L-Series Tensile Test Machines

Transcription

1 L-Series Tensile Test Machines Instructions For Use Issue 01 Unit 6 Perrywood Business Park, Honeycrock Lane, Salfords, Surrey, RH1 5DZ, England, UK Telephone: Facsimile: Website:

2 Contents 1. Introduction Specifications Load Frame Control Panel Force Measurement Extension Measurement Speed Control Hardware Options Dimensions Temperature Humidity Power Machine Supply Requirements CE Mark Manufacture Unpacking the Material Testing Machine H1KL & H5KL H10KL, H25KL & H50KL Contents Checking Contents Machine Installation Location Mains Supply Warning Symbols Connection to Supply Fitting Load Cell Connection to PC Power ON Checks Emergency Stop Switch Power ON/OFF Switch Mechanical Limit Switches Crosshead Control Keys Alarms Auxiliary Equipment Installation of Tooling Attachment Parts Method Tooling Alignment Operator Safety Protective Screens Operator Training Routine Maintenance Electrical Calibration Lubrication Machine Storage...31 Tinius Olsen Ltd L-Series Manual Issue 1 Page 2 of 31

3 1. Introduction This manual is to help the operator understand the operation of the L-Series Universal Testing Machine. The L-Series range of machines are designed to operate with an external personal computer (PC). Software is supplied to enable the machine to conduct tests in the chosen materials. The software operates under the Microsoft Windows environment. The L-Series range of testing machines with their versatile, easy-to-use software package are ideal for determining the mechanical and physical properties of materials in Tension, Compression, Flexure and Shear. Many other physical properties may also be investigated. There are five machine capacities in the L-Series range. These are H1KL (1000N), H5KL (5000N), H10KL (10KN), H25KL (25KN) and H50KL (50KN). All machines are similar in functionality and are supplied with the same auxiliary interface. The L-Series range of testing machines employs two load frame configurations. A single screw arrangement for low capacity machines (H1KL and H5KL) and a twin screw arrangement for high capacity machines (H10KL,H25KL and H50KL) All L-Series machines are supplied with an external Power Transformer. The standard power transformer is designed to operate from a 230V 50Hz public network supply. The output of the power transformer is 48V AC and is used to power the testing machine. The power transformer can be supplied for different public network supply voltage and frequency s, (110V 60Hz) however this must be specified when ordering There may be aspects of material testing not covered in this operation manual in particular the type of grips used and additional optional equipment, such as Extensometers, Printers, etc. See the accessory instructions provided for these options. Tinius Olsen Ltd L-Series Manual Issue 1 Page 3 of 31

4 2. Specifications 2.1. Load Frame Capacity H1KL Capacity 1kN (100kg) H5KL Capacity 5kN (500kg) H10KL Capacity 10kN (1000kg) H25KL Capacity 25kN (2500kg) H50KL Capacity 50kN (5000kg) Style Vertical Bench Mounting Construction (H1 &5 KL) Cast Aluminium crossheads with sheet steel panelling (H10,25 & 50KL) Solid steel -crossheads with sheet steel panelling Precision Ball Screws Ballscrew cover/protection bellows Pre-loaded Lead Screw Thrust Races Precision DC Servo Motor Programmable crosshead Limit Switches Emergency Stop Switch Travel & Stiffness H1KL Maximum crosshead travel excluding grips is 445mm Maximum Test Specimen Diameter 150mm Frame Stiffness 2kN/mm at normal load points H5KL Maximum crosshead travel excluding grips is 750mm Maximum Test Specimen Diameter 200mm Frame Stiffness 7kN/mm at normal load points H10KL Maximum crosshead travel excluding grips is 1100mm Distance between Columns 405mm Frame Stiffness 100kN/mm at normal load points H25KL Maximum crosshead travel excluding grips is 1100mm Distance between Columns 405mm Frame Stiffness 100kN/mm at normal load points H50KL Maximum crosshead travel excluding grips is 1075mm Distance between Columns 405mm Frame Stiffness 100kN/mm at normal load points 2.2. Control Panel Crosshead Up, Down, Stop and Test Keys LED Direction and Alarm indicators 1 Auxiliary option slot for external equipment High Speed RS232 Interface Port 16 Bit Microcontroller Audible alarms System Watch Dog Timer 2.3. Force Measurement Load Cell Z Beam Construction Conforms to EN10002, ASTM E4, DIN 51221, ISO Range 2% to 100% with Guaranteed Accuracy of 0.5% of applied force Extended Range down to 1% with Guaranteed Accuracy of 1% Rapid Change Load Cells Available:- 50kN, 25kN, 10kN, 5kN, 2.5kN, 1kN, Tinius Olsen Ltd L-Series Manual Issue 1 Page 4 of 31

