ATS 540 Series User manual

MAN - Series 540 Vertical Sealant Tester - REV: Original
Series 540
Vertical Sealant Tester
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 - Series 540 Vertical Sealant Tester - REV: Original
REVISED AUGUST 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: [phone].

MAN - Series 540 Vertical Sealant Tester - REV: Original i
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
C.2 General Product Description .................................................................................................................................6
C.3 Product Specications ...........................................................................................................................................6
C.4 Hot/Cold Chamber.................................................................................................................................................6
D. Installation.....................................................................................................................................7
D.1 General Installation ................................................................................................................................................7
E. Software Overview .......................................................................................................................8
E.1 Software Map.........................................................................................................................................................8
E.2 Main Screen...........................................................................................................................................................8
E.3 Alarm Screen.......................................................................................................................................................12
E.4 Language Screen.................................................................................................................................................12
E.5 Program Screen...................................................................................................................................................13
New Program Button.....................................................................................................................................14
Function Drop-down .....................................................................................................................................14
Program Steps Data Section.........................................................................................................................15
Name Field....................................................................................................................................................15
Backup Button...............................................................................................................................................15
Restore Button ..............................................................................................................................................15

ii MAN - Series 540 Vertical Sealant Tester - REV: Original
Nest Goto Step Commands..........................................................................................................................15
Do Not Turn o󰀨 Temperature at End of Program .........................................................................................15
Done Button ..................................................................................................................................................15
E.6 Program Log Screen............................................................................................................................................16
Cyclic Count Field .........................................................................................................................................16
Goto Count Field...........................................................................................................................................16
Elapsed Time Field........................................................................................................................................17
Delete All Log Data Button............................................................................................................................17
Backup All to USB Button .............................................................................................................................17
Month, Day, Year, Hour, Minute, and Second Fields ....................................................................................17
Done Button ..................................................................................................................................................17
E.7 New HMI Software...............................................................................................................................................18
F. Operation .....................................................................................................................................19
F.1 Test Frame............................................................................................................................................................19
F.2 Running a Test......................................................................................................................................................19
G. Maintenance................................................................................................................................20
G.1 General Maintenance...........................................................................................................................................20
Appendix A: Warranty ....................................................................................................................21
Appendix B: Glossary.....................................................................................................................22
Appendix C: Image Glossary.........................................................................................................23

MAN - Series 540 Vertical Sealant Tester - 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
[phone].
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 - Series 540 Vertical Sealant Tester - 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 [phone].
Read and follow these important instructions. Failure to observe these instructions can result in permanent damage
to the unit, signicant 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 qualied service personnel only.
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
injuries that may occur while operating this equipment.
WARNING: Keep hands and heads clear of the crossheads and load train when pressing the up
or down push buttons. Personal injury may result when the loading crosshead begins moving.

MAN - Series 540 Vertical Sealant Tester - REV: Original | B. Safety 3
WARNING: Always be certain the test area is clear of hands and heads and that the test is
complete before pressing the return push button. The return button provides a rapid return.
WARNING: Before energizing the electrical power to the Series 540 Sealant Tester, set all
controls and/or switches to the OFF position.
WARNING: Whenever a test is in progress, the operator MUST be at the controls.
WARNING: Keep hands clear of the specimen and load train when test is in progress.
WARNING: Always use the appropriate protective equipment when operating the Series 540
Sealant Tester and any accessory equipment.
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: Set the adjustable limit switches prior to test operation. The limit switches prevent the
moving crosshead from exceeding the pre-set range. Set the limit switches just above and below
the range set for the moving crosshead.
CAUTION: If necessary, stop test operation in case of emergency. Use the emergency stop
button on the Series 540 Sealant Tester to abort test operation.
CAUTION: Do not exceed the rated capacity of the adapter, grips, or load cell.
CAUTION: Lift the Series 540 Sealant Tester under the base, preferably or if necessary under
the upper crosshead. If lifting by the crosshead, be careful not to damage any components with
the lifting device. See Figure D.1 on p.8.
CAUTION: Observe maximum temperature ratings of test components (extensometer, grips,
xtures, couplings, etc.)
CAUTION: Avoid ramming grips and xtures together at high speeds.

