Satec 3100 Series User manual

Manual # PP3123-03-0101
Series 3100
Automatic Burst Testing System
Stage I, II and III Volume Control

Series 3100 PP3123-03-0101
Automatic Burst Test Systems User’s Guide
SATEC PIPE & PRESSURE
2
Information in this document is subject to change without notice.
This document is considered confidential and proprietary between INSTRON-SATEC SYSTEMS and its customers.
No part of this document may be reproduced or transmitted in any form or by any means,
electronic or mechanical, for any purpose, without the express
written permission of INSTRON-SATEC SYSTEMS.
Manual # PP3123-03-0101
SATEC Pipe and Pressure
© Copyright 2001 INSTRON-SATEC SYSTEMS

PP3123-03-0101 Series 3100
User’s Guide Automatic Burst Test Systems
SATEC PIPE & PRESSURE 3
TABLE OF CONTENTS
CONGRATULATIONS.....................................................................5
About Your Documentation................................................................6
General Safety Precautions...............................................................7
Support Services – Contact List.......................................................11
INTRODUCTION..........................................................................13
INSTALLATION...........................................................................14
Uncrating..........................................................................................14
Site Preparation...............................................................................14
Positioning the Burst Test Cabinet...................................................14
Connecting.......................................................................................14
SYSTEM COMPONENTS ..............................................................16
Air Powered Water Pump (Standard)..............................................16
Electric Piston Pump (Optional).......................................................16
Pressure Control..............................................................................17
High Volume Flow Regulator...........................................................17
Accumulator.....................................................................................17
Pressure Transducers......................................................................17
Water Filter......................................................................................17
High Pressure Relief Valve..............................................................18
Multiple Specimen Option................................................................18
CONTROLS ...............................................................................19
System Supply Panel.......................................................................19
Burst Panel......................................................................................20
Eurotherm Controller........................................................................22
Setpoints.................................................................................23
Parameters..............................................................................25
Alarms.....................................................................................25

Series 3100 PP3123-03-0101
Automatic Burst Test Systems User’s Guide
SATEC PIPE & PRESSURE
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OPERATION ..............................................................................26
Filling a Specimen...........................................................................26
Running a Test................................................................................27
Testing with Multiple Specimen Option............................................28
SHUTTING DOWN THE SYSTEM....................................................28
MAINTENANCE ..........................................................................29
Water Supply Filter..........................................................................29
Air Filter/Regulator...........................................................................29
Pump...............................................................................................29
Pressure Gauges and Transducers.................................................29
Electrical..........................................................................................29
System Drainage for Long Term Storage........................................30
CALIBRATION AND VERIFICATION ................................................31
Service Agreements/Contracts........................................................31

PP3123-03-0101 Series 3100
User’s Guide Automatic Burst Test Systems
SATEC PIPE & PRESSURE 5
CONGRATULATIONS
Welcome to the INSTRON-SATEC SYSTEMS family of materials testing.
INSTRON-SATEC SYSTEMS designs, manufactures, and delivers high-quality
materials testing hardware and software equipment for a variety of industrial,
commercial, and institutional customers. Tracing its roots to the century-old
Baldwin line of universal testers, INSTRON-SATEC SYSTEMS focuses on
responding to its customers through its international force of highly trained sales,
service, and technical personnel.
Our current line of machines and accessories range from simple, manually-
controlled units, to fully-automated, computer-controlled systems, complete with
the latest innovations. If your testing needs require unique systems, we view
special designs as if they were standards. We also carry an extensive line of grips
and fixtures to meet a wide variety of testing needs. Call for our catalog.
Whatever your testing needs, INSTRON-SATEC SYSTEMS delivers.
SATEC SYSTEMS
National Headquarters in Grove City, Pennsylvania, USA