5 500N, 250N, 100N, 50N, 25N, 10N, 5N Digital Encoding for automatic load cell recognition Automatic Load Cell Protection system, Triggered at 9% above load cell capacity. Force sampling rate typically 200 Times per Second Load cell resolution 1 part 64,000 (Tension or Compression) Digital Load Tear ±20% whilst maintaining full load cell capacity 2.4. Extension Measurement Extension Measurement by Precision optical encoder Single measurement range 0 to 1000mm Resolution mm accuracy 0.01mm/300mm 2.5. Speed Control 2 Default Test Speeds (5 mm/min & 100 mm/min) 1 Default Jog Speed (1 mm/min) Dual Speed Function whilst under test Speed Velocity Programmable in mm/min steps Speed accuracy ±0.05% of full speed 32 Bit Precision Motor Controller Drive system:- DC 4 Quadrant Motor Drive Automatic Over/Under Speed Alarms Motor Drive Alarms on Under/Over Voltage, Current, and Temperature Velocity Speed Range H1KL mm/min to 500 mm/min (up to 500N) mm/min to 1000 mm/min (up to 1kN) Return Speed mm/min to 1500 mm/min Jog Speed mm/min to 1000 mm/min H5KL mm/min to 500 mm/min (up to 2.5kN) mm/min to 1000 mm/min (up to 5kN) Return Speed mm/min to 1500 mm/min Jog Speed mm/min to 1000 mm/min H10KL mm/min to 500 mm/min (up to 5kN) mm/min to 1000 mm/min (up to 10kN) Return Speed mm/min to 1000 mm/min Jog Speed mm/min to 1000 mm/min H25KL mm/min to 500 mm/min (up to 10kN) mm/min to 1000 mm/min (up to 25kN) Return Speed mm/min to 1000 mm/min Jog Speed mm/min to 1000 mm/min H50KL mm/min to 250 mm/min (up to 25kN) mm/min to 500 mm/min (up to 50kN) Return Speed mm/min to 500 mm/min Jog Speed mm/min to 500 mm/min 2.6. Hardware Options Tinius Olsen range of Clip on Extensometers Tinius Olsen range of Displacement Transducers Tinius Olsen range of Grips and Attachments Clear protective screen Dust cover 2.7. Dimensions H1KL Height 820 mm Width 360 mm Depth 360 mm Weight 25kg H5KL Height 1140 mm Width 490 mm Depth 360 mm Weight 50kg H10KL Height 1575 mm Width 650 mm Depth 450 mm Weight 115kg H25KL Height 1575 mm Width 650 mm Depth 450 mm Weight 117kg H50KL Height 1620 mm Width 720 mm Depth 500 mm Weight 180kg Tinius Olsen Ltd L-Series Manual Issue 1 Page 5 of 31

6 2.8. Temperature Operating 0 C to 38 C Storage -10 C to 45 C 2.9. Humidity 10% to 90% Non-Condensing Wet Bulb Method Power External Power Transformer H1KL H5KL Type TX****-H1KL Type TX****-H5KL Input Supply Voltage 230V +/- 10% 50/60Hz Output Voltage 48v 330VA Internally Fused (5x20mm HRC 3.15A Type (T) for 230V Supply) H10KL Type TX****-H10KL H25KL Type TX****-H25KL H50KL Type TX****-H50KL Input Supply Voltage 230V +/- 10% 50/60Hz Output Voltage 48v 530VA Internally Fused (5x20mm HRC 6.30A Type (T) for 230V Supply) Machine Supply Requirements H1KL 48v +/-10% 330VA H5KL 48v +/-10% 330VA H10KL 48v +/-10% 530VA H25KL 48v +/-10% 530VA H50KL 48v +/-10% 530VA CE Mark EMC Directive 89/336/EEC, and conforms to the following Generic EMC specification for Commercial and Light Industrial products. Emissions EN , Immunity EN Low Voltage Safety Directive 73/23/EEC, and conforms to the following specification. EN (Safety requirements for Measurement, Control and Laboratory use) Manufacture TINIUS OLSEN LTD, 6 Perrywood Business Park, Honeycrock Lane, Salfords, Redhill, Surrey, RH1 5DZ, England. Tel Fax Tinius Olsen Ltd L-Series Manual Issue 1 Page 6 of 31

7 3. Unpacking the Material Testing Machine H1KL & H5KL Save all packing materials. You may need to re-pack and transport your Materials Testing Machine at a later date The machine is delivered packed in a Tri-wall cardboard case. This case has pallet style blocks at its base enabling the case to be moved with a fork lift truck. The diagram below shows the machine as delivered Cut all straps. Care must be taken as these straps are under tension Cut tape at top of case to enable the access and remove internal top packing. The diagram below indicates packing to be removed. Tinius Olsen Ltd L-Series Manual Issue 1 Page 7 of 31