4MAN - Series 540 Vertical Sealant Tester - REV: Original | C. System Overview
C. System Overview
C.1 Equipment Parts
Front of Unit
1. Upper Crosshead
2. Lower Moving Crosshead
3. Upper Fixed Limit
4. Lower adjustable limit
5. Ball Screw
6. Specimen Fixture
7. Guide Rod
8. Fixed Lower Crosshead
9. E-Stop
10. Power Indicator Light
11. Adjustable Leveling Feet
12. HMI
13. Adjustable HMI Arm
14. Hot/Cold Chamber
15. Door Latch
Figure C.1: Front of Series 540 Sealant Tester
3
8
5
4
1
2
7
9
10
11
6
12
13
14
15

MAN - Series 540 Vertical Sealant Tester - REV: Original | C. System Overview 5
Back of Unit
1. db 9 Connector
2. Ethernet
3. Power Switch
4. Power Connector
Figure C.2: Series 540 Sealant Tester (Rear View)
3
4
1
2

6MAN - Series 540 Vertical Sealant Tester - REV: Original | C. System Overview
C.2 General Product Description
Applied Test System’s Series 540 Vertical Sealant Testers are used to perform cyclic tension/compression tests on
joint sealing compounds. This tester may be used alone or with a refrigeration unit for testing at lower temperatures.
The information in this manual is related to the function, setup, safe operation, and maintenance of the Series 540
Vertical Sealant Tester and its related components. This manual is intended for anyone who will be setting up and/or
operating the Series 540 Vertical Sealant Tester.
Operation of the Series 540 Sealant Tester is controlled by the touch screen HMI. A variety of accessories are
available to provide added capability and exibility. These include furnaces, ovens, data acquisition, xtures, and
grips. For additional information on our full line of Series 540 Sealant Tester accessories, please contact your ATS
sales representative by calling [phone].
C.3 Product Specications
Capacity 4,000 lbf (17.7 kN)
Frame Type Bench top, vertical
Fixture Alignment Precision columns
Drive Type Dual-screw, single-motor, processor-controlled
Constant-Speed Testing .002 - 20 in./min (0.05 - 500.0 mm/min)
Variable-Speed Testing .002 - 20 in./min (0.05 - 500.0 mm/min)
Maximum Travel 1.0” (50.8mm) (extension)
Specimen Capacity 12 (standard)
Power Requirements 230VAC 60 Hz
C.4 Hot/Cold Chamber
See additional chamber manual for hot/cold chamber operation instructions.

MAN - Series 540 Vertical Sealant Tester - REV: Original | D. Installation 7
D. Installation
D.1 General Installation
1. Remove the shipping crate and packing material from the Series 540 Sealant Tester, leaving the Series 540 on its
pallet. Inspect the machine for any signs of damage incurred during shipment.
2. Lift the Series 540 Sealant Tester from the shipping pallet, preferably by lifting under the base. If using a fork lift,
make sure the forks are fully supporting the front and back of the base otherwise damage may occur to components
under the base or the unit might tip. If necessary, the Series 540 may be lifted by the upprt crosshead, but suitable
care should be taken. Use padding or soft wood blocking as necessary to prevent damage.
3. Position the Series 540 Sealant Tester with a fork lift or crane. Lift the Series 540 under the housing or by the
upper crosshead. Make sure that the HMI is out of the way when lifting so that it does not get damaged.
4. Connect the line cord to the line cord connector provided on the rear of the Series 540 Sealant Tester (see Figure
C.2 for location). Make sure all controls are set to the OFF position. Check the main power switch/circuit breaker
beside the connector to make sure it is in the OFF position.
5. Connect the Series 540 Sealant Tester to the appropriate grounded source of power, as listed on the data tag.
CAUTION: Only
lift Series 540
under base or
upper crosshead.
Figure D.1: Lifting Series 540 Sealant Tester