Series 3100 PP3123-03-0101
Automatic Burst Test Systems User’s Guide
SATEC PIPE & PRESSURE
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About Your Documentation
This User’s Guide describes the installation, construction and maintenance of the
SATEC PIPE & PRESSURE Series 3100 Stage I, II, or III Automatic Burst Test
Systems.
Please read this User’s Guide carefully and study the illustrations and drawings
that are provided in the “Reference Drawing” section.
A thorough understanding of the machine and close attention to maintenance will
pay big dividends in trouble-free operation.
Throughout your documentation are NOTE, CAUTION and WARNING
statements that alert your attention to important information.
NOTE:
Notes provide further clarification on particular issues.
CAUTION:
Cautions alert the user to situations that may cause equipment damage.
WARNING!
Warnings alert the user to situations that may cause serious personal
injury or death.

PP3123-03-0101 Series 3100
User’s Guide Automatic Burst Test Systems
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General Safety Precautions
Materials testing involves inherent hazards from high forces, rapid motions and
stored energy. You must be aware of all moving and operating components that
are potentially hazardous.
Whenever you consider that safety is compromised, press the EMERGENCY
STOP button, shutoff the air supply, bleed off high pressure from the system and
check system thoroughly before returning it to service.
Carefully read all relevant manuals and observe all Warnings and Cautions. As
discussed previously, the term Warning is used where a hazard may lead to
personal injury or death. The term Caution is used where a hazard may lead to
damage to equipment.
Ensure that the test set-up and the actual test you will be using on materials,
assemblies, or structures constitutes no hazard to yourself or others. Make full
use of any mechanical and electronic limits. These features are supplied for your
safety.
The following pages detail general warnings that you must heed at all times while
using materials testing equipment. Specific Warnings and Cautions appear
whenever a potential hazard exists.
Your safest precautions are to gain a thorough understanding of your equipment
by reading your instruction manuals, and to always use good judgment.
WARNING!
If the equipment is used in a manner not specified by SATEC, the
protection provided by the equipment may be impaired. Injury to
personnel or damage to machine may result. Be sure to read and
understand the material presented in this User’s Guide and in any other
accompanying instructions.
WARNING!
Keep all body parts clear of the testing space while the machine is in use.

Series 3100 PP3123-03-0101
Automatic Burst Test Systems User’s Guide
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WARNING!
This equipment uses water at very high pressures. Use caution when
working near any high pressure line.
WARNING!
Wear eye protection and use protective shields or screens whenever any
possibility exists of a hazard from the failure of a specimen, assembly or
structure under test.
Use protective shields whenever a risk of injury to operators and
observers exists from the failure of a test specimen, assembly or
structure, particularly where explosive disintegration may occur. Due to
the wide range of specimen materials, assemblies or structures that may
be tested, any hazard resulting from the failure of a test specimen,
assembly or structure is entirely the responsibility of the owner and the
user of the equipment.
WARNING!
Never pressurize a specimen without bleeding out the trapped air. Use
purge valves on specimen end caps (one end).
WARNING!
Shut off the air and water supplies and discharge residual pressure in high
pressure lines before working on system.
– Disconnect air supply and shutoff water supply.
– Shutoff each manifold shutoff valve.
– Discharge pressure in each high pressure line. Crack line from each
station and line between manifold shutoff valve and static pressure
regulator.
– Bleed pressure between accumulator and manifold shutoff valves.
Make sure system On-Off valve is open.

PP3123-03-0101 Series 3100
User’s Guide Automatic Burst Test Systems
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WARNING!
Shut down the hydrostatic/burst power supply and discharge pressure
before disconnecting any fluid coupling.
Do not disconnect any coupling without first shutting down the hydrostatic
power supply and discharging stored pressure to zero. Tie down or
otherwise secure all pressurized hoses to prevent movement during
system operation and to prevent the hose from whipping about in the
event of a rupture.
WARNING!
Disconnect the air pressure supply prior to shutting off electric. Possible
pressure could be released.
WARNING!
Disconnect the electrical power supply before attempting to disassemble,
inspect, or clean the system.
WARNING!
Disconnect the electrical power supply before removing the covers to
electrical equipment.
Disconnect equipment from the electrical power supply before removing
any electrical safety covers or replacing fuses. Do not reconnect the
power source while the covers are removed. Refit covers as soon as
possible.
WARNING!
Shut off electrical power before servicing or making any adjustments
inside the cabinet.
WARNING!
Take care when installing or removing a specimen.
Installation or removal of a specimen involves working with high pressures
and possibly high temperatures.