8 Remove case by lifting it upwards. Care must be taken as internal cartons may have become dislodged. The diagram below indicates the direction of case removal Remove internal cartons. Care must be taken when removing these cartons as they may be heavier than first expected. The diagram below indicates the location of internal cartons Remove base packing from the machine by lifting the machine vertically. Whilst carying out this operation it is an ideal opportunity to transfer the machine to the prepared location. Caution This material testing machine weighs 50Kg/110 pounds. It is recommended two or more people carry out this operation. The diagram below shows the machine with its packing removed. Tinius Olsen Ltd L-Series Manual Issue 1 Page 8 of 31

9 Remove the protective packing around the electronic control panel. Tinius Olsen Ltd L-Series Manual Issue 1 Page 9 of 31

10 3.2. H10KL, H25KL & H50KL Save all packing materials. You may need to re-pack and transport your Materials Testing Machine at a later date The machine is delivered packed in a wooded case. This case has pallet style blocks on its back and bottom sides enabling a fork lift truck to be used when manoeuvring the case. The packing case has been designed so that it can be shipped on its back. This is to enable easier transportation for air shipment etc. The diagram below shows the machine as delivered Place Upright Before attempting to unpack the machine, the case must be stood on end, bottom end indicated by pallet style blocks. Rotating the case to its upright position should not be attempted by hand and will require a overhead hoist or fork lift truck. The diagram below the machine in its up-right position Open Case Remove all screws around the edge of the panel and remove side. Care must be taken when detaching the side as internal cartons may have become dislodged. Tinius Olsen Ltd L-Series Manual Issue 1 Page 10 of 31

11 Remove all internal cartons. Care must be taken when removing these cartons as they may be heavier than first expected. The diagram below indicates the position of additional cartons Remove Constraints The machine is held in position by packing material at top and bottom and by a shipping restraint beam mounted at the machines crosshead. Remove the shipping restraint beam. This beam is held in position by screws each side of the case. Finally remove all packing material. The diagram below indicates the shipping restraint bead to be removed. Tinius Olsen Ltd L-Series Manual Issue 1 Page 11 of 31

12 Remove Machine The machine is now in a position to be removed from the case. Position the fork lift truck, in front of the case. Arrange the forks of the truck so that they can fit between the side covers of the machine and below the crosshead. Slowly move the fork lift truck towards the machine ensuring the forks do not hit the machine side covers. Raise the forks to lift the machine so that its base is clear of the case, then remove the machine form the case. Note To stop damage to the paint work on the machines crosshead place strips of cardboard on the forks before lifting. The diagram below indicates machine lifting positions. If a fork lift truck is not available the machine may removed using a hoist and straps. The lifting positions are the same however the top of the case will need to be removed. The diagram below indicates the machine removed from its case. Tinius Olsen Ltd L-Series Manual Issue 1 Page 12 of 31

13 4. Contents 4.1. Checking Contents The machines are shipped completely assembled except for the optional accessories. The basic machines are supplied with the following items, please ensure that these are included for the installation Load Cell Z-Beam Load Cell at or below the maximum capacity of the load frame. Single screw machines will have a mounting bolt, hex key and washer for the load cell(s) (H1KL and H5KL) and twin screw models (H10KL, H25KL and H50KL) will have mounting stud(s) with different threads depending on the capacity of the load cell(s) supplied Nose Piece 25 kn capacity 5/8" diameter nose piece attachments and 5/16" diameter Grip Pins.,(machines above 25 kn will also be provided with a set of 50 kn capacity with 3/4" diameter nose piece attachments and 3/8" diameter Grip Pins ) Breaker Bar 1/4" diameter Breaker Bar (5/16" bar with 10 kn and larger load cells Power Transformer with twist-on connector Operating instruction manual and load cell calibration certificate D type 9 way socket RS232 Serial Port Lead for external computer control Hex Key (H1KL and H5KL only) Load Cell Bolt Sleeve (H5KL only) Mounting Studs ( H10KL, H25KL and H50KL only ) Tinius Olsen Ltd L-Series Manual Issue 1 Page 13 of 31

14 The following diagrams are to help to identify each item Load Cell Nose Piece Attachment Grip Pins Load Cell Bolt Sleeve Breaker Bar Hex Key Bolt & Washer Hex Key Mounting Studs Power Transformer RS232 Lead Operating Manual Calibration Certificate Additional parts may be supplied, which are not listed above and will depend on the system configuration. Tinius Olsen Ltd L-Series Manual Issue 1 Page 14 of 31

15 5. Machine Installation 5.1. Location Place the machine on a sturdy bench ensuring that is capable of taking the following loads (H1/5KL > 50kg), (H10/25KL > 117kg),(H50KL > 180kg). It is also important to make sure the bench is level especially when using lower capacity load cells. The diagram below outlines the required area for each machine Mains Supply Place the external power transformer within reach of the of the machine. (shown in the above diagram) The transformer voltage is indicated on the power transformer label and will require a supply connector to be fitted. The supply cable must be connected as follows :- Brown=Live, Blue=Neutral, Yellow/Green =Earth NOTE External Power Transformer MUST BE EARTHED. Under no circumstance must the machine be operated without an earth connection Positioning of the machine and external power transformer should be arranged so that the mains supply plug and socket are easily accessible. Under NO CIRCUMSTANCE must the main supply plug and socket be OBSTRUCTED by any equipment. This is to allow disconnection of the external power transformer in the event of an emergency. Tinius Olsen Ltd L-Series Manual Issue 1 Page 15 of 31

