WinCCS Manual Updated 2009

System Overview Safety Setup & Installation Operation Maintenance
WinCCS
ATS 93310 Rev. 3
FIFTH EDITION, JANUARY 2009 Information in this document is subject to change without notice and does not represent a commitment on the part of Applied Test Systems, Inc. Comments or suggestions pertaining to the contents of this manual can be sent to the address below: Editor/Technical Manuals Applied Test Systems, Inc. 154 East Brook Lane Butler, PA 16002. Information you supply may be used by ATS without obligation. Necessary changes will be made in future editions of this manual. Copyright Applied Test Systems 2009 For assistance with set-up or operation, contact ATS Field Services. Please have this manual and product serial number available when you call. Telephone: (724) 283-1212 FAX (724) 283-6570
WinCCS II Software
for ATS Computer-Controlled Direct Load and Lever Arm Testers Instruction Manual Table of Contents
Unpacking..6 Warranty....6 After-Sale Support6 1.1 General Description..7 1.2 Computer Specifications..7 1.3 Test Specifications7 1.4 Test Specimen..7 1.5 Sequence of Events7 2 For Owners, Operators, and Maintenance Personnel..10 Cautions..10 3.1 Unpacking Equipment....12 3.2 Hardware Installation..12 3.3 Software Installation....12 3.4 Setup..12 3.5 Assistance/Field Support.12 4.1 General Overview.....13 4.2 Manual Frame Controls, Classic Version.....13 4.3 Manual Frame Controls, Modular Version.13 4.4 Manual Control via Computer..13 5.1 Assigning User Names..15
Applied Test Systems, 2009 ATS 93310R3 3
5.2 Privileges15 5.3 Passwords..16 6.1 Setting System Units16 6.2 Frame Setup..17 6.2.1 Accessing Frame Setup...17 6.2.2 Frame Controller Information..18 6.2.3 Frame Load Capacity...18 6.2.4 Frame Naming...18 6.2.5 Thermocouple Setup....19 6.2.6 Extensometer Setup.19 6.2.7 Load Control/Automatic Loading Setup.21 6.2.8 Frame Setup Digital..23 6.2.9 Furnace Setup...24 6.2.10 Arm Ratio Setup..27 6.2.11 Misc. Setup...27 6.3 General Setup...29 6.3.1 Text Field Setup.29 6.3.2 Material Application Types...29 6.3.3 Report Header29 6.3.4 Site Information..29 6.3.5 Specimen Text....30 6.3.6 Test Specification Text..30 6.3.7 Default Setup..30 6.3.8 Specimen Loading.31 6.3.9 General Calibration.............................................................33 6.3.10 Test Lockouts35 6.3.11 Additional Options35 6.4 Thermocouple Calibration36 7.1 General Overview..36 7.1.1 User Login and Logout.............36 7.1.2 System Status Display...37
7.1.3 Overview of Operation Steps37 7.2 Test Specifications.39 7.2.1 Creating Test Specifications.39 7.2.2 Editing Test Specifications43 7.2.3 Viewing Test Specifications..43 7.2.4 Deleting Test Specifications.43 7.2.5 Copying Test Specifications.44 7.3 Specimens..44 7.3.1 Specimen Creation.44 7.3.2 Specimen Edit.46 7.3.3 Specimen Review......46 7.3.4 Specimen View ..46 7.3.5 Specimen Delete. ..46 7.4 Testing.46 7.4.1 System Status Display..47 7.4.2 Starting a Test.47 7.4.3 Reloading a Test.49 7.5 Stopping a Test..49 7.6 View Test Data50 7.6.1 View Running Tests 50 7.6.2 View Previous Tests..........................................50 7.6.3 Report/Graphing Options...51 7.6.4 Exporting Data.54 7.6.5 Exporting Test Data Files..54 7.6.6 Viewing Test Data55 7.7 Maintenance.55 7.8 Tools..57 7.9 Graphing Options.57 Appendix A...58 Appendix B...63 Glossary68
PREFACE
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 and the carrier immediately. If it is necessary to file a damage claim, retain the packing materials for inspection by the carrier.
Warranty
All new ATS, Inc. systems are shipped with a warranty. Units have a warranty against defective parts and workmanship for one full year from date of shipment.
After-Sale Support
If you have any questions concerning the operation of your unit or how to opperate the software, contact our Service Department. Before calling, please obtain the serial number from the units data tag (shown below)and the software revision number. Also, please be prepared to give a complete description of your problem to our Service Engineers at 724-283-1212.
SECTION 1.
1.1
INTRODUCTION
General Description
The ATS WinCCS system combines proprietry hardware and software, used in conjunction with any direct load or lever arm tester, to provide computer automation of the entire test process.Using archived test specifications, the system will control furnace temperature, apply the appropriate load, collect creep, load, and temperature data, and archive test results in a logical format. Constant stress and stress relaxation testing is accomodated. The system is suplied with new ATS frames as well as retrofitted into existing frames of ATS and other manufacturers.
1.2
Computer Specifications
Minimum Computer Specifications include the following: Processor: 2.8 GHZ or Better Operating System: Microsoft Windows XP Professional Memory: 512 MB or better Hard Drive: 80 GB or better CD Drive: 48x CD-RW or better RS422 Card Note: Only (1) computer is required for use with the WINCCS software, regardless of the number of frames.
1.3
Test Specifications
The test specification contains all the details of the test. The specification can be either the AMS specifaction supplied with the software or can be configured by the user. Specification is saved each time that set of parameters is appropriate.
1.4
Test Specimen
The test specimen is specific to one item, and specimen names must be unique for the specimen, as names are used for archival purposes. Associated with the specimen name is all data, such as physical size, material, etc. specific to that particular item.
1.5
Sequence of Events
The test is performed in the following sequence of events: 1. Select or create a specification to be used to control the test 2. Create a specimen using the software process 3. Select an idle test frame and follow the start a test software routine 4. When the test is complete or stopped manually, the from state will change to the post test state. NOTE: Post test allows the operator to restart the test or enter appropriate data, such as elongation information. The test data is then automatically archived and this test is now classified as a previous test. 5. Test results can be viewed either before the post test procedure, or a running test, or after the post test procedure as a previous test. 6. All of the above functions are described in detail in this manual.
SECTION 2.
SAFETY
All Applied Test Systems Inc. equipment is designed to be operated with the highest level of safety. To maintain the safe operation of this tester, ATS endeavors to educate the operator about safety issues surrounding certain parts of the machinery. These safety issues are addressed through the use of labeling on the equipment. The following labels may appear on your test unit:
Burn Hazard Hot Surface
Electrical Shock/ Electrocution
Hand Crush Force From Above
Protective Earth (Ground)
European Directive CE Mark
General Danger
No Access For Unauthorized Persons
Read Operators Manual
A. For Owners, Operators, and Maintenance Personnel 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 at 724-283-1212 In addition to the safety warnings listed below, warnings are posted throughout the manual. 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. 1. 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: Disconnect power prior to performing maintenance. Turn off the unit and disconnect the line cord from the power source before performing any maintenance procedures.
WARNING: Hot / Burn surface, use personal protective gear when opperating equipment, and handeling materials associated with the testing procedure.
WARNING:
Pinch hazard.
WARNING:
Do not open the panel.
WARNING: surface.
Unpack and operate on a stable
2. 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 in order to ensure safe operation of this equipment.
CAUTION: Installation of electrical devices must be accomplished by competent personnel and done in accordance with any current local and national codes. Equipment grounding is a MUST.
CAUTION: Before energizing the electrical power to the equipment, turn off all power switches and place all controls in an OFF. Check that your power source is of the appropriate voltage and is surge-protected. Use appropriate power adapters based upon your region.
SECTION 3. EQUIPMENT SETUP AND INSTALLATION

3.1 Unpacking Equipment
Carefully unpack the equipment and inspect for damage during shipment. Please do not discard any packing materials in the event of lost or missing pieces.
3.2
Hardware Installation
All hardware is installed at the ATS Factory. In the event hardware installation is required, please contact the Service Deparment at 724-283-1212.
3.3
Software Installation
All software is pre-installed at the ATS Factory. In the event software installation is required, please contact the Service Department at 724-283-1212.
3.4
Set Up
Please have all of the equipment unpacked and placed in the location required for set up, and be sure to have an appropriate electrical power source available for professional set up. It is recommended to have this equipment installed by ATS Service.
3.5 Assistance / Field Support

If you encounter problems in setting up any of your ATS Equipment, please contact your ATS Engineer or the ATS Service Department.
SECTION 4.
4.1
MANUAL OPERATION
Overview
While in most instances the frame is controlled by the system during testing; it is necessary to provide full manual control for test set up and for trouble shooting purposes. There are two basic versions of the hardware, Modular and Classic. This manual control is accomplished in various ways depending on the version of WinCCS hardware you have. In addition, manual control is provided through the computer under the maintenance routine.
NOTE:
When under manual control via computer, most safety interlocks are disabled. This is necessary to allow for trouble shooting purposes.
If you are not thoroughly familiar with the use of these controls, consult ATS prior to attempting this operation.
4.2
Manual Frame Controls, Classic Version
The drawhead and weight elevator can be jogged up and down when the frame is in Idle state.
4.3
Manual Frame Controls, Modular Version
The drawhead can be jogged up and down when the frame is in the Idle state.
4.4
Manual Control via Computer
This function is used for trouble shooting only. Refer to the figures on the following page.
Fig. 1 Manual Frame Controls, Classic
Fig. 3 Manual Control via Computer
Fig. 2 Manual Frame Controls, Modular Version
SECTION 5. ASSIGNING USER NAMES, PRIVILEGES, AND PASSWORDS