8MAN - Series 540 Vertical Sealant Tester - REV: Original | E. Software Overview
E. Software Overview
E.1 Software Map
Figure E.1 illustrates the proper navigation of the Series 540 Sealant Tester’s software screens.
E.2 Main Screen
Figure E.2 illustrates the Main Screen that is shown when the machine is started. It allows you to setup, and run,
tests. The screen will show machine Displacement. It also has several controls to set-up and run the machine.
Figure E.1: Series 540 Sealant Tester Software Map
Main Screen
Backup Program
La nguage
Progr amm in g
Temp Setpoint
Temp Enable
Data
Fu nc ti on
540 Menu Flow
Return Crosshead
Only wh en not in c yc le
Displacement Units
Fast Jog Speed
Stop Cycle
Only when in cycle
Sta rt Cycl e
Drive Enable/Disable Jog Speed
Te mp Uni t s
Restore Program
Rese t AlarmAl arm
IP Address
Ste ps
Jog Up
Only wh en not in c yc le
Jog Down
Only wh en not in c yc le
High Jog Speed
Only wh en not in c yc le
Only wh en not in c yc le
Only wh en not in c yc le
Only wh en not in c yc le
H ol d Cyc le
Only when in cycle
Only with Temp Optio n
Only with Temp Optio n
Only wh en not in c yc le
Only wh en not in c yc le
Only wh en not in c yc le
Only wh en not in c yc le
Only wh en not in c yc le
Only wh en not in cyc le
Only wh en not in cyc le
Program Log
Save Logs to USB
Set Date / Time
Delete Logs

MAN - Series 540 Vertical Sealant Tester - REV: Original | E. Software Overview 9
The following buttons are located on the Main Screen:
Zero Button
Located to the right of the Displacement name and used to zero out the value. This button will be hidden
when a test is running.
Overtravel Indicators
Will turn on if the system goes into over travel going up or down.
Drive Enable Button
Used to enable (Green) and disable (Red) the drive system. The drive must be enabled to jog or run a test.
As a safety you should ALWAYS disable the drive when you are loading or unloading samples.
Alarm Button
Only shows up if there is an alarm or warning. If displayed, press to go to the alarm screen and see what
has triggered the alarm.
Start Button
Starts a test if the drive system is enabled.
Jog Up and Down Buttons
Will jog the machine in the desired direction at the currently selected jog speed.
Return Xhead Button
Send the crosshead back to the zero displacement position at the current jog speed if the drive system
is enabled. Please note that if you press the “Return Xhead” button and the system is moving to the zero
Figure E.2: Main Screen

10 MAN - Series 540 Vertical Sealant Tester - REV: Original | E. Software Overview
position, pressing it again will stop it.
High Speed Button
Turns fast jogging speed on and o󰀨.
Program Button
Takes you to the program edit screen. When the system is running a test this button is hidden so that
changes cannot be made.
Language Button
Used to access the Language Screen where you can change the text language for the system. When the
system is running a test this button is hidden and changes cannot be made.
Displacement Units
Allow the system displacement to show and be programed in English (In) or Metric (mm) units. This is
hidden if the system is running a test.
Jog Speed Field
Shows the speed that the system will travel for normal jog, when the jog buttons or the “Return Xhead” are
pressed. This is hidden if the system is running a test.
Fast Jog Speed Field
Shows the speed that the system will travel for fast jog, when the jog buttons or the “Return Xhead” button
are pressed. This is hidden if the system is running a test.
NOTE: Fast jog speed is used instead of the normal speed if the “High Speed” button has been
pressed. If the system is in fast jog the “High Speed” button will light up. You can turn o󰀨 fast jog
by pressing the button again, or fast jog will time out and return to the normal jog speed after 15
seconds if the system is not moving. If the system is moving (Jog or Return Xhead), the speed
will return to normal after 15 seconds and after the movement stops.
IP Address Field
Used to allow someone at a remote location to monitor the system using a VNC viewer program. It is also
used for data logging using other programs. This is hidden if the system is running a test.
Temperature Units
Allow the system temperature to show and be programed in English (°F) or Metric (°C) units. This will only
be displayed if the system has a temperature control option and is not running a test.
Current Temp
Displays the current chamber temperature. This will only be displayed if the system has a temperature