16 5.3. Warning Symbols There are two warning symbols displayed on the L-Series machine. The purpose of these symbols is to indicate a potential hazard and requires reference to the operating instructions Refer to Manual The Refer to Manual Symbol is shown below The warning symbol is located on the front left hand edge of the protective screen if fitted. It indicates a hazard due to moving mechanical parts and the operator must refer to the operating instructions when attempting to operate the machine. Additional hazards may be present when carrying out sample testing and for this reason the operator must ensure the protective screen be closed throughout the test Power Transformer Hazardous Warning Symbol The power transformer hazardous warning symbol is located on the front of the unit next to the serial number/voltage/power label. It indicates that the unit is operating at a HAZARDOUS VOLTAGE and the operator must refer to the operating instructions regarding Installation Environment, Operating Voltage, Connection and Maintenance. Power and Voltage Ratings The diagram below shows where to locate the Power and Voltage rating of the equipment. (H1/5KL 230V =+/- 10% 50/60Hz 330VA is) and (H10/25KL and H50KL 230V =+/- 10% 50/60Hz 530VA) The mains supply cable and machine supply connector are also indicated Connection to Supply The connection of the power transformer to the machine is via a 4 pin twist on connector. The following diagrams indicate how to connect the power transformer :- Although these diagrams relate to the H5KL the method still applies to the 1/10/25/50KL) Tinius Olsen Ltd L-Series Manual Issue 1 Page 16 of 31

17 Rotate socket to align with plug then push to engage lock ring Rotate lock ring clockwise to jack socket into final position Fitting Load Cell The machine will be provided with a load cell equal to or less than the maximum capacity of the machine. These interchangeable Load Cells are available in capacities from 50kN (11,250 lbf, 5100 kgf) down to 5N (1.1 lbf, 0.5 kgf) Single Screw Machines On H1KL single screw machines, the load cell is mounted on the underside of the fixed crosshead at the top of the loading column. The H5KL requires the load cell to be mounted on the underside of the moving crosshead, both machines use a hex bolt and washer for fixing. Lower capacity load cells require a spacer sleeve to be inserted in the crosshead enabling smaller load cell mounting bolts to be used (H5KL only). Use the hex key provided to tighten the cell in place. Before mounting any load cells to the crosshead, always check to insure that the contact surfaces are clean. Connect the load cell by plugging the 15 pin connector into the load cell socket just under the crosshead. Care must be taken when mounting the cell as it is handed. The correct orientation is with the slot to the top and cable at the rear for single screw machines Note Failing to do so will effect the overall performance of the cell. The following diagrams indicate how to mount a 5KN load cell to the H5KL Machine. Ensure both areas are free of packing and are clean Align plug with socket and push together Store excess cable in area shown Hold load cell in safe area and position it parallel to the crosshead then fully tighten with Hex Key. When installing low capacity load cells (less than 5kN) it is imperative the load be held in the safe area when locking the load cell in position (shown in the diagram below). Failure to carry out the above procedure may lead to load cell damage beyond repair. Tinius Olsen Ltd L-Series Manual Issue 1 Page 17 of 31

18 Align load cell to guides and mounting hole with slot at top and facing out Fit hex bolt and washer, hold load cell in safe area when tightening with Hex key Note Load Cells other than 5kN rely on manual alignment with crosshead Twin Screw Machines On the larger capacity twin screw machines, the load cells are mounted under the moving crosshead with a mounting stud, and a breaker bar provided for tightening the load cell in place. Again care must be taken when mounting the load cell as it is handed. The correct orientation for twin screw machines is with the slot to the left and cable to the right. The diagram below indicates how to mount the load cell to a twin screw machine (H10KL / H25KL / H50KL) Align the load cell with the with mounting hole beneath the crosshead. Place the mounting stud through crosshead and screw into load cell. Hold load cell in safe area and position it parallel to the crosshead then fully tighten with breaker bar. Connect load cell by plugging the 15 pin load cell plug connector into load cell socket located beneath and to the right of the moving crosshead Connection to PC Before attempting to connect the RS-232 Serial cable, ensure both Testing Machine and PC computer are SWITCHED OFF This connection allows the computer to communicate with the testing machine s internal electronics. Tinius Olsen Ltd L-Series Manual Issue 1 Page 18 of 31