Series 3100 PP3123-03-0101
Automatic Burst Test Systems User’s Guide
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WARNING!
Use protective guards or screens if any possibility exists of a hazard from
the failure of a specimen, assembly or structure under test.
Use protective guards whenever a risk of injury to operators and
observers exists from the failure of a test specimen, assembly or
structure, particularly where explosive disintegration may occur. Due to
the wide range of specimen materials, assemblies or structures that may
be tested, any hazard resulting from the failure of a test specimen,
assembly or structure is entirely the responsibility of the owner and the
user of the equipment.
WARNING!
Protect all cables and hoses (electric, hydraulic and air) from damage and
inadvertent disconnection.
The hoses used for this system are high pressure hoses. If hoses are
damaged or disconnected without being properly drained, water can be
emitted at very high pressures and cause injury to personnel. Never route
cables or hoses across the floor without protection, nor suspend them
overhead. Use padding to avoid chafing where they are routed around
corners or through wall openings.
WARNING!
Wear protective clothing when handling equipment at extremes of
temperature.
Materials testing is often carried out at non-ambient temperatures using
ovens, furnaces or cryogenic chambers. Extreme temperature means an
operating temperature exceeding 60 °C (140 °F) or below 0 °C (32 °F).
You must use protective clothing, such as gloves, when handling
equipment at these temperatures. Display a warning notice concerning
low or high temperature operation whenever temperature control
equipment is in use. You should note that the hazard from extreme
temperature could extend beyond the immediate area of the test.

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User’s Guide Automatic Burst Test Systems
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Support Services – Contact List
If it becomes necessary to contact us, these guidelines should be followed:
•For systems sold within the United States, contact INSTRON-SATEC
SYSTEMS. See the information listed below.
•For systems sold outside the US, contact your local INSTRON Office. A
listing of these can be found on the INSTRON website at
www.instron.com.
INSTRON-SATEC SYSTEMS can be reached at:
900 Liberty Street
Grove City, PA 16127
Phone: [phone] or
1-800-473-7838, select Option 2
Fax: [phone]
Contact INSTRON-SATEC SYSTEMS for information about other products,
options, retrofits or replacement parts.
The following phone list can be used to contact specific INSTRON-SATEC
SYSTEMS departments for help in designated areas. Call either of the above
phone numbers and enter the appropriate phone extension as listed below.
Customer Support Hotline – Hardware...........................................Service, ext. 772

Series 3100 PP3123-03-0101
Automatic Burst Test Systems User’s Guide
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PP3123-03-0101 Series 3100
User’s Guide Automatic Burst Test Systems
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INTRODUCTION
WARNING!
If the equipment is used in a manner not specified by SATEC, the
protection provided by the equipment may be impaired. Injury to
personnel or damage to machine may result. Be sure to read and
understand the material presented in this User’s Guide and in any other
accompanying instructions.
The purpose of this manual is to supplement, but not to replace the services of
qualified personnel to start up and adjust this equipment.
Persons without previous experience with this equipment should not attempt the
initial adjustment and check out procedures required until this installation is
considered ready for operation by a qualified operator.
Each cabinet carries an individual serial number on the nameplate mounted on the
cabinet. Please refer to this number when ordering replacement parts or when
requesting any further information.
This pressure supply system is primarily designed for the burst testing of plastic
pipe.