5.1 Assigning User Names
Other than certain viewing functions, no operation of the system is possible unless a user possessing the appropriate assigned privileges has logged in. User names and passwords should be assigned by a System Administrator prior to testing. It is important to setup and use individual user accounts if more than one operator uses the tester. This function denies unauthorized access. Note: If you wish to add a new user to the system, select Privileges from the User Menu and select the Add button. Enter the new user name or operator name and select OK. This will return you to the User Information screen with the new user or operator name displayed. Enter the password and check all privileges assigned to this user. Account information can also be entered at this time. When finished, select OK to save all changes. Refer to Section 7.1.1 for information on how to Login and Logout user names.
5.2
Privileges
Privileges refers to the specific tasks an operator can employ. One administrator with full privileges is necessary. Normally, the ATS service department assigns an administrator login with full privileges. In order to assign user privileges, proceed with the following: From the User menu, select Privileges. On the Setup for User Name window, select the tab entitled Privileges. Check the appropriate box to assign a privilege. In the event that you need to modify user privileges, select Privileges and enter the name of the user in the User Name pull down list. Make the appropriate changes and select OK to save the changes. Under the Setup for User Name window, there are additional user options listed. The user can change the units displayed on the screen, modify the status display screen, and select the preferable status display graph by clicking on the tabs entitled Units, Status Display Screen, and Status Display Graph(s), respectively. In addition, the user can adjust graph line sizes to fit the screen or fit printer requirements by choosing the Graph Settings tab. The typical default values for screen and printer pixels are 1 pixel and 3 pixels, respectively.
5.3
Passwords
To change the password of a previously assigned user, follow the procedure in 5.2 and enter the new password under Account Information.
SECTION 6.
6.1
SYSTEM SETUP
Setting System Units
System units of measurement can be easily set or changed at any time by performing the procedure described below. 1. From the System Menu, select General Setup. 2. Click on the tab entitled Frame Controller Units. A screen, like the one shown below, should appear.
1. Choose the desired unit of measurement for each of the eight choices. To use all English or Metric units, select the appropriate button. 2. Select OK to save the choices and close the screen. Note: This applies to the units shown on the Classic WinCCS Console or the Modular Portable Display Module. The units displayed on the computer screen are set under UserPrivileges.
6.2
Frame Setup
The proceeding options enable the user to setup individual frame information.
6.2.1
Accessing Frame Setup
From the System Menu, select Frame Setup. Indicate the frame to be setup by entering the frame number/name in the Frame Number pull down list. See figure below.
Note: Failure to select the proper frame is the single most common reason for setup errors.
After selecting the proper frame, select the Type from the pull down list. Make sure the frame type agrees with the machines specifications. The most common type is Class One Lever. If you have any doubt as to the frame type, consult ATS.
6.2.2
Frame Controller Information
You must know the common RS422 port on which the cable between the computer and frame controller is installed. Enter that information into the proper space. You must also know the address of the frame controller. Each frame controller has an address from 0 to 31, and each controller on a common port must be set to a unique address. This address is set by ATS Personnel during setup. ATS Personnel will determine which address is used by the controller servicing the frame that is being set up. Enter that address in the Address pull down list under Frame Controller Information. To locate a controllers address on WinCCS Classic, use the left side of the Frame Controller Box underneath the left display window and press both outside buttons in the set of three at the same time. The address will be displayed. WinCCS Modular requires the address to be set on the CPU Board via dip switches. (Insert Picture) Each frame controller services two frames, and they have been designated left (main) and right (secondary). The controller is commonly mounted on the main tester. Enter the proper designation in the Side pull down list under Frame Controller Information. Except in the rare case that a frame controller is configured to support only one frame, the proper designation under Type should be listed as dual.
6.2.3
Frame Load Capacity
The minimum and maximum frame loads are specified by the frame manufacturer, and it is important that the correct information be entered. The frame load specified during any test is checked against this information and tests, which require loads outside the specified limits, are not allowed to run. This can protect the frame and load components from damage. To access frame load, click on SystemFrame Setup and enter the appropriate information under Frame Load Capacity.
6.2.4
Frame Naming
Each frame must be given a unique name, or simply let the system use the default name, which is the frame number. In the event that you wish to assign a specific name to a frame, proceed with the following:
Under Frame Setup, go to the General Information box and enter the frame title in the Name box. The name you enter in this space will be viewed on the status display screen and used in all reports and graphs. PROCEED NOW TO THE SETUP OF THE VARIOUS SUB MENUS LISTED UNDER THE FRAME SETUP MAIN MENU.
6.2.5
Thermocouple Setup
Note that there are spaces to specify four NIST type thermocouples. See figure below.
Typically, a creep furnace will use three control T/Cs on the specimen, and a space is made for a fourth User T/C for monitoring purposes. This fourth T/C may be used to monitor room temperature or any other temperature of interest. The temperature of this T/C can be displayed on the temperature graph of any test run on this frame, but does not appear on the Status Display screen. Enter the appropriate information in the boxes.
6.2.6
Extensometer Setup
Note that the word extensometer is often used to describe the transducer mounted on the bottom of the actual extensometer frame, as is the case here. Some more modern extensometers provide the use of two transducers, and the system will average the results for better creep data. If one transducer is used, enter its description in the Left/Center box. Enter none in the Right box. If two are used, enter their descriptions in the appropriate boxes. Note that the left and right designations
will be used during calibration and verification. The designation of the transducers is determined by the electrical connections to the signal conditioner board located in the system console. Note and preserve this information. Inadvertently switching transducers during any phase of operation will result in faulty data. To access the General Extensometer sub menu, go to Frame Setup and click on the tab entitled General Extensometer(s).
GENERAL EXTENSOMETER(S) INFORMATION: Measurement Head Type(s) If you are using only one transducer, Left/Center is the only selection, and you will complete this menu once. If you are using two transducers, you will complete the menu for both Left/Center and Right transducers. Extensometry Rods All information listed under Extensometry Rods, including Gage Length, is for reference only and does not have any effect on the data or calibration process. Enter the gage length of the typical specimen. This entry does not influence strain reporting but is used in extensometer grading only. General Physical/Calibration Information
Enter the appropriate information under Physical/Calibration Information. Consult ATS if you are unaware of the proper voltage or displacement information. The number of steps tells the calibration and verification program how many data points to take. Ten is the commonly used value. Verification Information You have a choice of a single pass or ASTM specified multi-pass verification. If you select ASTM, two is the minimum number of passes. The ASTM procedure will choose the amount of required steps. If you select single pass, 1 is the default number of passes. The user selects the number of steps. The default number of steps is 10 and will appear in a box under the number of passes. You also have a choice of assigning a verification cycle. This option enables you to designate the amount of time needed for re-calibration. For example, if you enter 365 in the cycle box, you will not need to re-calibrate your equipment for 365 days or 1 year. Click Apply and then OK if all the information is selected and/or entered. THIS CONCLUDES THE GENERAL EXTENSOMETER MENU.
LEFT/RIGHT EXTENSOMETER INFORMATION: Return to SystemFrame Setup, and choose the tab labeled Left Extensometer or Right Extensometer. If the identification numbers are not entered, then continue. Both sides should be the same except for the serial number. This information should appear in the report.
6.2.7
Load Control/Automatic Loading Setup
There are two types of automatic loading, weight based and load control. The descriptions are self explanatory. If your system uses weights to apply the specimen loading, then you should select the Weight Based entry. If you do not use weights but have the chain tied directly to the frame, select the Load Control option. To select an option, go to Frame Setup and click on the tab labeled Load Control. Choose the appropriate Load Type-either weight based or load control-under Control Setup. Refer to the figure on the following page.
Weight Based Auto Loading Loading Parameters of the load cell are specified by the Load Cell Manufacturer and are indicated on data sheets supplied with the load cell. In the event of load cell replacement, this data should be updated. The only other information affecting the operation of the frame is Weight (Load) Pan Tare. This is the weight of the main load pan, not of the preload pan. Since this weight is balanced out during the frame balancing procedure, this tare is not subtracted from pan weight but is used during the load cell calibration process, which is automatically performed by the system during the automatic hot step loading process. Caution: Do not change the Load Operate Time of 500 mS without consulting ATS. Load Control Information Data for this menu is determined by ATS and should not be changed without instructions from your ATS support contact. Some tuning of individual frame types is routinely required, and this will be done at time of installation. In the event that the load control is not functioning properly, or the configuration of the hardware changes, consult ATS for the procedure required to change the entries. VIEWING FRAME SETUP SUMMARY: A summary of the frame setup parameters can be obtained by double-clicking with the left mouse button on the status line of a frame while holding down the shift key.
6.2.8
Frame Setup Digital
There are a series of switches on the hardware, whose states indicate such events as the draw head requiring leveling, the weights resting or not resting on the weight pan, or a weight elevator at limit of travel. In order for the computer system to know the status of the frame, these switches are sensed by the WinCCS System Controller and action is taken depending on the state of the switch. In order to avoid the necessity of making hardware changes, it is possible to reverse the polarity of the logic by software change. This is accomplished by use of the Input Logic Switch. For example, if the switch which indicates the crosshead has moved to the position requiring leveling is normally an open switch, and closes when this event occurs, the crosshead lower limit box would be checked to tell the computer that the event has occurred upon switch closure. If the switch were a normally closed switch, and opens upon this event occurring, then the check would be removed from the box for the logic to be correct for the computer. Directions: This menu is usually set up by ATS personnel at the time of system configuration, and the menu should not be changed unless some equipment change has been made. At this time, contact ATS Service for help. 1. From Frame SetupBasic Controls, select the specific frame to be set up and choose the Frame Hardware Types. 2. Under the Input Switch Logic menu, set the polarity of the various signal inputs. Note that some boxes are not accessible because some frames do not have all of the inputs. 3. After changes are made to this menu, go to MaintenanceViewFrame Controller Status to check that the status of the input agrees with the logic of the switch. In some cases, having the box checked will result in an active input; and, in others, the reverse is true, depending on whether the switch is normally open or normally closed. In some cases, experimentation is the easiest way to determine the proper configuration of the box. If the logic is reversed, simply change the box status in the Setup menu, and the logic will reverse.
6.2.9
Furnace Setup
Since many different types of furnaces and ovens can be attached to the test frame, it is necessary to have the capability to tell the system what is attached and to set parameters properly for optimum control. To make this set up, select Furnace from the Frame Setup menu, making sure that the proper frame has been selected. After making this selection, the Furnace menu will appear. Check the appropriate boxes to indicate the number of independent control zones in the furnace, which are attached to the frame. Refer to Zone Usage and Initial Settings. This must agree with the wiring configuration. If you do not know the correct configuration, refer to the installation drawings or consult ATS. The typical installation will have three furnace zones, but special circumstances, such as the use of a high temperature furnace, or the use of a box oven may require that a single control zone be used. Note that the number of thermocouples attached to the specimen is not necessarily the same as the furnace zone number. After completing this step, click to Control Parameters and configure the remaining information listed under the Furnace menu. Refer to the figure below.
CONTROL PARAMETERS:
The system uses a PID algorithm to determine the power to each zone in order to maintain the specimen temperature at a value that is near the specified setpoint value. Since furnaces vary widely in size and power rating, the PID terms will probably require tuning in order to realize optimum operating performance from the furnace. The following are typical default terms and will serve as a starting point. A short explanation of the term, and some guidelines as to the indicated change is included. NOTE: UNLIKE OTHER SETUP PARAMETERS, THE PID PARAMETERS MAY BE CHANGED WHILE THE FURNACE IS OPERATING. The Proportional term is in control during ramp to setpoint. The Integral term is enabled when the temperature reaches the difference between setpoint and Integral Enabled value. This value is normally set at 25F and is not to be changed. To experiment with furnace tuning, proceed as follows: 1. Set the I term to zero and raise the P term until the oscillation of the temperature is observed. Then reduce the P term until oscillation disappears. This is the optimum value for the P term. 2. Next, increase the I term until the transition from ramp to steady state setpoint value is a smooth, continuous curve without overshoot and the transition occurs within a reasonable time. If overshoot exists, reduce the I term. If the transition is excessive, increase it. *It should not be necessary to change the remainder of the defaults values. Consult ATS if satisfactory temperature is not achieved.
P (Proportional) Default value 1.000%/F Please see the detailed information above. I (Integral) Default value 0.030%/FThe integral term is enabled during the latter part of the ramp function. D (Derivative) Default value 0.01%/F/M The derivative term will not need to be changed during normal circumstances. Consult ATS before changing this term. Band Default 85F This is the amount of swing allowed to the control parameters, as the WinCCs Control Box varies them during the control process. In the case of any normal creep furnace, this value will not need to be changed. Integral Enabled Default 25F This is the point on the ramp, in degrees, at which the control algorithm enables the I term as the temperature approaches the setpoint value. In the case of the value set at 25 and the set point at 1000 degrees, the I term will be enabled at 975 degrees. Enabling the I term prematurely results in a longer time to reach the setpoint. Enabling it later may contribute to overshoot when the setpoint is reached. It is seldom necessary to change this term. Temperature Gain Default 1.00 This gain term is not normally changed. Maximum Power is normally set at 100%, allowing the control system to make use of the full potential of the furnace. If, for some reason you do not wish to apply full power to
