-gram and (2) 2-gram
•Crack Sealant Specimen Molds
•Non-Compliant Beam
•Crack Sealant (CS) Non-Compliant Beam

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Product Specifications
Load Frame Construction
Integral stainless steel, frictionless construction
Loading Shaft Point
In-line stainless steel with blunt point
Test Load
Variable test range from 0 to 4,500 mN (459 g) standard.
System maintains required test load within +/- mN (0.5 g)
throughout test cycle.
Test Cycle Times
Cycle times for pre-load, recovery, and test load are
completely operator-adjustable.
Load Cell
500 g (temperature-compensated)
Mechanical Overload Protection
Standard
Testing Temperature Range
0 to -40°C (32 to -40°F)
Temperature Measurement
Platinum RTD
Power Requirements
115 VAC, 1 ph, 50/60 Hz, 2 A or 230 VAC, 1 ph, 50/60 Hz, 2
A
Air Pressure
60 PSI Inlet Pressure (414 kPa) @ Class 3 Quality Max
Particle of 5 µm
Test Weights
Calibrated and traceable to NIST
Rating
IP20 Enclosure rating
Sample Supports
3 mm (0.118 in) radius stainless steel spaced 101.6 mm
(4.00 in) apart
LVDT Displacement Transducer
0.25 in (6.35 mm) calibrated range to provide 2 µm resolution
throughout testing and verification range.
Data Display
Large on-screen display of load, displacement, and bath
temperature provides ease of setup and operation. Real time
displacement, loading, and temperature graphs are displayed
during the test cycle and can be re-plotted and re-scaled as
needed for easy viewing.
Tank Liquid Volume
1.5 Gallons (5.5 liters)
Weight
150 lb.
Dimensions
BBR: 24 in W x 26.5 in D x 23.5 H (with load frame) Chiller:
10.5 in W x 20 in D x 9.25 in H

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Environmental Conditions
The BBR3S is designed for use in an industry/laboratory setting in an indoor and dry
environment. The base unit should be placed on a clean, stable work surface with the
connecting mechanical refrigeration unit nearby. The mechanical refrigeration unit
should be placed 6 inches above the floor and in an area that will not constitute a
tripping hazard.
The Bending Beam Rheometer 3S (BBR3S) should be kept in the following conditions,
in an ideal setting:
•Temperature of 15° C to 35° C
•Relative humidity should not exceed 75%
•Air Pressure of 75 kPa to 106 kPa
•No hard-frost, percolating water rain, solar irradiation, etc.
•Installation category II
•Pollution degree 2
Load Frame
The load frame is an independent three-point loading device designed to apply a load of
up to 4500 mN (459 g). The load frame may be operated in the supplied fluid bath, or it
may be used in ambient conditions. The load frame is made with a space-saving
design, rigid construction, and corrosion resistance material.
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 4500 mN. The air bearing also
provides reliable and rapid loading with an accuracy of ± mN.
The load frame is constructed with a horizontal shelf that extends across the top of the
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

18
Figure C.1.8 – Load Frame with
Anvil Adapters
viii Figure C.1.7 - Load Frame Without Anvil Adapters
pan for easy calibration of the load cell and the Linear Variable Differential Transformer
(LVDT). Two low weight pan for easy calibration of the load cell and the Linear Variable
Differential Transformer (LVDT). Two low voltage, sealed lamps are mounted in the
base of the load frame in order to illuminate the specimen in the fluid bath.
The load frame is made up of an LVDT shaft, weight pan, air bearing, load shaft, load
cell, and adapter. A metal plate cover is mounted to the front of the load frame and
serves to protect the load cell from splashing fluid and minimize the effect of fluid
movement on the load nose.
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 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.
Resting on each of the anvil’s specimen supports are two anvil adapters (see Figure
C.7). During crack sealant testing these anvil adapters need to be removed by lifting
STRAIGHT UP on the adapter and pulling it off 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 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 buoyant force that counterbalances the weight of the specimen.
Picture Coming Soon.

19
Air Bearing
The BBR3S incorporates an air bearing to provide frictionless loading performance. The
air bearing control system requires a constant 60 – 65 PSI (414 – 448 kPa) minimum
clean and dry air supply, @ Class 3 Quality max particle of 5 µm. 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.
Linear Variable Differential Transformer (LVDT)
The LVDT is calibrated between 0 and 6 mm and is mounted in the upper section of the
load frame assembly. A free-floating core rod is attached directly to the load shaft. It
measures the displacement of the specimen as the test load is applied.
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 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.
Resistance Temperature Detector (RTD)
The RTD is a platinum device that measures the cooling fluid bath temperature. It is
connected to the chiller and relays the information to the computer control system
software. It is mounted in the BBR3S bath directly under the test specimen supports.
Computer Control System Software
The computer control system software provides user control of the BBR3S system in a
Windows® environment with touchscreen access. The software provides pull-down
menus, button selections, and data entry text boxes for easy updates and access to
information.
The base unit contains an integrated personal computer, designed to efficiently run the
software. 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 internally.
Mechanical Refrigeration Unit (Chiller)
The refrigeration unit (chiller) is an immersion designed to act as a cooling source for
sub ambient work in liquid baths. It maintains the cooling fluid at a constant temperature
using 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.

20
ix Figure C.1.9 - BBR3S Step
Refer to the separate manufacturer’s literature for more detailed information regarding
safety, operation, and maintenance of the refrigeration unit.
WARNING: Refrigeration unit (chiller) 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.
Accessories
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 BBR3S.
Confidence Beam
The BBR3S comes with a Non-Compliant Beam and a Crack Sealant Non-
Compliance Beam. The Non-Compliance 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.
The Crack Sealant Non-Compliance Beam is the thicker of the two beams, and is used
only for Crack Selant tests.
Step Disk
The step disk, shown in Figure C.8, is used during LVDT standardization and
verification. It 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 (3 mm),
C (5 mm), and D (6 mm). This provides the 6 mm test range required by both ASTM and
AASHTO specifications.
Load Cell Calibration Weights
Four 100 gram and two 2 gram load cell calibration weights are supplied with the
BBR3S. These weights are placed on the load frame weight pan during load cell
verification. The weights are also used to calibrate the load cell and ensure system
compliance.