19 Lead Connection from your PC to the Testing Machine is via a D type 9 way RS-232 socket to socket cable, as indicated below. Note This cable is not a one to one cable, (some of the signals are reversed). For this reason it should only be used for RS-232 machine to computer connection Machine Port The RS-232 Port is located on the front, right hand side of the machine. Simply align the 9 way D type cable socket connectors to its mating plug on the machine, taking care not to bend any pins, whilst held in this position tighten the two socket jack screws until the connector is fully engaged. The diagram below indicates position of machine RS-232 Port. The other end of the RS-232 serial cable connects to the PC Computer RS-232 Port (Com 1) located at the rear of the PC Base Unit. The method is the same as used on the machine by aligning the 9 way D-type connectors then tighten the two jack screws PC Port The diagram below shows a rear view of a typical PC Base Unit. Care must be taken to locate the RS-232 Port (Com 1) as many of the connectors look very similar. Tinius Olsen Ltd L-Series Manual Issue 1 Page 19 of 31

20 6. Power ON Checks Before Powering the machine on, check the following 6.1. Emergency Stop Switch Before the machine can be turned ON it is necessary to check the position of the emergency stop switch. The function of this switch is to STOP the machine as quickly as possible in the case of an emergency. e.g.:- where the machine behaves in an unexpected manner, or when there is a risk of injury to the operator. The emergency Stop switch should NOT be used as the Machine OFF/ON switch Location The emergency stop switch for the H1KL and H5KL is located on the front, top right hand side of the machines base. Twin screw machines (H10/25 and 50KL) have the emergency stop switch located on the top left hand side of the machine s base. The diagrams below indicate location of the emergency stop button H1KL / H5KL Emergency and Power Switch located on right hand side of machine H10KL / H25KL / H50KL Emergency and Power Switch located on left hand side of machine Operation To check if the emergency stop switch is in its normal position rotate the top part of the switch clockwise (direction shown by arrows on top of switch). If the switch had been previously activated, on rotation the top will spring upwards. If no upwards movement is felt the switch is already in its normal position Power ON/OFF Switch Location Power ON/OFF Switch Power ON/OFF Switch H1KL / H5KL Power Switch located on right hand side of machine H10KL / H25KL / H50KL Power Switch located on left hand side of machine Turn the machine ON with the power switch. The control panel STOP Switch LED will now illuminate. If the direction/stop LEDS are blinking and the alarm beeping the EMERGENCY STOP Switch is probably activated. Reset the emergency stop switch as described in the above section, turn the machine OFF, allowing a few seconds before turning the back ON again. Tinius Olsen Ltd L-Series Manual Issue 1 Page 20 of 31

21 The diagram below indicates the Control Keys and LED S. Note If the stop LED does not illuminate, the most likely fault is the machine has NO power. Check power transformer installation and supply Mechanical Limit Switches Before attempting to move the crosshead in ether direction it will be required to set the mechanical crosshead limit switches. The purpose of the limit switches is to reduce the travel of the crosshead enabling a safe working area. A typical example is to protect the load cell and attachments for unforeseen over travel and in doing so avoid a collision. These limit switches are located on the left hand side for both single and twin screw machines. There are slight differences in the arrangement of the limit switches, the single screw machines having them located in the side cover and the twin screw machines being located on a slider rod. The diagram below shows the location of the mechanical crosshead limit switches Adjustment of the limit switches are similar for both types of machine. The limit switches are held in position by a locking screw. To set the limit switch unlock by turning the locking screw in an anti-clockwise direction and slide to the required new position. Before locking allow for the limit switch striker being in the middle of the crosshead for the single screw machine (H1/5KL) and at the bottom of the crosshead for the twin screw machines. (10/25/50KL) To lock limit switch rotate locking screw in a clockwise direction (Note To eliminate slippage re-tighten locking screw securely) Tinius Olsen Ltd L-Series Manual Issue 1 Page 21 of 31

22 The diagrams below shows the H5KL mechanical crosshead limit switch. (The H1KL has a similar arrangement) Release Upper Limit Switch, move crosshead to new position, slide limit switch to crosshead striker, re-tighten. Release Lower Limit Switch, move crosshead to new position, slide limit switch to crosshead striker, re-tighten. The diagrams below indicate Twin Screw (10/25/50KL) mechanical crosshead limit switch. Release Upper Limit Switch, move crosshead to new position, slide limit switch to crosshead striker, re-tighten Release Lower Limit Switch, move crosshead to new position, slide limit switch to crosshead striker, re-tighten Crosshead Control Keys There are two crosshead [directional] arrows, a [STOP] key and a [TEST] Mode key. The UP direction arrow key is used for raising the crosshead, the [STOP] key for stopping the crosshead, and the DOWN direction arrow key for lowering the crosshead. Each of these keys have a LED to indicate the mode selected. Pressing one of the directional arrow keys once will run the crosshead at the first default speed (Power ON default speed 5mm/min), pressing the same arrow key again will run the crosshead at the second default speed (Power ON default speed 100mm/min). Pressing the [STOP] (O) key when it is already illuminated will activate the JOG Mode, indicated by the [STOP] LED flashing, pressing one of the arrow keys will run the crosshead at the default Jog Speed setting (Power ON default speed 1mm/min) as long as the key is held down, releasing the arrow will stop the crosshead and pressing the [STOP] when flashing will exit the Jog Mode. Tinius Olsen Ltd L-Series Manual Issue 1 Page 22 of 31