the furnace, set this default to some lesser value, and the control system will limit the power applied to that value. Ramp Cutback Factor As the setpoint is approached, furnace power is automatically cut back between the transition between the ramp and the steady state. This avoids overshooting and creates a steady, continuous curve. This is governed by the Ramp Cutback, and the value of 2.50 is normal for a creep furnace. ZONE USAGE AND INITIAL SETTINGS/INITIAL POWER SPLIT: During the ramp of the furnace to the setpoint, no attempt is made to balance the power into the zones. Equal power is applied to all zones. Due to the nature of the furnace, and the chimney effect, the bottom zone will normally be colder than the others. Due to the cooling effect of the top pull rod, the top zone may or may not also be colder. After observing the temperature graphs of several tests, the situation regarding differential temperatures may be apparent. Note: The relative temperatures vary as the overall temperature approaches the setpoint. The only relevant data is the information near the setpoint. If one zone is always significantly colder or hotter (at least 15 degrees) as the setpoint is reached, then the initial power split may be changed to improve the balance of the zones. This will then result in less time spent in the presoak state, as the computer has less change to make in order to get all zones within the minor alarm limit and allow the test to proceed to the programmed soak time. When changing this initial power split, it is important to note that if power is added to one zone, it must be taken from another zone. The total of the three zones must still equal 300. EXAMPLE: It is observed that the bottom zone is 35 degrees low when the top zone reaches the setpoint value. A reasonable reaction would be to remove power from the top zone, and add it to the bottom zone. If the values were set to Top 90, Middle 100, and Bottom 110, the situation would probably be improved. Experimentation would be the only way to evaluate the change. When the zones are within a reasonable value, 10 or 15 degrees, changing the initial split values is a waste of time. ZONE POWER CONTROL: It is necessary to tell the system some information about the furnace zone control for optimum temperature stability and furnace performance. To access the setup menu from the main menu, select SystemFrame Setup Furnace. The entries in this menu seldom change, and the values found in the original
setup will most likely never need changing. Consult ATS if you perceive a need to change this portion of the menu. Typical default values are:
Minimum Maximum Delta Interval Increment
10% 190% 0.3 F 3.0 min 0.50%
6.2.10
Arm Ratio Setup
Lever arm testers are available with a wide range of arm ratios, and some have multiple ratios available, which are determined by the position of the arm. Therefore, in order for the system to calculate the proper pan load for the stress level specified, it must be told the proper arm ratio. In order to set up the ratio(s), enter the Frame Setup menu, select the proper frame to be setup, and click on Arm Ratio. To input the arm ratio, click in the text box under the title, Add Ratio and enter the dividend of the ratio. For example, if the arm ratio is 20:1, enter 20. Click on Add and observe that 20 to 1 appears in the Available Ratios box. If the frame is a multiple ratio type, repeat the procedure for the second ratio. Both ratios will then show in the box. When a test is started on this frame, you will specify which ratio is in use. If you need to remove a ratio, highlight the appropriate ratio in the Available Ratios box and click on Delete. This ratio should then disappear. If you need to change a ratio, first delete the old one and then add the new one. The most normally used ratios are 10 to 1, 20 to 1, and 3 to 1. Click OK when finished.
6.2.11
Miscellaneous Setup
There are miscellaneous items, which must be specified. Again, these are established at the time of system installation, but may for various reasons need to be changed. From the Frame Setup menu, select the Miscellaneous tab after specifying the appropriate frame number. FRAME MOTION DELAYS:
In certain cases, delays are needed between the control input and the resulting action in order to protect the hardware. In most cases, the unload value is not used and the box is left clear. In the case of frames with motorized drawheads or elevators, a manual control delay is essential. If the motor has not stopped before the reverse motion command is given, it may continue to run in the previous direction. If both commands are given simultaneously, the motor may be drawing excessive current and will be damaged, or may open protective devices. For this reason, a three second delay is normally used. This means that the frame motion controls on the system console are inactive for three seconds when a reverse direction is specified. Be aware of this situation because a casual operator may be unaware that the motion controls are malfunctioning. FRAME MOTION TIMEOUTS: If the computer commands a motion and does not see the result through the switch inputs, it will make a decision that something is amiss. For example, if it commands level, and does not see action from the drawhead low limit and specimen-loaded switches, it will assume the specimen is not intact and indicate a specimen break. The time between commanding the action and making the resulting decision is specified by the timeout entry. The specimen level timeout value can be left unspecified, but the break value is normally set at 30 seconds.
TARE VALUES: The tare value referred to here is the weight of the main load pan and the chain BELOW the preload pan. This value is used during the automatic load cell calibration, which is part of the modulus calculation. It has nothing to do with the calculation of the pan load for stress level. MISCELLANEOUS OPTIONS: At the present time, the only entry here is whether or not there is a separate preload pan for the preload weight. If the frame is equipped for automatic hot step loading, as used in the weight based option, it will have this detached pan. If no load option is used, and the load pan is of the normal, older variety, there is no detached pan. From this information, the computer knows what instructions to give the operator when he is told to load the frame. Click OK when finished entering the information under the Miscellaneous menu. THIS COMPLETES THE FRAME SETUP PROCEDURE.
6.3
General Setup
The proceeding fields contribute to general system setup.
6.3.1
Text Field Setup
Throughout the systems documentation, there are various text fields, headers, and report identifiers that are automatically affixed by the system. In order for these to be read appropriately, they must be set up. These will not have been previously set up at the time of system installation, as the appropriate entry will likely not be known to ATS. The default entry will likely not be appropriate. To access this area and the proceeding areas, select General Setup from the System Menu. Choose the appropriate tabs and fill in the information.
6.3.2
Material Application Types
During the process of creating a test specification, you are asked to enter the application type for which the specification is intended in the Applications Section. This field in the General Setup menu allows you to add or subtract specific applications from the list of entries in this field. In this way, the test operator can select from a list of applications, rather than having to type data into the field.
6.3.3
Report Header
Each report and graph contains a header, which is automatically inserted by the system. The Report Header menu allows the desired information to be configured. Its set up should be self-explanatory.
6.3.4
Site Information
The site information refers to the name of the lab that conducts the testing and will appear on system reports. The setup should be self-explanatory.
6.3.5
Specimen Text
During the creation process for each individual specimen, there is a text field in which the operator is asked to enter specific information about the specimen. Since individual installations may require different information, the titles of these text fields may be specified. Enter into the menu the desired title for the text field in which operator input is desired. If less than the total available text fields are required, leave the title area blank. Only the number of fields, which are titled, will be shown to the operator. To view the application of these text fields, select the Specimens Menu and go to Create. Step through the specimen creation process until you reach the Text Information page. Use of these text fields is optional. The test creation process will proceed even if the operator enters no data. Only in the case of essential information, such as specimen dimensions, will the system require entry of data.
6.3.6
Test Specification Text
The same type of text field exists for the test specification and set up is identical to that for the specimen field.
6.3.7
Default Setup
To configure the System Defaults menu, select SystemGeneral Setup. General information regarding certain defaults is contained in this section. While most of these parameters can be set during testing or specification creation, the default values can be set as well, and by setting the default to the most commonly used values, operator convenience is enhanced. DEFAULT THERMOCOUPLE USAGE: Testing may be done using one, two, or three thermocouples, regardless of the number of control zones in the furnace. Most systems will ordinarily use three thermocouples and the normal configuration is to check all three boxes. If less than three are used occasionally, leave all three checked and change the configuration as the individual test is set up. If less than three is the most common situation, then set this menu to the most common situation.
AUTOMATICALLY SEND: It is possible to automatically send either a long form or a short form report to a remote location at the end of each test. This assumes that the computer is equipped with a network card and is configured to be on the network. If this is desired, check the appropriate box, and the report will be sent automatically at the end of the test. DEFAULT TEMPERATURE LIMITS: Two separate alarm bands are maintained by the temperature control system. The first, referred to as the minor alarm, is intended to notify the operator of a condition, which is unusual, but not serious enough to warrant stopping the test. The occurrence of this temperature excursion is logged in the test event log, is indicated in red on the system status display, and is noted by flashing the display on the frame controller. Individual high and low limits are programmable for each individual test, and the default values are set in this menu. The normal value is 3F, which corresponds to the ASTM suggested excursion limit. This value is also the point where the system performs some control decisions and state changes during the ramp process. The shutdown alarm terminates a test in the event of temperature instability. For instance, if the temperature excursion exceeds this value, the test will be aborted, and the event log will record that the test was stopped for a major temperature alarm. The normal value for this alarm level is 15F. A normal excursion will not harm the system or the load train components but the previous magnitude should never be reached unless something is drastically wrong. In practice, once temperature stability is reached, the temperature will very seldom exceed 3 degrees above or below the setpoint and never 15 degrees unless something has failed.
6.3.8
Specimen Loading
This section establishes defaults for the step loading of creep specimens. To access this menu, go to SystemGeneral Setup and click on the tab entitled Specimen Loading. Refer to the figure on the next page.
Under the Creep Loading menu, there is a series of parameters that may be fixed. Minimum Steps is the lowest number of loading steps, which will be calculated for the loading process. Four is the common minimum number of steps. Target Steps establishes the optimum number of steps assuming the load required to reach the specified stress level is large enough to be divided into the targeted number of steps. In some cases, the pan load is so low that it is not practical to divide it into the normal ten steps, which is the universally used target. ASTM suggests that the preload should be no more than 10 percent of the total load. Therefore, 8 percent is the common default used for the preload calculation. Note that this value can be changed in the individual test at test start time. If it is deemed to be more convenient, a fixed preload can be specified. If the Use Fixed Weight for Preload box is checked, then the value of that fixed load in pounds can be entered in the preload window, and the load calculation will be made using this preload value. The value can be overridden at the time a test is started, if desired. If the normal operation is for the system to automatically load the specimen once the programmed soak period has expired, then check the Automatically Load box.
This too can be overridden at the start of the test. SECOND OPTION: STRESS RUPTURE LOADING: Since stress rupture loading convention may vary from creep loading, a separate menu area is provided so that different defaults can be entered for stress rupture testing. Stress rupture tests are not ordinarily step loaded, so no step load information is entered. Click OK when finished, and you will be returned to the status display screen.
6.3.9
General Calibration
In this menu, certain standards, which relate to calibration, are set. From the main menu, select SystemGeneral SetupCalibration/Verification Defaults.
EXTENSOMETER OPERATIONAL CHECK: This area allows details of the extensometer operational check to be specified by the user. It is similar to the setup of the extensometer calibration, but it is an abbreviated version.
FRAME LOAD CALIBRATION/VERIFICATION: This section allows the option of calibrating the frame with a load cell rather than the traditional proving ring. The Calibration recall period and the Verification recall period are additional user options for extensometer calibration. EXTENSOMETER LINEARIZATION: Normally, a polynomial curve fit is used to reduce the effect of the non-linear output normally found in LVDT transducers. This will greatly improve performance of the average LVDT, and permit most extensometers to achieve ASTM class A or B1 performance. If, for some reason, it is desired not to use the linearization, it can be deselected using this section. IGNORE STANDARDS TARE: This option allows the operator to ignore the tare measurement listed for the load cell. Check the box listed under the Calibration/Verification menu to ignore the standards tare. To review load cell information, go to CalibrationFrameLoad Cell(s). Refer to the figures below.
6.3.10
Test Lockouts
This section prevents the operator from starting tests when various system components have not been calibrated. Normally, all blocks in this section will be checked and the operator will be prevented from starting a test when these components have not been calibrated or when the normal calibration interval has been exceeded. Under special circumstances, it may be desired to test without calibration, and this screen allows this to be done. Test records will be annotated with information regarding the lack of calibration. To access this menu, go to SystemGeneral Setup and click on the tab entitled Test Lock Outs.
6.3.11
Additional Options
There is a series of additional options listed under the General Setup menu. Text Report Archive: This feature enables the operator to select the directory he prefers to save text reports in. Weights: Add weights to match the compliment of weights available for use with the tester. Typical systems are supplied with 0.5 lb, 1.0 lb, 5.0 lb, 10.0 lb, 20.0 lb, and 30.0 lb weights. Refer to the figure below.
Debug: This function is reserved for trouble-shooting by ATS personnel.