MAN - Series 540 Vertical Sealant Tester - REV: Original | E. Software Overview 11
control option.
Temp Setpoint
Manual set point for the chamber temperature. This will only be displayed if the system has a temperature
control option and no test is running.
Temp Enable
Allows the operator to manually turn the chamber temperature control on and o󰀨. This will only be displayed
if the system has a temperature control option and no test is running.
Figure E.3 illustrates what the Main Screen looks like when the system is running a test. Several buttons and elds
disappear while other buttons and elds appear.
Stop Button
Stops a running test at any time.
Hold Button
Puts program execution on hold until pressed again. The hold will only take e󰀨ect once the current program
step nishes.
Speed Display
Displays the last commanded speed of the system.
Step # Field
Displays the step number of the program that is currently being executed.
Count Fields
Figure E.3 - Main Screen, Test Running

12 MAN - Series 540 Vertical Sealant Tester - REV: Original | E. Software Overview
Only show up if the current program step is a “Cycle Position” move. The gray eld is the total number of
cycles programed. The light blue eld shows how many cycles have been executed so far.
Time Fields
If the current program step is a “Hold” the “Count Fields” will be replaced with “Time Fields”. The gray eld
is the total amount of time in minutes programed. The light blue eld is how much time has been executed
so far in minutes.
Goto Count Fields
Only show up if the program is in a Goto loop. The gray eld is the total number of returns programed. The
light blue eld is how many have been executed so far.
E.3 Alarm Screen
Figure E.4 illustrates the Alarm Screen. It is shown anytime the “Alarm” button is pressed on the Congure or Main
Screen, and displays the current alarm(s) or warning(s) that triggered the button’s appearance.
The Alarm Screen shows all current alarms (in Red) and warnings (in Yellow). Users can attempt to reset these with
the “Reset” button. Some alarms will go away automatically when the alarm condition goes away. However, some
will not go away until a power cycle. The “Done” button will return you to the previous screen.
E.4 Language Screen
Figure E.6 illustrates the Language Screen. It is shown anytime the “Language” button is pressed on the Congure
Screen.
To change the language the system is using, simply press the ag of the language you wish to use.
Figure E.4: Alarm Screen

MAN - Series 540 Vertical Sealant Tester - REV: Original | E. Software Overview 13
Pressing the “Done” button will return you to the Congure Screen.
E.5 Program Screen
Figure E. 9 shows the “Program” screen. It is appears anytime the “Program” button is pressed on the main screen.
Its main purpose is to display, edit, save, and load the program in the machine.
NOTE: There are 10,000 steps possible for each program. Most programs will have
less than 20.
The “Step#” displays the current step of the program. Note, programs always start at step 0.
Total Steps shows the total number of steps in the current program.
The following buttons are used to navigate through the program steps, and to add or delete steps:
Figure E.5: Language Screen
Figure E.6: Program Screen