23 The diagram below indicates Up/Down/Stop/Test Keys and LED s 6.5. Alarms The [Test] LED and key are computer controlled. The software supplied uses the [Test] LED to indicate a test is in operation. The [Test] Key when pressed requests the software to start a new test. This in turn will illuminate the [Test] LED. Under computer control the power ON default speeds are overridden. These can now be selected using the software control panel. Additional speeds can also be selected that are not available in manual operation. E.g. Auto return speed. For more information on the additional features refer to the Software Manual. Note If power is lost to the machine, the computer speeds are lost. Re-establishing the supply will return the machine to the power ON defaults speeds settings Alarm Indicators Crosshead Limit Alarm A crosshead limit alarm is flagged when the crosshead strikes either crosshead limit switch and places the machine into a stop condition. The indication that an alarm is present is by a Flashing LED indicator on either direction key, reporting an alarm message on the software control panel and audible alarm. The alarm direction is indicated by the Flashing LED indicator on the appropriate direction key and alarm message on the software control panel. The alarm can be cleared by backing the crosshead off the crosshead limit switch using the appropriate direction key or by moving the crosshead limit switch away from the striker. The diagram below indicates the direction alarm indicators. Note The direction key which is indicating the alarm will be disabled. This is to protect the crosshead limit switch in the event of incorrect direction selection. Tinius Olsen Ltd L-Series Manual Issue 1 Page 23 of 31

24 Load Limit Alarm A load limit alarm is flagged when the machine or load cell capacity is exceeded either in tension or compression. The value of the alarm depends upon the load cell fitted and is approximately 9% greater than load cell capacity. E.g. If a 10KN load cell was fitted to a H50KL machine the alarm would be triggered at 10.9kN in tension or compression. This system should not be relied on to protect the machine or operator, as the machine s ability to stop prior to damage is greatly reduced at high crosshead speeds. The alarm direction is indicated by the Flashing LED indicator on the appropriate direction key, reporting an alarm message on the software control panel and audible alarm. The alarm can be cleared by backing the crosshead off in the opposite direction to reduce the applied force using the appropriate direction key. If the alarm persists it is possible that the load cell has been damaged. Note A load limit alarm can be triggered if the load cell is not fitted or incorrectly installed. The direction key which is indicating the alarm will be disabled. This is to protect the machine or load cell in the event of incorrect direction selection. The diagram below indicates the Load Limit alarm indicators Emergency Stop Alarm Activation of the emergency stop switch is by pressing the top of the switch downwards. On activating the emergency stop switch the machine will be placed into a stop condition and flag an emergency stop alarm by flashing both direction and stop LED indicators, reporting an alarm message on the software control panel and audible alarm. To reset the emergency stop switch rotate the top part of the switch clockwise (direction shown by arrows on top of switch). On rotation the top will spring upwards returning the switch to its normal position. To clear the alarm indicators select OK on the software alarm panel. This panel automatically appears when an alarm condition is present. The machine will now return to normal operation. Note Resetting the emergency stop alarm by powering the machine OFF and ON again may require restarting the software. Tinius Olsen Ltd L-Series Manual Issue 1 Page 24 of 31

25 Motor Drive Alarm The motor drive alarm is flagged in the same way as the emergency stop alarm. (Direction and Stop LEDS flashing) This alarm can be triggered by a number of conditions. These conditions are, Motor Position Alarm, Motor Velocity Alarm, Motor Over Current Alarm, Motor Drive Temperature Alarm, Motor Drive Over/Under Voltage Alarm, and Encoder Fault. To clear the motor drive alarm and indicators select OK on the software alarm panel. This panel automatically appears when an alarm condition is present. If the alarm persists turn the machine OFF, wait until the machine cools to room temperature and power back ON. If the fault continues, turn OFF machine, isolate from supply and call TINIUS OLSEN service department. Note Resetting the motor drive alarm by powering the machine OFF and ON again may require restarting the software Auxiliary Equipment Auxiliary Port The auxiliary port is located at the front right hand side of the machine s base. This port allows connection to a range of external equipment, enabling the machine to cover a greater scope of testing. The type of equipment frequently connected are Extensometers and LVDT Transducers. Use of this type of equipment removes inherent errors that are associated with material testing. The diagram below indicates the location of the Auxiliary port connector. This section does not cover the installation of auxiliary equipment, refer to the appropriate installation/operating manuals. Tinius Olsen Ltd L-Series Manual Issue 1 Page 25 of 31