The Options, Import/Export, and Automatic Verification selections are functions that are not used at this time. THIS CONCLUDES THE GENERAL SETUP MENU.
6.4
Thermocouple Calibration
CAUTION: ATS SERVICE PERSONNEL HAVE ALREADY CALIBRATED THE THERMOCOUPLE BOARD BEFORE YOUR MACHINES AND COMPUTERS ARRIVE AT YOUR ESTABLISHMENT. But your thermocouple board will need to be checked yearly. If you have any questions, please call ATS Service Personnel at (724) 282-1212. Please refer to appendix A for instructions on thermocouple and extensometer calibration.
SECTION 7.
7.1
OPERATION
GENERAL OVERVIEW
The General Overview section describes two important features of WINCCS and gives a general overview of the operation of the system. User Login and Logout System Status Screen Information Overview of Operational Steps
7.1.1
User Login and Logout
WinCCS incorporates password protection and individual operator identification. When any action, such as calibration, test start-up, specification edit, etc., is taken by an operator, the identity of the operator is archived with the record of the action. The operator identification is the name assigned to the operator who is logged in at the time the action is taken. Therefore, it is important that each operator insure that he/she logs out when not responsible for the system. Before any action (other than viewing status and test information) can be taken, an operator possessing the appropriate privileges must be logged in. In this manner, unauthorized and potentially damaging action can be eliminated. When no operator is present, no operator should be logged in. When operators change, the new operator should log in. Note: If an operator is logged in and a second operator
logs in, the system recognizes the identity and privileges of the new operator only. A second consideration should be noted: System Units and the Status Display Option configuration are unique to the individual operator. For example, if operator A has selected metric units, all aspects of the system will use metric units when this operator is logged in. If a second operator has selected English units, the system will automatically revert to English units when this operator logs in. Likewise, the configuration of the Status Display screen will change to that chosen by the operator who is currently logged in. Note that any function not assigned to the operator will be grayed out in the menu. Access the user login screen by clicking on UserLogin. When the login screen appears, type in the name of the user exactly as it was input originally when the user name was established. Tab to the Password field and enter the password, making sure that it is typed correctly. Click on OK or press the ENTER key, and the new operator is now Logged in. If the user name or password is entered incorrectly, an error message will be displayed.
7.1.2
System Status Display
The system status display is the primary screen to which the operator refers during system operation. The status of the system is displayed here, and it is to this screen that the system reverts when no other operator function is in process. To access this menu, click on the Status Display icon located in the upper left hand corner, underneath the main menu bar.
When the Status Display screen appears, column headers and frame status conditions are displayed. Note that the purpose of the Status Display is to allow the operator to quickly scan the system status and too many entries will make this difficult. Perform this procedure each time a new operator is logged in, and the field will be customized for him/her.
7.1.3
Overview of Operation Steps
This section will provide an overview of the steps involved in actually operating the system for its intended purpose of performing creep or stress rupture testing of a specimen. In this section, it is assumed that the system is properly set up, the frames are calibrated and balanced, and all accessory items such as extensometers and
thermocouples are properly calibrated as described in the appropriate sections of this manual. In order to perform a test, we must first have a description of the test parameters, such as the temperature of the furnace, and the load to be applied to the test subject. We refer to this description as the Test Specification. We must also have information on the test subject, such as its identity and physical description. We refer to the establishment of this record as Creating a Specimen. Each specimen is a distinct entity. Since all identification and archival information is based on the specimen name, each must be unique and different. Once a specimen name has been assigned, it cannot be used for another test. Each lab will develop a naming protocol, which best suits the record keeping practices in use. Note that any number of specimens can be created, and they will remain available in the computer until used. The test specification, however, can and will be used for more than one test. The specification is automatically retained in the specification sub-directory unless deleted, and is available for use whenever it is appropriate. A naming protocol should be adopted so that the name of the specification is descriptive of the test parameters. This will aid the operator in selecting the appropriate specification. Note that each test specification will include any number of Test Conditions. Information under this section actually defines the test parameters and allows the operator to create a family of test conditions under one specific name. For example, it may be convenient to create a series of conditions, which are identical, except for temperature or stress level. In this way, a single specification name can be used to define all the tests, which might be used for a particular type of material, or for a common product line. Therefore, a naming protocol for the test condition should be created, allowing the condition name to be descriptive of the test parameters. This will aid the operator in selecting the appropriate condition. Since a test specification is selected as the specimen is created, the test specification must be present when the specimen is created. If it is known that none of the specifications already archived are appropriate, the first task is to create the specification, then the new specimen can be created. After the specimen is created, actual testing can begin. Below is a general outline that details the necessary steps needed to begin, execute, and terminate a test. 1. Test Specifications: Test Specifications must be defined before setting up the specimen type being used. Refer to Section 7.2. for more details.
2. Specimen Setup: Enter information about the specimen being used. Any number of test specifications can be used during testing for one specimen type. Refer to Section 7.3. 3. Testing: After the test specifications are entered and the specimen setup is complete, testing may begin. Refer to section 7.4 4. Stopping a Test: Tests in progress may be stopped at the users request. Refer to section 7.5 5. Viewing Test Results: The user may view results from current and previous tests. Refer to section 7.6
7.2
Test Specifications
This section will describe Specification Creation, Editing, Viewing, and Deletion.
7.2.1
Creating Test Specifications
This section enables the user to create new specifications specific to his test requirements. These new specifications will automatically be saved and can be re-used any time the details are appropriate for the test to be performed. From the main menu, select SpecificationsCreate and observe that the specification menu appears with the cursor positioned in the Test Specification field, where you should now type the name you wish to identify the specification that you are creating. Refer to the figure below.
After entering the name, tab to the remaining text fields and enter the appropriate information. Note that these fields are optional and the field designations may vary since they can be changed in the Test Specification Text listed under the General Setup menu. After completion, select Next. The Condition field will appear with the cursor positioned in the Test Condition field. The condition field contains the name of the condition and significant terms of the test, such as test temperature, stress level, furnace ramp rate and soak time, type of specimen and type of test. Enter the name you wish to assign to this test condition. Use the pull down menus to select the appropriate Specimen Type and Test Type. If you are a beginning operator, spend a few minutes reviewing the available entries, in order to make sure you are selecting the most appropriate entry. Use the tab function to proceed to the remaining data fields and enter the appropriate test parameters. Note that the units can be changed by accessing the User Units function. Optimum ramp rate is usually determined at time of system installation, and is not normally changed unless testing at an unusually low temperature, where a slower ramp may be necessary to prevent overshoot as temperature reaches set point. Select Next and the Temperature Limits field will appear. The Temperature Limits field allows temperature alarm limits unique to this individual test specification to be defined. The default limits will appear in these fields and normally are not changed. The minor limit is usually specified to be 3F, as this is the limit generally specified by ASTM. A reasonable shut down limit should also be specified. The default is chosen at 15F, as this is a value that should not be experienced unless something is very wrong. If, however, you have reason to use other than the default limits, enter the desired data. Be certain, however, to enter values, which will protect the specimen and the system hardware in case of control failure. Note that in case of the temperature exceeding minor alarm levels, testing will continue with operator notification and event logging only. Tests are not interrupted for minor alarms. The Setpoint Ramping Offset entry is used to aid the furnace in reaching operating temperature more rapidly. A value of 0.0 F is normally set. This value should remain set at zero. Consult ATS for further details. Select Next, and the Change Temperature field will appear. The Change Temperature field is seldom used; however, it is possible to change the setpoint temperature during a test. To use this feature, click on the Change Temperature box and specify the run time at which the temperature is to change and indicate the new setpoint. Click Next to proceed. The Power Failure field will appear. If the box is checked, the frame will be unloaded before the specimen is reheated if the test has been interrupted by a power failure long enough to drop the specimen temperature below the major alarm level. If not, the
specimen will remain loaded during the reheat process. Select the desired option and select Next. NOTE: At this point, a different screen will appear, depending on whether a creep or a stress rupture test is being defined. Assuming a creep test is being defined, the Creep field will appear. If the test is stress rupture, this field will be skipped. The Specimen Loading field specifies how the specimen will be initially loaded once the soak period has been satisfied. Note that this is not the up-loads which may be applied to a Stress Rupture specimen during the test. If Plastic Strain is to be separated from Creep data, then the specimen must be loaded in steps, either manually or via the load control feature of the system. In the Specimen Loading field, select Multiple steps or Single step from the pull down menu. Normally, multiple steps will be selected. From the pull down menu, select the Minimum Extensometer Classification, which is acceptable for the test. Since the extensometer verification process grades the extensometer to ASTM specifications, the system can alert the operator if the extensometer does not meet the minimum requirements. Select Not Classified if you do not wish to use this feature. Since normal creep action during the test occurs at a rate much less than at time of loading, provision is made to collect data at a faster rate at the time of initial loading. Enter values for initial and subsequent reading rates and time of crossover under Creep Data Logging Rates. The default values, which appear automatically, are appropriate for any normal ASTM type testing and are not typically changed. Select Next and the Step Loads field will appear. Step loads are normally used for Stress Rupture testing, where higher loading is desired if the specimen has not broken during the initial test load time. This feature allows the user to specify the time to initial step load, step load value, and step load period. (In the case of a stress rupture test, this field would have appeared after the Power Failure field was completed.) Select Next to proceed. The Cyclic field will appear. It is possible, with a very specific type of frame, to cycle load during a test. This feature is not covered in the manual, and should be discussed with your ATS representative if cyclic loading is desired. Select Next and the Pass/Fail and Shutdown field will appear. The Pass/Fail and Shutdown field allows the operator to specify certain test criteria, which can determine acceptance or rejection grading or automatic shutdown of the test. If only the Fail box is checked, the test runs to completion, but the report is annotated that the test failed for this reason. If the Shutdown box is checked, the test is terminated.
The Life Hours field is used to terminate a test after a specific number of hours. Enter the desired criteria in each data area. Leave the boxes unchecked if this feature is not desired. Select Next and the Elongation field will appear. Select the method of Elongation Measurement from the pull down menu. Note that it is possible to defer this decision until after the test is completed. If pass/fail or assigning an elongation limit is desired, make the appropriate entries. In some instances, a separate elongation limit may be desired. This limit allows the operator to measure an alternate elongation after a specified time. For example, if the operator initially wants to measure 3% elongation and then decides he wants to measure 5% elongation after 48 hours, he can select the appropriate information in the window shown below.
Select Next and the Intermediate Creep Pass/Fail field will appear. Use the Intermediate Creep Pass/Fail field to establish criteria based on creep performance. Note that creep at a specified run time, or run time to a specified creep can be selected from the Fail if pull down menu. After defining a criterion, click on Add to establish this criterion. Also, notice that any number of criteria can be established by clicking on Add after each is defined. Select Next when finished and the Report Intermediate Creep field will appear. The Report Intermediate Creep function is very useful since most operators are interested in creep at several points during the test, either as creep at specified run time, or run time to a specified creep value. Either can be selected by using the Report pull down menu. Enter the appropriate time or creep value and click on Add. Enter as many reporting points as desired, clicking on Add as each is defined. Select Finish when all points have been established and the creation process for this specification is completed.
7.2.2
Editing Test Specifications
The Edit Test Specification function allows details of a specification to be changed. One frequently used edit function is the addition of a new condition to an already established test specification. To use the Edit function, select from the main menu: SpecificationsEdit and the Test Specifications field will appear. Use the Test Specification pull down menu to select the specification to be edited. Select from the available entries the desired field to be modified. For example, click on Condition and observe that the entries in the condition field are accessible for change. To add a new condition, click on Add a New Condition and the cursor will be positioned to allow a new condition name to be entered. Type in the new name and revise the data fields to reflect the new test condition. Click on OK when finished, and the new test condition is available for use. The revision field should be changed in order that the system can keep track of the revisions. Each time the test specification is used, the revision level is noted as part of the test report. If the revision level is not updated, then this information is lost. The test report will append the word modified to the specification name, but this los es some information that would be available if the proper procedure is followed. Any other detail of the specification can be changed by selecting the proper field and making the appropriate change.
7.2.3
Viewing Test Specifications
The details of a test specification can be viewed on the screen or printed by selecting SpecificationsView. When the Select a Test Specification to View field appears, use the Test Specification and the Test Condition pull down menus to select the desired Specification and Condition. All details of the selected specification and condition can be viewed on the screen or printed by using the normal Windows print functions.
7.2.4
Deleting Test Specifications
If a Test Specification is no longer needed, it can be deleted from the list, in order to avoid possible operator confusion. From the main menu, select Specifications Delete. When the Select a Test Specification to Delete field appears, use the pull down menu to select the appropriate specification to delete. Select OK. Verify your decision to delete the specification by answering Yes to the Really delete specimen question, and the selected specification will be deleted from the list.
7.2.5
Copying Test Specifications
The Specifications Copy feature is convenient if you are creating specifications that have details in common, or if you want to create a new specification that is very similar to an existing one. To use the Specifications Copy feature, go to Specifications Copy, select the existing specification to be copied, and click on OK. You will be asked to input the name of the specification to be copied. Assign the desired new name and click OK. Note that the original specification will remain unchanged under the original name.
7.3
Specimens
The specimen, in reality, is the object to be tested. In order to perform tests, we must give the test subject an identity and tell the system what parameters to use in testing. We refer to this process as Creating a Specimen.
7.3.1
Specimen Creation
From the main menu, select SpecimensCreate. When the Specimen Name frame appears, enter the name, which is to be assigned to this specimen. Note that the name must be unique and cannot be used for any other test. Click on Next and the Test Specification field will appear. Use the pull down Test Specification and Test Condition menus to select the desired Test Specification and Condition. The remaining data fields show the details of the test parameters of the test specification you have selected. If these are not correct, you have chosen the wrong specification or condition. Re-select the proper specification or condition. NOTE: These data fields can be changed at this time, and the test parameters will be revised to reflect the new parameter(s). This specimen will be tested to the revised parameter(s), and the test record will show the identity of the specification with the word Modified appended. The test specification will not be permanently modified, and the next time the specification is used, it will revert to the original parameters. This feature is useful if it is desired to do a one time test with one or two parameters changed, and the need for a new specification is not seen. Use this feature carefully. Select Next when you are satisfied that the test parameters are correct.