14 MAN - Series 540 Vertical Sealant Tester - REV: Original | E. Software Overview
Go to rst step
Previous step
Next step
New Program Button
Erases the entire program and starts a new one. Caution should be used as there is no undelete and once pressed
the program is gone unless it had been previously backed up.
Function Drop-down
Will display the current step function and allow it to be changed. The data entry elds will change depending on the
function selected. Current functions are:
No Operation
Has no data and is simply a place holder with no action.
Move to position
Has a position and speed entry. The system will start to move to the position entered. Note, the program will
not wait for anything, but go to the next step in the program as soon as the move is started.
Wait for Position
Has a position entry. The program will wait at this step until the system has reached the entered position.
Cycle Position
Has a position, speed, and count entry. This is a cyclic move, the system will move back and forth between
its current position and the position entered. It will do this for count times.
Goto Setp
Has a step number and count entry. The step number must be a previous step. This is a loop control. The
program will jump back to the entered step and execute the program from there to the goto for count times.
Then it will move on to the next step of the program. Note, if the step number entered is not a previous step
the program will jump over a section of program not executing them and the count will not be used. Also,
remember that the code has executed once before it gets to the goto command so if you wish to execute a
block of code a certain number of times, enter one less in the count.
Hold
Has a time entry. The program will wait at this step until the entered time has expired.
Set Temperature
Has a temperature and rate entry. This command will set the temperature control to the entered temperature
at the ramp rate entered and move on to the next step. Note, the program will not wait for anything, but go
to the next step in the program as soon as the temperature is set. This command will only be displayed if the
Go to last step
Insert a step
Delete a step

MAN - Series 540 Vertical Sealant Tester - REV: Original | E. Software Overview 15
system has the temperature control option.
Wait for Temperature
Has a temperature entry. The program will wait at this step until the system has reached the entered
temperature. This command will only be displayed if the system has the temperature control option.
Program Steps Data Section
Allows you to backup and restore the program to a USB ash drive. This may be useful in the event of a hardware
failure, or if you wish to have multiple programs to run on this machine. The “Idle” to the right of the section name
will change to “Busy” when the system is accessing the ash drive.
Name Field
Used to name the le that is to be backed up to or restored from the USB ash. The name may include a path if
desired.
Backup Button
Used to save the program data from the machine to the ash drive. Note, this button will only be displayed if a ash
drive is plugged in.
Restore Button
Used to restore the program data from the ash drive to the machine. Note, this button will only be displayed if a
ash drive is plugged in. The white box to the right of the name eld will display the le names of the programs
already stored on the ash. This is where you select a le to be restored.
Nest Goto Step Commands
Can be checked if you wish to nest goto commands. They may be nested as deep as you like but the “Goto Count”
on the main screen will not be displayed when a test is running.
Do Not Turn o󰀨 Temperature at End of Program
May be checked if you have many samples to run and wish the
chamber to stay at temperature. Otherwise the control system will shut
down at the end of a test. The Program Log Button will take you to the
Program Log Screen.
Done Button
Will return you to the Main Screen.
Anytime you insert a ash drive you will see the screen in Figure E.7.
If you are just inserting a ash drive with machine programs on it
just press “Cancel”. You would only need the other buttons if you are
updating the HMI software. Figure E.7: Flash Drive Pop-Up

16 MAN - Series 540 Vertical Sealant Tester - REV: Original | E. Software Overview
E.6 Program Log Screen
Figure E.8 below shows the Program Log Screen. It is shown anytime the “Program Log” button is pressed on the
Program Screen. Its main purpose is to display the program log of programs run on the machine
The data display in the top left corner will show the program log for the selected log le. The top of the display will
be the program start point, and the bottom of the display will be the end of the program or where program execution
stopped.
The rst two elds are date and time and is logged as each program step is executed.
The next eld is the program step number.
The next eld is the program function for that step. The following is a list of these functions.
Program function numbers:
0 No Operation
1 Move to Position
2 Wait for position
3 Cyclic Position
4 Goto Step
5 Hold
6 Set Temperature
7 Wait for Temperature
Cyclic Count Field
Shows the current count for a “Cyclic Position” move. The cyclic position command will create a log entry for each
cycle nished. If your current function is not 3, this value is not updated and has no meaning.
Goto Count Field
Shows the current count for a “Goto Step” loop. If you are not in a goto loop, this value is not updated and has no
Figure E.8: Program Log Screen