26 7. Installation of Tooling TINIUS OLSEN manufacture a wide range of sample tooling (grips). A large proportion of this tooling uses the same method of attachment. The attachment consists of five parts, these are, male nose piece, attachment locking collar, tooling locking collar, fixing thread and grip pins 7.1. Attachment Parts The diagram below indicates attachment parts. The tooling attachment and grip pin can be supplied in two sizes of capacity. These are 5/8 inch diameter male nose piece with 5/16 inch diameter grip pins for loads up to 20kN and 3/4 inch diameter male nose piece with 3/8 inch diameter grip pins for loads up to 50kN. The attachment fixing threads range from M6 to M16, depending on the capacity of load cell used. The tooling attachment for the fixed crosshead uses the same thread size (M16) for all machine capacities. (Except H1KL) Before attempting to install the tooling attachments check the following :- a) Size of fixing thread in load cell b) Size of female noise piece used on tooling c) Size of grip pin 7.2. Method To install the tooling attachment to the load cell, first ensure both locking collars are centralised on the tooling attachment. Align the fixing thread to the load cell and rotate in a clockwise direction to engage. Once engaged rotate a further 6 to 8 times. This is to ensure the correct amount of thread has been inserted. Ensure the tooling attachment hole is facing forward. Now rotate the fixing locking collar clockwise until it makes contact with load cell. Do not tighten the attachment locking collar at this stage. Repeat the above procedure for the fixed crosshead, this will require a M16 fixing thread tooling attachment. The diagrams below indicate tooling attachments for load cell and fixed crosshead. Installing Tooling Depending on the type of tooling to be installed, this procedure may require additional help (tooling may be heavy). Ensure the distance between the load cell and the fixed crosshead is sufficient for installation of tooling, the distance may require to be increased using the direction control keys. Align tooling female nose piece with load cell attachment male nose piece, slide the two together until daylight can be seen through both grip pin hole in tooling and attachment. Insert the grip pin from the front, make small adjustments to the tooling position to enable the grip pin to slide in freely. Repeat the above procedure for the fixed crosshead tooling. Tinius Olsen Ltd L-Series Manual Issue 1 Page 26 of 31

27 The diagram below indicates the HW20 Wedge Grip fitted to the load cell. Note The HW20 Wedge Grip is shown as an example, the same principals apply to all tooling using this type of attachment Tooling Alignment Tinius Olsen Ltd L-Series Manual Issue 1 Page 27 of 31

28 Tooling alignment is extremely important to obtain realistic measurements. Misalignment distorts the test sample leading to irregular loading and in extreme cases generates large errors in extension measurement. Alignment problems can be greatly reduced by the method used to tighten the attachment and tooling locking collars. Ensure the fixed crosshead tooling is parallel to the crosshead. Whilst held in this position lightly tighten both attachment and tooling locking collars. Repeat this procedure for the tooling attached to the load cell. Check alignment in all three axis. If alignment is out, loosen the tooling locking collars, reposition tooling and retighten collars. Repeat this procedure until the tooling is aligned. Fully tighten the fixed crosshead locking collars with the breaker bar supplied. Care must be taken when tightening locking collars attached to a load cell as lower capacity load cells can be damaged from excess torque. To minimise risk of damage ensure the sensitive area of the load cell is supported when tightening these locking collars. The same care must be taken when removing tooling from the load cells. As a general rule load cell capacities from 25 to 100N only require locking collars finger tight. Load cells from 200N to 2kN should be lightly tightened with breaker bar. Load cells from 5kN to 10kN can be fully tightened with breaker bar, and above 10kN the breaker bar limits torque that can be applied. Note Load cells below 25N can be damaged by handling alone. When installing low capacity load cells, extreme care must be taken. Tinius Olsen Ltd L-Series Manual Issue 1 Page 28 of 31

29 8. Operator Safety Under NO circumstances must the machine/tooling be used if damaged. Under NO circumstances should the machine/tooling be modified without consent from Tinius Olsen. Installation of machine must be carried out as described in section 6 of this manual. Only trained operators should use the machine. (Including operation of software) Operator must wear correct clothing. (No loose clothing) Eye protection must be warn at all times when operating the machine. Operator must not place any part of body within test area when machine is moving. Mains Supply isolator must not be obstructed and be in easy reach. Machine Emergency Stop switch must not be obstructed. The machine should never be left unattended in a loaded condition. Service/Repair of the machine must be carried out by trained personal 8.1. Protective Screens Standard machines are not supplied with protective screens fitted. Depending on the type of material being tested a protective screen may be required. TINIUS OLSEN can supply two types of protective screens, interlock and non-interlock types. Non-interlock screens can be retro-fitted to the machine after supply, however interlocked screens (machine cannot be operated with screen open) must be factory fitted. The operator must assess the type of sample failure prior to testing. This assessment will enable the correct protective screen to be selected. Generally with ductile materials with low failure energy, no screen is required. As failure energy increases, the risk of injury to the operator increases. The type of failure at higher energy often becomes more violent possibly causing the test sample or parts of the sample to become detached from the tooling, when testing brittle or non-ductile material protective screens must always be fitted. Test samples that fail at high loads inherently store more energy. There are two extremes in sample failure, high failure loads on brittle test samples and high failure loads on highly extendable samples. Both types of failure are normally catastrophic and are extremely dangerous. Testing this type of sample must utilise inter locking protective screens Operator Training TINIUS OLSEN or local authorised distributors with qualified factory trained engineers can give operator training at the time of machine installation. Training covers both machine hardware and computer software. Training can be further extended to give a more in-depth knowledge of system on request. Contact TINIUS OLSEN or local authorised distributors to discuss your requirements. Tinius Olsen Ltd L-Series Manual Issue 1 Page 29 of 31