When the Dimensions field appears, enter the appropriate specimen dimensions. Note that the required load and resulting strain information is calculated from the cross section and gauge length dimensions entered. Make sure they are correct or the test results will be in error. Select Next when the dimensions are correctly entered. Enter any comments, which are desired when the Comments field appears. This is optional, and you may proceed without entering any comments if none are desired. Select Next to proceed. Enter the appropriate text in the various fields when the Text Information field appears. Again, this is optional, and you may proceed without entering text information. Select Next to proceed to the Review field. The Specimen Information and Test Information areas of the Review field allow the operator to confirm details of the test specification and specimen. In the case of dual ratio lever arm testers, the operator is permitted to change the arm ratio selection if not correct. If checked, the Release for Test function requires the operator to certify that he has reviewed the details of the test and is satisfied that they are correct. This information is retained as part of the test record. Select Finish to complete the process and save the specimen record for later use. Refer to the proceeding figure.
Note that any number of specimens can be created; it is not necessary to start the test at this time.
7.3.2
Specimen Edit
Part of the Specimen menu is allocated to change details of a specimen after it has been created but before the test has started. To access this portion of the menu, go to SpecimensEdit. When the Edit Specimen field appears, use the pull down menu in the Name box to select the specimen you wish to edit. Select the appropriate tab (test specification, dimensions, etc.) and make the desired revisions. A review of the pertinent details can be seen by selecting the Review tab. Select OK when the process is completed. The revised specimen will return to the list of specimens ready for a test.
7.3.3
Specimen Review
A separate selection from the main menu, identical to Specimen Edit in all details except one, is provided for review of specimen information. This selection does not allow change, only review. In this way, an operator who has no authority to change specimen information can still see it in detail. To access this feature from the main menu, select SpecimensReview.
7.3.4
Specimen View
As in the case of specifications, the specimen information can be viewed and printed in report form by selecting, from the main menu SpecimensView. When the Select Specimen to View field appears, use the pull down menu to select the specimen to be viewed. You may print the report if desired, using the normal Windows print routine.
7.3.5
Specimen Delete
If it is desired that all record of a specimen be deleted after it has been archived but before starting a test, go to Specimens and select Delete. When the Specimens to Delete field appears, use the pull down menu to select the specimen you wish to delete. Select OK or press Enter to delete the specimen. CAUTION: As soon as the OK button is selected, the specimen data will be lost.
7.4
Testing
We now have everything in place to begin actual testing on the specimen. Assure that: 1. All setup procedures outlined in Section 6 have been completed. 2. The frames have been properly balanced. 3. A specimen is installed in frame with thermocouples properly attached. 4. The drawhead/elevator is positioned properly. 5. Observe safety precautions.
SAFETY WARNING: TESTING MAY INVOLVE VERY HIGH FURNACE TEMPERATURES. ENSURE THAT THE FURNACE IS CLOSED, NO MATERIAL IS IN POSITION TO POSE A FIRE HAZARD, AND HIGH TEMPERATURE WARNING NOTICES ARE POSTED TO ALERT PERSONNEL OF THE POTENTIAL HAZARDS.
7.4.1
System Status Display
The system status display is the main display used by the operator during normal operation of the system. Note that machine states and alarm conditions are displayed on the status display screen. Please refer to appendix B for a listing of the various status display headings, display colors, and alarm codes.
7.4.2
Starting a Test
The general procedure to start a test is to select an idle frame, install the specimen in the frame, and tell the system to start testing the specimen. There are four ways to begin this procedure and the method chosen is up to the preference of the operator. The options are as follows: 1. From the main menu, select Tests, and then Start. The Start a Test menu will appear. 2. From the main menu, select Specimens and then Start. The Start a Test menu will appear. 3. Click on the Frame icon on the main menu.
The Frame Services menu will appear. Click on Start a Test and the Start a Test menu will appear. 4. Double-click on the Status Display line representing the frame you wish to use. The Frame Services menu will appear. Click on Start a Test and the Start a Test menu will appear. Note that in all four options, you must select the frame you wish to perform the test on by either double-clicking on it (Method 4) or selecting it from the Frame pull-down menu (Methods 1-3).
Verify that the Calibration/Verification Status section indicates that all required functions are calibrated. Verify that the Usage area of the Thermocouple Information section agrees with the thermocouple installation for this particular test. Revise it, if not. Select the appropriate Thermocouple Batches if you use calibrated T/Cs, or select zero offset if not. Note that your temperature control will be much more accurate if you use calibrated T/Cs. Also, using a single batch for all Thermocouples will be more convenient and present less chance of an error. Verify that the information in the Extensometers and Arm Ratio areas is correct. By default, both boxes are checked under Extensometers and 20:1 is entered under Arm Ratios. It is possible to delay furnace ramping until a future time. For example, this feature might be used in the case of a manual loading system, where it would be desirable to have the furnace up to temperature at a convenient time to perform the loading. By default, ramping is set for Now. If this feature is to be used, enter the appropriate information. Select OK when completed. After selecting OK, the Specimen Loading Information window will appear. Enter the appropriate pre load amount (in lbs.), making sure to adjust the value if it doesnt agree with ASTM standards. See figure below.
The system will automatically populate the values listed under Creep Loading Information. Refer to the figure above.
If you plan to utilize the Automatic Load Method, click on the box entitled Automatic Loading. Otherwise, the operator must manually load the weights on the machine. In the event of manual loading, the administrator may display the amount of weight needed to be loaded on the frame. In order to view this information, the user should select Required Step Loads from the View menu. Follow the loading instructions and click OK to begin testing.
7.4.3
Reload a Test
In some instances, you may wish to reload a test in order to start it anew. To do this, go to TestsReload.
7.5
Stopping a Test
At any time a test is running, the operator may stop the test manually. This might be done if a problem with the frame, or some other anomaly were detected, such that the test results will be invalid. It may be that the test has reached the point where no further useful data will result, or for a variety of reasons, it is desired that the test be terminated. There are several ways to accomplish this: 1. From the main menu, select Tests and select Stop from the list of options. Select the appropriate frame from the resulting menu and click on OK. Answer Yes to verify that you wish to stop the test, and the test will be terminated. 2. Click on the Frame icon on the main menu and select the appropriate frame from the resulting Frame Services menu. One of the available options will be Stop the Test. Click on this and answer Yes to verify. The test will be terminated. 3. Double-click on the appropriate line of the Status Display screen, and select Stop the Test when the Frame Services menu appears. The test will be terminated. After the operator has terminated the test, the system will proceed through several states, depending on the system configuration. The furnace will be shut down, and the load will be removed from the specimen if computer load is implemented. The frame will proceed to the Post Test state, where it will remain until the operator intervenes. NOTE: At this point, the operator may choose 3 test options: Post Test, Reset and Clear, or Restart. If Reset and Clear is selected, all record data of the test is lost. Be careful not to select Reset and Clear in error. Test data can, of course, be viewed prior to Post Testing by selecting View Data and can be viewed after Post Testing by viewing as a Previous Test. If Restart is selected, the system will go through the ramp, soak, and load procedures as in the initial start of the test. If Post Test or Reset and Clear is selected, the frame will then be set to the Idle state, ready for use for another test.
7.6
View Test Data
The WinCCS System incorporates provisions to view the results of both currently running and previously archived tests in both graphic and report form. The procedure is to first select the desired test (by specimen name), and then to select the desired reports/graphs. The procedure to select the test is listed below.
7.6.1
View Running Tests
There are three methods to select for viewing a test which is currently running: 1. From the main menu, select ViewRunning Test. When the Select Frame to View field appears, select the desired frame and click OK. The Report/Graphing Options menu will appear. 2. Click on the Frame icon from the main menu. When the Frame Services field appears, use the Frame pull down menu to select the desired frame. Select View Data from the list of options and the Report/Graphing Options menu will appear. 3. Double click on the appropriate line of the Status Display screen and the Frame Services menu for that frame will appear. Select View Data and the Report/Graphing Options menu will appear. A quick look at data on a running test can be achieved by double-clicking with the right mouse button on the status line of the frame displayed on the Status Display screen. In the case of a creep test, a creep graph and an event log will be displayed. In the case of a stress rupture test, a temperature graph and an event log will be displayed.
7.6.2
View Previous Tests
Tests which have been completed and automatically archived through the Post Test procedure are known as Previous Tests. The test data along with the supporting information on test specifications, calibration, etc. are archived on the computer hard drive in a sub directory reserved for that purpose. The default name for this subdirectory is Tests. In order to view a test that has been completed, select from the main menu View Previous Tests. The Select Archived Test to View field will appear. Use the Directory pull down menu to select Tests and the File menu to select the appropriate specimen name from the list of archived tests. See the figure below.
There are two special cases of tests which are not necessarily complete, yet are not currently running on a frame, that have their records stored on hard drive. These are tests that have been chosen to be cleared from the frame for a new test before the post test process has been completed or tests that are already stopped but are slated to resume at a later time. If the tests which are to be viewed fit these categories, their records will be found in the Post Test Queue or Continue Test Queue, respectively. Select them as in the case of completed tests.
7.6.3
Report/Graphing Options
The Report/Graphing Options menu allows the user to select the specific report or graph which is desired and to configure graphs to display the test data in the most advantageous form. This menu also allows selection of data to be exported in a common separated variable format for spread sheet use. To access the Report/Graphing Options, go to View and select either Previous or Running Test(s). The figure on the following page displays the report window.
Most of the report titles are self explanatory. If a short form is selected, the report will be limited to the following basic information: Specimen Information Test Condition Test Results Intermediate Creep Values (if appropriate) Post Test Comments Operator Identification If a long form report is selected, all the reports listed below the Long Form area are automatically selected. If some, but not all of these reports are desired, they may be selected individually. Any or all of the listed items can be selected simultaneously and they will be presented over laid or tiled formatting. However, the system will gray out any inappropriate selection, such as a creep graph in the case of a stress rupture test. Click on OK to see the selected reports. If creep data is selected to be reported, attention should be paid to the Creep Data Options area. During an extended creep test, the number of data points can number in the thousands. It may not be desirable to report this many data points. The Creep Data Options allows the selection of data points to be reported. NOTE: Selecting options in this area does not affect the archived data. The only thing affected is the generated
report. Experiment with the various selections offered in the pull down menu to determine which is optimum for the application. When graphs are to be displayed, use the Graph Options feature to customize the graph to present the optimum display. Refer to the figure below.
The options are explained below. DATA: Run time data covers the test from the beginning or the Run state until the test is stopped, either by operator action or by system action, such as the rupture of a specimen. Entire Test data covers the test from beginning to end and will include data during initial ramp up of the furnaces to operating temperature. This feature is particularly useful in initial setup of the frame parameters. THERMOCOUPLES: This section allows the user to select which thermocouple signals to display. THERMOCOUPLE SCALING: Under normal operation, the temperature always remains very close to the setpoint value. Therefore, displaying the entire range between start-up and run values would result in a drastic loss of detail during the test. When it is desired to see temperature during the test, select + / - setpoint for maximum resolution. If it is desired to view temperature during the ramp process or to view the user T/C, select Entire Test Range. AXIS and LEGEND TYPES are self-explanatory and can be selected based on user preference.
7.6.4
Exporting Data
To export data, select FileExport and select either Previous or Running Test (s). It may be desirable to export the test data in ASCII common separated variable format for analysis in a specialized format, such as EXCEL or other spreadsheet programs. If this is desired, select Export Data and the Export Data to ASCII File field will appear. This field allows the user to select the type of data to be exported, control the number of data points if less than the total amount is desired, and to determine the path of the exported data. Use this field as follows: Select the type of data to be exported by making the appropriate choice from the Export Data field. Specify File name and Path by clicking on Browse. When the Save As field appears, modify the file name if desired, and specify the Save in destination for the file. Select OK or press ENTER to complete the export process.
7.6.5
Exporting Test Data Files
Test data files are the complete files, containing all aspects of the test, which are archived automatically once the test proceeds beyond the Post Test state. These are the files that are accessed when previous tests are viewed. There is no built in routine to export archived test data files. If it is desired to export test data files for analysis on another computer in which the WINCCS program is installed or to copy files to another storage medium for back up storage, or to delete them from the disk, WINDOWS EXPLORER must be used. NOTE: Care must be taken to select the correct directory before deleting or moving files. There are two directories with similar names, and if the wrong one is chosen, running tests will be disrupted. If you are not familiar with WINDOWS EXPLORER, consult your internal computer support group or contact your ATS support person.
7.6.6
Viewing Test Data
After the desired test has been selected, use the Report/Graphing Options, menu to select from the list of available reports and graphs of the desired items. Any or all of the listed items can be selected simultaneously, and they will be presented in layer or tile format. However, the system will gray out any inappropriate selection, such as creep graph in the case of a stress rupture test. Click on OK to see the selected reports and graphs. Normal windows functions are used to select the particular display to be viewed. Any of the reports or graphs can be printed via the normal windows print routine.
7.7
Maintenance
The WinCCs software offers a variety of maintenance options that can be accessed easily via the Maintenance menu. The following is a list of features, located under the Maintenance toolbar. Diagnostic Displays: This function is reserved for ATS Service. Furnace Logging: The furnace logging option allows the operator to select a frame and consequently log data for that frame. The logged data is sent to the WinCCs Logs directory, where it can be accessed and reviewed at the operators convenience. Lockout Frame(s): If an operator wishes to prevent a frame from functioning, he may select lockout frame, and he will render the frame non-operational. On the status display screen, the alarm code, MLO, will appear, indicating a Machine Lockout. Manual Control: This feature should be used ONLY in coordination with your ATS Service Personnel. Upon selection of manual control, the following warning will appear.
This option is typically used for trouble-shooting purposes and can damage the machine if utilized improperly. Contact ATS for further details and assistance. Reset Frame to IDLE: This option is another trouble-shooting feature and may be used in the event of a computer lock-up. Note that if you reset the frame to idle, you will lose all data for that particular frame. Test Load Control: This is a very useful function. It allows the user to input a setup parameter and then test it in real time without going to the test function. There are three Viewing options listed under the Maintenance menu. All three are pretty self-explanatory but a brief definition of each is given below. Frame Controller Status: Relates information pertaining to the frame such as temperature, inputs, outputs, furnace power, etc. Some information can be viewed in volts by clicking the appropriate box. Frame Status: Similar to frame controller status but gives different frame parameters such as frame flags, alarms, etc. Furnace Data: Relates information pertaining to the furnace such as setpoint, target temperature, ramp rate, etc. There are two additional maintenance options that are alternatively listed under the File menu. These include: Write Communication Statistics and Write System Info. These functions are both reserved for trouble-shooting purposes and are usually used by ATS Personnel only. However, it is important that the customer knows how to access these options in the case of machine difficulties.
7.8
Tools
Various tools are available to modify, reclassify, and refine tests. These tools are listed under the Tools menu and are described below. Fast Fourier Data Plots: This is a way to search a temperature graph or a creep graph for something that is periodic, i.e. it makes a spectrum analyzer plot out of the temperature graph. This option is useful for finding sources of extraneous data, e.g. temperature fluctuations from room temperature variations. Fix Creep Data Anomalies: This function allows the system to recognize an anomaly in the creep graph and delete it so that the creep graph more accurately portrays the actual creep, rather than a graph which has some discontinuity in the creep data. Modify: This feature enables the operator to modify certain test details after the test is completed. For example, an operator may add Remarks to a certain test, redefine the Specimen Measurements, or add Post Test Information. Rename: The operator has the option of assigning an alternative name to a Previous Test, Running Test, or a Specimen. Generate Test Info: ?????
7.9
Graphing Options
There are a variety of graphing options available to the user, so that he may display data in a style/format that is preferable to him. These options are listed under the View menu. Multiple Creep Graph: This option allows you to select multiple creep tests and superimposes the creep data so that you are able to view multiple graphs simultaneously. This graph is useful if you want to compare creep curves for more than one test.
Appendix A Thermocouple Calibration