Series 3100 PP3123-03-0101
Automatic Burst Test Systems User’s Guide
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INSTALLATION
Uncrating
Remove the shipping crate and packing material carefully from the burst supply
cabinet. Do not discard the packing material until all the items on the packing
lists have been accounted for.
Site Preparation
The testing area requires floor drains.
Positioning the Burst Test Cabinet
When transferring the burst supply cabinet from the shipping pallet or from
location to location, use moving blankets between the cabinet and the moving
machinery. Follow accepted practices to avoid damage to the equipment and
personnel.
Use a fork truck to remove the burst supply test cabinet from the shipping pallet.
Position the cabinet in the desired location and level the cabinet. Verify that the
by-pass valve, located inside the cabinet, is in the Off position. Be sure to allow
adequate floor space for maintenance personnel to have easy access to the system.
Connecting
1. Connect the water supply line into the “water supply” inlet port on the side of
the cabinet with the customer provided shut off hand valve. It is
recommended that additional water filters be added as required to provide
clean water to the system.
WARNING!
Always connect the water supply first, before applying the compressed air
to the system. The pumping system will start as soon as air pressure is
supplied to the pump. Damage to the pump may result if the pump is run
dry. A 40 psi minimum and 100 psi maximum water supply pressure is
recommended. Use ½ inch I.D. fittings. Using smaller fittings could
reduce the capacity of the pump.
2. Connect the high-pressure supply outlet and return to the burst fixture. Use
only suitable high-pressure hose, tubing and fittings with appropriate psi rating
(typically 3000 or 5000 psi depending on the system).

PP3123-03-0101 Series 3100
User’s Guide Automatic Burst Test Systems
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3. Plug in the electrical power cable to the customer’s power outlet. Normal
electrical requirements are 120 Volt, 60 Hertz, and 1 Phase.
4. Start the supply of water into the unit by opening the fill valve. Some
discharge flow from the drain should be noticed.
5. Connect the compressed air supply line into the “air supply” port on the side
of the cabinet with the customer provided filter compressed air shut off hand
valve.
CAUTION:
DO NOT connect the air supply to the pumping unit without first turning
ON the water supply.
NOTE:
For the best performance the air supply pressure should not drop below
90 PSI or exceed 115 PSI.

Series 3100 PP3123-03-0101
Automatic Burst Test Systems User’s Guide
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SYSTEM COMPONENTS
Some of the major components of the burst system are described below.
Air Powered Water Pump (Standard)
The standard burst test system is supplied with an air operated high pressure water
pump. It provides the high-pressure water supply for the burst system. Water
pressure will be either 3000 or 5000 psi depending on the supply pressure, check
the SUPPLY PRESSURE gauge on the burst cabinet. Refer to the
manufacturer’s instructions included separately in this manual for more specific
information about the pump.
CAUTION:
Avoid running the pump dry. Always be sure water is on to the console
before turning on the air. Operate pump only when testing a specimen.
TO STOP THE PUMP, TURN OFF THE COMPRESSED AIR SUPPLY TO
THE PUMP.
Electric Piston Pump (Optional)
In lieu of the standard air over water pump, Stage II and Stage III burst systems
can be purchased with an optional electric piston pump. Like the air over water
pump, it provides the high-pressure water supply for the burst system, but at a
faster rate. Water pressure is typically 3000 psi, check the SUPPLY PRESSURE
gauge on the burst cabinet. Refer to the manufacturer’s instructions included
separately in this manual for more specific information about the pump.
CAUTION:
Avoid running the pump dry. Operate pump only when testing a
specimen.