30 9. Routine Maintenance The mechanics within the machine are designed for a minimum amount of maintenance. Typically the replacement and re-adjustment of the drive belts should be performed by a qualified serviceman and should not be attempted by the customer unless instructed on how to do the required service Electrical All the electronics in the machine are solid state which do not require any maintenance Protection Fuse The L-Series of machines operate from a single phase 230V +/- 10% 50/60 Hz mains supply with a maximum power requirement of 330VA for the H1/5KL and 530VA for the H10/25/50KL. This supply is reduced to 48V AC via the external power transformer and becomes the supply for the machine. To protect the machine and external power transformer a Protection Fuse has been incorporated within the external power transformer unit. In the event of this fuse blowing and requiring replacement it should be replaced with an identical type. (H1/5KL requires a 5x20mm HRC 3.15A Type T (Bussmann S A) and (H10/25/50KL requires a 5x20mm HRC 6.30A Type T (Bussmann S A). Under no circumstances should the fuse rating be changed Protection Fuse Replacement Before attempting to replace the Protection Fuse isolate the external power transformer from the mains supply by unplugging it. To gain access to the fuse turn the unit over and remove the four M4 cover retaining screws. The transformer cover can now slide side wards. The fuse is located near the supply cable entry and is mounted in a clip type fuse holder. Simply unclip the blown fuse and replace with a new fuse. Refit the transformer cover and retaining screws including locking washers. Reconnect the external power transformer to the machine and mains supply. Power the machine On and check its function. If the machine does not power up it has a fault and has possibly blown the protection fuse again. Do not attempt to change the protection fuse again and contact TINIUS OLSEN or one of our authorised distributors Calibration Note Protection Fuse Replacement should only be carried out by a qualified electrical technician. The internal force and extension range calibration adjustments on this machine are set to factory specifications and should not be changed in the field. Each load cell has its own Span Adjust Pot for final calibration to the machine. All the load cells shipped with a machine will already be calibrated and a calibration certificate provided. Any additional load cell provided for a machine after shipment will be factory checked for calibration before shipping, but no report is provided. It is also recommended that routine calibration of the load cell(s) in Tension and/or Compression be performed by qualified personnel since improper use or adjustment of the load cell could result in calibration errors or possibly damage to the machine. Re-calibration of the machine and auxiliary equipment should be performed regularly at yearly intervals or as required. TINIUS OLSEN maintains a Calibration and Service Department within the UK or through local authorised distributors with qualified factory trained technicians. TINIUS OLSEN LTD, 6 Perrywood Business Park, Honeycrock Lane, Salfords, Redhill, Surrey, RH1 5DZ, England. Fax Tel Tinius Olsen Ltd L-Series Manual Issue 1 Page 30 of 31

31 9.3. Lubrication Ballscrews Rotating Ball Screw(s) should be checked for lubricant every six months and if found dry, re-grease with a general purpose medium grade grease (SKF LGMT 2/1). Partial disassembly of the Screw Cover(s) will be necessary to gain access to the ballscrew(s) Grips Wedge-Type Grips - MUST BE WELL LUBRICATED with a mixture of medium Flake Graphite and Grease. Clean and re-apply the lubrication when it becomes dry or foreign matter accumulates. Lack of proper lubrication can cause specimen slippage and damage to the wedges, inserts or even the grip housings. (This Mixture is available from TINIUS OLSEN.) 9.4. Machine Storage Long Term Storage If the machine is not to be used for some time ensure that it is unloaded and the supply to the external power transformer is disconnected. To help to keep the machine clean cover the machine with a protective cover. If the machine is to be stored outside its normal working environment repack into its original packing case as supplied. The storage environment should be clean and dry and out of direct sun light with an ambient temperature range of -10 C to 45 C. Under certain conditions condensation can form within the packing and cause parts within the machine to rust. To reduce this problem place at least one desiccator within the packing case. Tinius Olsen Ltd L-Series Manual Issue 1 Page 31 of 31