Frame Controller Thermocouple Calibration The WinCCS Controller Thermocouple Calibration is the software procedure that is performed locally at each frame controller. The procedure generates individual software gain and offset correction parameters that are applied to the raw temperature data for each of the three provided gain ranges. Other than to connect the calibrator, this is a closed box procedure with no physical adjustments required. In order to perform the calibration, the ATS Service Person will need a traceable voltage source of sufficient accuracy that can supply 17.0 mV, 35.0 mV, 70.0 mV or a stable reference voltage source that can supply approximately the same voltages, along with a traceable high accuracy voltmeter. The supply and or voltmeter are connected directly to any one of the thermocouple input channels during calibration. This must be done using suitable cabling so that there are no parasitic thermocouple junctions or other error sources present. The following table shows thermocouple measurement system gain range, supported thermocouple types, and the maximum calibration voltage uncertainty allowed to achieve specified performance. Nominal Range 0-70 mV 0-35 mV 0-17.5 mV Supported Thermocouples J, K, E, N T R, S, B Maximum Calibration Voltage Uncertainty 3.5 V 3.5 V 1.5 V
CAUTION: Calibration may only be performed on controllers where both sides are idle. Calibration of the thermocouple board can be performed by an outside service or the customer with the before mentioned equipment. A user authorized to perform hardware calibrations must first log into the system and then fill in the Calibration Methods and Standards Form. This form is accessed by selecting: CalibrationThermocouple BoardMethods and Standards. After this form is filled out, the calibration procedure may be started on whichever frame controllers the user wishes to calibrate. This is done by selecting: CalibrationThermocouple BoardCalibration and then selecting the frame to calibrate. This will activate the thermocouple calibration routine at the appropriate frame controller. Because one thermocouple board and controller serves two frames, thermocouple calibration need only be done for one of the two frames sharing a controller. Either frame may be selected; if both are calibrated, only the most recent data will be used. On the window screen, select which frame to start calibration on: frame 1, 2, 3,
From this point on, all service personnel or operator interface is provided at the selected frame. The calibrator should be connected to any one of the thermocouple board channels and the cover replaced on the enclosure. Sufficient time should be provided for the cold junction compensation block temperature to be equalized along the block. Rapid or wide temperature changes immediately before or during the calibration procedure will result in calibration errors. After thermal stability is achieved, the prompts on the selected frame controller should be followed. During the calibration procedure, the operator will be prompted to apply various voltages, typically 17.5 mV, 35 mV, and 70 mV. Some boards will also require 0.0 V. Other than zero, each voltage may be from 20% below to 10% above the requested value; simply use Yes or No buttons on the controller front panel to increment and decrement the controller display until it shows the actual applied voltage. Once all voltages have been measured, the system will then compute and display the calibration coefficients. If any coefficient is outside of a nominal range, the calibration procedure will be flagged as bad and the data from the calibration disk will be rejected. This may be caused by either a faulty calibration procedure or a faulty thermocouple board. If a subsequent calibration attempt also fails, there may be a problem with the board. If the coefficients are within limits, the operator is presented with the option of verifying the calibration. It is highly recommended that this be performed, since it is possible to have mis-calibration but still be within the coefficient limits. The three gain ranges are verified individually, with the operator free to check at any point within each range. At least five points across each range should be verified. If the calibration is found to be satisfactory, the operator can then choose to send the calibration data to the host PC where it is stored on disk. All future temperature measurements on that pair of frames will then use those calibration coefficients. Many standard organizations and internal company policies also require verification using a thermocouple simulator. This is the only method that also tests the cold junction compensation and thermocouple equations and calculations. This verification is done by connecting the simulator to one of the thermocouple channels and using the standard temperatures within specification. Virtech strongly recommends that this be done after every calibration or any time temperature performance is in question. Each thermocouple type that is in use should be checked at a minimum of five points across its range. If certain temperatures are particularly important, they may be verified. Thermocouple Batch Calibration The system is set up to use any standard NIST specified thermocouple type. Simply by selecting, during the setup procedure, the type of thermocouple wire used, the temperature read out will be correct for an ideal perfect thermocouple. However, no thermocouple ideal exists so it is common practice to calibrate the actual thermocouple and provide a chart of actual temperature, indicated temperature, and offset. The calibration information can be entered with an identifying (Batch) name. Every time a thermocouple is made from this particular batch of wire used, the system will correct temperatures using this calibration information. In this way, temperatures are always corrected to their calibration data.
If uncalibrated thermocouples are used then select the Zero Offset Batch Name, and the system will assume a perfect NIST Thermocouple. Typically, the thermocouple is tested at several temperatures over the useful range of the thermocouple wire type and a chart, similar to the following, is provided as a calibration record. The problem arises in that sometimes the error is reported, as below, and in other instances, the program will present it as a correction factor, which will return the temperature to the NIST profile. True Temperature (C) 200 400 600 800 Indication/Indicated Temperature) 199.40 399.50 599.60 800 Offset/Deviation -0.60 -0.50 -0.40 +0.00
Note: The Indicated Temperature is the sum of the True Temperature and the Offset. The system will simply add the indicated temperature and the offset. If you entered the previous offsets into the batch file, the correction would be opposite of the desired effect. The operator must, therefore, examine the calibration report carefully and make sure that the sign of the correction factor is entered properly. In order to create a batch name and enter calibration information, perform the following steps: 1. From the main menu, select CalibrateThermocouple BatchCreate. 2. Click on New or Add and enter the Batch name, using a unique name, which is associated with the wire batch. Enter the appropriate information. 3. Enter the Temperature and the Offset Correction in the appropriate window. Then click on Add. Do this for each temperature point on the Correction Data.
Note that options are allocated to view, edit, or delete a thermocouple batch. The function of these selections is obvious and will not be explained in detail. To access these options, go to CalibrationThermocouple Batch and select the appropriate function.
Extensometer Calibration
Each extensometer must be calibrated in the channel in which it is to be used. In practice, the LVDT or other transducer remains attached to the signal conditioner board in the system console. In this manner, the inadvertent switching of transducers is avoided. There are two distinct, but similar functions available to the operator to insure proper operation and accuracy of the extensometer: Calibration and Verification. They both involve using a precise micrometer to increment the LVDT in precise amounts through its range of operation but differ in the way the signal is handled by the system. In the calibration function, a polynomial curve fit is used to effectively linearize the device, allowing much greater accuracy of operation. In this process, the calibration device is assumed to be perfect and the output signal is corrected to a straight line, against which the data will be compared to produce strain information. In the verification process, the LVDT is again incremented through its range using a precise micrometer and the resulting output is compared to the original. After correcting for non-linearity, any difference is presumed to be error and the extensometer is graded based on the result.
Therefore, it is important to run the verification process frequently, since this is the true check of the extensometer performance. Find System Calibration Report under ViewSystemCalibration. For other reports, look under Calibration. Note that details of both calibration and verification are defined during the Frame Setup Process. To initiate extensometer calibration, select from the main menu Calibration ExtensometersCalibrate. The Select Frame to Calibrate Extensometers screen will appear. Select the appropriate frame from the pull down menu and click on OK. At this point, the main menu and status display screen will be displayed, and the status display line corresponding to the selected frame will turn red. Cal/Ver will be displayed in the alarm column. Further action is now moved to the control console of the appropriate frame. Use the buttons located below the LCD display on the Control console to proceed, as directed by instructions on the LCD display. You will be directed through a series of steps in which you will move the LVDT in precise steps measured by the micrometer calibration device. At the completion of the process, the status display screen will return to normal and the calibration report and graph can be viewed. In order to view the calibration report and graph, select from the main menu: Calibration ExtensometersView Calibration Report. The Select Extensometer screen will appear. Select the appropriate extensometer and click on OK. The selected report will appear. This report will provide all pertinent data on the calibration, including a grading (gradation comparison) against ASTM standards. Note that in almost all cases, the data will indicate a class A extensometer. This does NOT guarantee that the extensometer will perform as a class A extensometer. In order to know how the extensometer will perform in actual operation, repeat the above process, selecting Verify instead of Calibrate. After completing the verification process, the resulting verification report will show the true capability of the extensometer. In practice, it is normal to perform the calibration process at the interval specified in the setup field, and to perform verification much more frequently. Both calibration and verification reports are archived with the data for all completed tests. Both Calibration and Verification report windows are a list of information on a plain screen. It is possible to view these reports for frames on which tests are currently running by selecting from the main menu: ViewRunning Test and then selecting the appropriate frame from the screen which appears. Another, and probably better way to view a report, is to access the Frame services menu by double-clicking on the status display line of the frame in which a test is running and then
selecting View Data from the Frame Services menu. Select Extensometer Calibration from the Report/Graph menu which appears and click OK. The desired calibration report will appear. Any of the reports or graphs can be printed if a printer is attached.
Viewing Calibration Summary