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User’s Guide Automatic Burst Test Systems
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Pressure Control
Specimen pressure is controlled by means of a Eurotherm controller and an
ER-3000 pressure regulator. The Eurotherm is a digital, programmable controller
and the ER-3000 is a very precise programmable pressure regulator. Operators
enter test parameters (maximum pressure and ramp rate) into the Eurotherm,
which then sends output signals to the ER-3000 based on these test parameters.
The ER-3000 controls a dome regulator to pressurize the specimen. The
Eurotherm displays the current specimen pressure and the programmed setpoint.
It also records the maximum pressure reached (burst pressure) by the specimen.
For more information on the Eurotherm controller, refer to page 22 and to the
manufacturer’s information included separately in this manual. For more
information on the ER-3000, refer to the manufacturer’s information included
separately in this manual.
High Volume Flow Regulator
Stage II and Stage III burst systems are equipped with a high volume flow
regulator that controls the flow to the specimen. Operation of the high volume
flow regulator is controlled via the ER-3000/Eurotherm controller.
Accumulator
An accumulator provides the volume capacity necessary for testing. The
accumulator(s) can vary from 1 gallon to two 10-gallon units or larger depending
upon the volume needed for the individual testing requirements. Refer to the
manufacturer’s instructions for more specific information about the accumulator.
Pressure Transducers
The burst system is equipped with two pressure transducers. One transducer
communicates with the ER-3000 for specimen control; the other is located on the
return line from the specimen and communicates with the Eurotherm controller
for its display and programmed alarms. For more information on the programmed
alarms, see page 25.
Water Filter
Protects the system from dirt particles to help keep system maintenance to a
minimum.

Series 3100 PP3123-03-0101
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High Pressure Relief Valve
A high pressure relief valve protects the system from overpressure by relieving
excess pressure. The relief valve discharges excess water from a tube on the side
of the control cabinet. If water drainage is visible from this tube, immediately
disconnect the air supply and slowly open the by-pass valve until pressure is
below the system maximum; watch the SUPPLY PRESSURE gauge. Call
INSTRON-SATEC SYSTEMS for service.
WARNING!
Immediate attention is needed if this valve starts relieving high pressure.
Shut off the air to the system and bleed off the high pressure by opening
the internal by-pass valve inside the cabinet. Check system thoroughly,
especially the pump’s air regulator for correct setting, before returning the
system to service. Call INSTRON-SATEC SYSTEMS for service.
Multiple Specimen Option
A multiple specimen option can be purchased that permits the preparation and
testing of multiple specimens. Specimens are tested one at a time through the use
of a SPECIMEN selector dial. The number of specimens that can be prepared
and tested varies from system to system and depends on customer requirements.

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CONTROLS
System Supply Panel
Figure 1: System Controls.
System Pressure
Gauge: This pressure gauge (1, Figure 1) indicates the pressure
(psi) available in the accumulator. The maximum range
displayed on this gauge is the maximum range of the
system.
Burst Supply
ON/OFF Valve: This is the main shut-off valve (2) for the system. When
in the OFF position, the water supply is shut-off from the
cabinet.
Main Power
Circuit Breaker
and Indicator:
The main power circuit breaker (3) is a Ground Fault
Interrupt type (GFI) and controls all of the electrical
power to the burst test cabinet. The power indicator (4)
will illuminate to show a power ON condition.
1
3
4
1. System Pressure Gauge
2. Burst Supply ON/OFF Valve
3. Main Power Circuit Breaker
4. Main Power Indicator
2

Series 3100 PP3123-03-0101
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Burst Panel
Figure 2: Burst Controls.
Eurotherm
Controller: Refer to page 22.
Elapsed Timer and
Timer Light: The elapsed timer (2, Figure 2) indicates the time to
specimen burst or the elapsed time in a static test. The
timer light (3) will illuminate to show that the timer is
counting. Press the button on the timer to reset it to zero.
The timer and timer light are activated by an alarm set in
the Eurotherm controller once the starting pressure is
reached. This starting pressure is set at 75 psi.
1
2
5
3
4
6
7
1. Eurotherm Controller
2. Elapsed Timer
3. Timer Light
4. Enclosure Open Indicator
5. Start Test Button and Indicator
6. Stop Test Button and Indicator
7. Specimen Fill Valve