A review of the calibration status of a frame can be acquired by double-clicking with the left mouse on the status line of the frame while holding down the Ctrl key. This can be done regardless of the state of the frame. A report screen is generated after the frame calibration. This type of calibration is normally done once a year with the proper equipment. For more information on how to calibrate a frame, please call ATS Service Personnel. Please note that for the initial test, the frame is precalibrated at ATS but to keep it up to date, the frame should be recalibrated one year later.
Appendix B Status Display Headings

Elevated temperature creep testing is the most commonly used application for this system. While some column headings are self explanatory, the meaning of each one is explained below. Frame: Each frame has an identifier, either a name assigned during the setup process, or a number from 1 to the total system complement. The default condition lists frames in numerical order. State: The frame state allows the operator to monitor the process of the test. Specimen Name: The specimen name is the unique identifier assigned to the particular test subject installed in the frame. This identifier will be used for all archival purposes for the subsequent test data. Setpoint: The setpoint is the temperature specified in the test specification to which the specimen will be tested. In the case of room temperature tests and idle frames, N/A is displayed to indicate the furnace is not in use. Average: This column displays the average of the temperatures of all the thermocouples I use on this frame. The user T/C is not included in this average.
Top (Middle, Bottom): The display here assumes three T/Cs are in use, and the temperature of the uppermost T/C is displayed here. The middle and lower T/Cs are likewise shown in the adjacent columns. Power: At any time during the test, the furnace control algorithm will be varying the power into the furnace in order to keep the temperature at the specified value. This display, which is a % of the total power available, provides an indication to the operator of the power level being delivered to the furnace. Time: Depending on the frame state, time may have different meaning. For example, if a test is running normally, time will be the total run time of the test, starting from initial specimen loading. A frame in soak state will show the time remaining until specimen loading. % Creep: When a creep test is in process, this display will show the amount of creep of the specimen in real time. Alarms: This display shows an abbreviation name for the alarm state of the frame. In addition, this column indicates to the operator that some action at the individual frame is required. For example, load weights, zero extensometer, etc.
Status Display Colors

Note that the individual frame lines will change color frequently as the frame state and alarm conditions change. The meaning of the colors is as follows: Red: Major alarm or action required, alarm condition will be displayed. Green: Normal run state, test in progress. Blue: Indicates normal activity under Temperature Columns and signals a Minor alarm State; alarm condition will be displayed. Black: Column header, idle frame state. Orange: Time only, normally indicates time remaining until change of frame state.
System Status Error Codes

The following list of error codes may help you to understand what is happening with the system. Note that some of these errors are fatal, and will stop the test, while others are merely information and indicate a potential problem but do not indicate that the test is faulty. At the end of the list, a more detailed explanation of the FZONE alarm, which is causing concern, is attached. ACLow - The frame controllers AC power line has dropped below 95VAC indicating a sever brown out condition.
ACV - The frame has no AC power to the frame and/or furnace. BAT - The frame controllers battery for the NVRAM needs replacing. Break - The frames break detect switch is active. Cal/Ver - The frame is currently having the extensometery calibrated or verified. Com - The host PC is unable to communicate with the frame controller. ECnt - The number of events in the event log is greater than fifty. FZone - The furnace zone control algorithm has reached its limits and is unable to control the differential temperature between zones. This is usually caused by one or all of the following: open furnace zone, thermocouples in wrong position on the specimen, open zone control relay or specimen too high or low in the furnace. LCtrl - The automatic load control system has faulted. This is usually due to elevator style machines running out of travel, and the lever arm must be re-zeroed. Load - The test is ready to load weights.
MLO- Machine Lockout Open - A control thermocouple is open. SErr - Start up error has occurred. This is caused by a reversed thermocouple or a thermocouple specified as active in a test that is currently open. Once the problem is corrected the test will start automatically. SLoad - The test is ready for a load increase. TCBCal - There is no thermocouple measurement unit calibration found on the system. THigh - A control thermocouple is above the minor temperature alarm limit. TLow - A control thermocouple is below the minor temperature alarm limit. ZExt - The extensometer has traveled beyond its specified re-zero range and must be re-zeroed.
Further Explanation for the FZONE alarm: If you refer to the furnace set up menu, under Zone Power Control, you will find a set of parameters which define the zone power control limits.
Min and Max, usually 10 and 90 percent, mean that of the available power to the furnace, any one zone should be receiving a minimum of 10 %, and no zone should be receiving more than 90%. If the control algorithm cannot achieve the required control within these limits, the FZONE alarm will be activated, which indicates to the operator that there is something wrong with the furnace or the specimen arrangement. It does not mean that the test should be stopped or that the test is invalid. It is a warning that attention is required. The problem can be with the hardware, such that one half of the furnace elements in a zone may be open, for example. In unusual circumstances, a wiring error in the thermocouples connections or the furnace zone control relays could result in the thermocouple or zone relay being associated with the wrong zone. This produces a very distinctive temperature pattern, and a review of a test file will easily identify this problem. If you e-mail one of the archived test files to Denny King, we will review it and advise our comments. It may be that one or more of the thermocouples are not properly attached, or not in the proper location. It may mean that the furnace is not properly closed up, or that the end caps are not in place. By far the most common problem is that the specimen is not in the center of the furnace, and that the position of the furnace should be adjusted vertically. If the specimen is below center, the bottom end of the specimen, which tends to be cooler than the others because of convection, is made even cooler by the fact that less of the bottom pull rod is inside the furnace. This makes it much more difficult for the differential algorithm to function, and results in the FZONE alarm. With a specimen installed, and the Lever Arm in the position which it will assume with the specimen loaded, the furnace should be positioned so that the specimen is vertically centered in the middle zone. This is part of the installation procedure, and should be checked any time any change is made to specimen length or pull rod length. TLOW simply means that the temperature of one or more of the Thermocouples is more than the minor alarm value below the set point of the test specification. The fact that the specimen is only a few inches long is not a factor. The system is designed to operate at optimum in the typical creep furnace which is usually of three zone arrangement, with each zone typically 3 or four inches long, and the specimen perhaps 3 inches long. In fact, the short specimen is easier to control than a longer one.. You could relax the specification by widening the alarm band, but this is not the real solution. In fact, depending on the reason for the frequent alarms, relaxing the limits may exacerbate the problem.
Frequently, the same problems which cause the FZONE alarm lead to persistent TLow, or even Thigh alarms. If TLow occurs frequently during the soak cycle, it may be that the Integral Algorithm is not active enough, and increasing the I term of the furnace set up may help. For example, if the setting is 0.03, it may be beneficial to increase the value to 0.04 or even 0.05. Note that these parameters may be reset during operation of the furnace, so if there is a test which has persistent TLow alarms, change the I term value and observe what happens. If you observe the furnace power during operation, you will see typically a relationship between the zones, such as the bottom zone will be receiving more power than the others. The exact relationship may vary, but it would be really unusual to see all the same. If everything is set up correctly, it is not unusual to see perhaps one TLow alarm at the beginning of the test, but repeated alarms are not common, and the majority of the tests should proceed without any alarms showing at all during the entire test. There are many hundreds of testers operating on this system, and once set up, the vast majority operate daily without any of the problems you are experiencing.
Glossary I.
Section 1 of 2- Prompts that may appear during Setup and Running a Test at least one of the T/Cs is within the minor limit, the soak state is entered.
Apply Load The load is applied to the

specimen.
Remove The frame controller is waiting

for the host to upload the final test data before the specimen is removed.
Cal/Ver The frame is having the

extensometer calibrated, verified, or checked.
Restart The system is restarting the test

after a power failure.
Disable This state makes sure that if the

termination was due to a temperature alarm that the specimen did not actually break.
Run Normal running state of the test. Shutdown Entered at the termination of a
test. Stops all frame motion and stops the furnace.
Fault A hardware fault has occurred on the

frame.
Soak Furnace soak state. Start-up Refers to frame status. Start-up Delay Test start-up was
delayed.
Idle The frame status is idle. Initial Load Sets the initial draw head or
elevator position before ramping the furnace.
Loading 2 No action, except to take the

frame off-line. Used by the test load control.
Shutdown Entered at the termination of a

test. Stops all frame motion and stops the furnace.
Load Invalid The load control has been

unable to maintain the load within the 1% limit for over five minutes.
Terminate This state is entered when a

test is terminated by the operator.
Manual The frame is in manual control. Pre Start up The frame is requested to
start; all parameters are downloaded to the frame controller.
Unload The load on the specimen is

removed.
WF Power A power failure has just

occurred and the system is waiting for the hardware to reinitialize.
Post Test The test is complete and ready

to be removed.
Ramp The furnace is ramped from the

current temperature up to the setpoint. When
Glossary II.
normal operation, which is less than 32F or greater than 120F.
Rezero of Extensometer Requested

Section 2 of 2- States that occur while Running a Test The system has detected that the specimen has creeped close to the range of the displacement transducer. The system is requesting a mechanical rezero of the extensometer.
All Specimen Thermocouples are Open All control thermocouples are open
and the test will be shutdown.
Automatic Loading Failed The

automatic creep loading system failed; this statement is usually accompanied with a reason for load failure.
Shutdown Due to Furnace Out of Band Time Exceeded The furnace has
been out of band limits for more than fifteen minutes and the ramp up will be terminated. Check for the following conditions: Open furnace element or solid state relay, too fast a ramp rate specified, shorted thermocouple, low AC line voltage.
Automatic Loading Timed Out The

automatic creep step loading routine failed due to insufficient load change during the loading procedure.
Specimen Broke During Loading

The system was loading the specimen and after five minutes the break switch never went to a not broken state. The system assumes that the specimen broke.
Cannot Start, Open TCs One or more

T/Cs are open during the initial start-up or ramp of the specimen.
Check Furnace Alarm, Shutdown A

fatal temperature event precedes this message. This indicates the actual shutdown of the furnace control due to that event.
Specimen is Ready to Load Weights

Message for manual loading frames that the specimen is ready to be loaded.
Control T/C Switched to Highest T/C Informational alarm which indicates

that the temperature control is completely stable and the control is now on the highest physical T/C in the furnace.
Specimen Loaded The specimen was

loaded by the system.
Specimen Reached Creep Limit The

test is being shutdown because the creep limit specified in the test specification has been reached.
Furnace Split Exceeded Indicates the

system has adjusted the power split between the zones as much as possible and was not able to control temperature uniformity
Specimen Reached Life Hours The

test is being shutdown because the run time limit specified in the test specification has been reached.
ISO Thermal Temperature Range Error, Shutdown The temperature

measurement subsystem ambient temperature sensor is outside of the range of
ATS 93310R3
Specimen Reached Reference Plain or Life Hours The notch specimen has
Applied Test Systems, 2009 69
reached the reference plains hours and the test will be shutdown.
Test Restarted Manually The test was

restarted by a user after it had shutdown.
Specimen Ruptured The system has

detected a specimen rupture
Test Terminated by User Name

Indicates which user terminated the test.
Step Load Completed by User Name Indicates user completed the manual
step load.
(Top, Middle, or Bottom) T/C at x.x F has returned from below limit, dev x.x F from setpoint Indicates that
a specimen thermocouple has returned from below temp. limit
Temperature Measurement Error, Shutdown A fatal hardware error has

occurred in the temperature measurement subsystem of the frame controller.
(Top, Middle, or Bottom) Thermocouple is Open The T/C is

open.
Test Reloaded or Restarted Indicates

that a test which had been previously removed and post tested has been restarted.
(Top, Middle, or Bottom) Thermocouple Repaired The

thermocouple that was previously open has been repaired.
Test Restarted Automatically by System The test has been automatically

restarted after a controller power failure.

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WinCCS Manual Updated 2009

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System Overview Safety Setup & Installation Operation Maintenance

Applied Test Systems, 2009 ATS 93310R3 5

Applied Test Systems, 2009 ATS 93310R3 6

Applied Test Systems, 2009 ATS 93310R3 8

Burn Hazard Hot Surface

Electrical Shock/ Electrocution

Hand Crush Force From Above

Protective Earth (Ground)

European Directive CE Mark

No Access For Unauthorized Persons

Read Operators Manual

Applied Test Systems, 2009 ATS 93310R3 9

Do not open the panel.

Unpack and operate on a stable

Applied Test Systems, 2009 ATS 93310R3 11

SECTION 3. EQUIPMENT SETUP AND INSTALLATION

3.5 Assistance / Field Support

Applied Test Systems, 2009 ATS 93310R3 12

Manual Frame Controls, Classic Version

Manual Frame Controls, Modular Version

Manual Control via Computer

Applied Test Systems, 2009 ATS 93310R3 13

Fig. 1 Manual Frame Controls, Classic

Fig. 3 Manual Control via Computer

Fig. 2 Manual Frame Controls, Modular Version

Applied Test Systems, 2009 ATS 93310R3 14

SECTION 5. ASSIGNING USER NAMES, PRIVILEGES, AND PASSWORDS

Applied Test Systems, 2009 ATS 93310R3 15

Setting System Units

Applied Test Systems, 2009 ATS 93310R3 16

Accessing Frame Setup

Applied Test Systems, 2009 ATS 93310R3 17

Frame Controller Information

Frame Load Capacity

Load Control/Automatic Loading Setup

Applied Test Systems, 2009 ATS 93310R3 21

Applied Test Systems, 2009 ATS 93310R3 22

Frame Setup Digital

Applied Test Systems, 2009 ATS 93310R3 23

Applied Test Systems, 2009 ATS 93310R3 25

Applied Test Systems, 2009 ATS 93310R3 26

Minimum Maximum Delta Interval Increment

10% 190% 0.3 F 3.0 min 0.50%

Arm Ratio Setup

Applied Test Systems, 2009 ATS 93310R3 27

Applied Test Systems, 2009 ATS 93310R3 28

The proceeding fields contribute to general system setup.

Text Field Setup

Material Application Types

Applied Test Systems, 2009 ATS 93310R3 29

Test Specification Text

Applied Test Systems, 2009 ATS 93310R3 31

Applied Test Systems, 2009 ATS 93310R3 34

Debug: This function is reserved for trouble-shooting by ATS personnel.

User Login and Logout

System Status Display

Overview of Operation Steps

Applied Test Systems, 2009 ATS 93310R3 38

Creating Test Specifications

Applied Test Systems, 2009 ATS 93310R3 39

Applied Test Systems, 2009 ATS 93310R3 41

Editing Test Specifications

Viewing Test Specifications

Deleting Test Specifications