H150KU Tensile Test Machine

Transcription

1 TINIUS OLSEN LTD H150KU Tensile Test Machine Instructions For Use Doc. Ref _15 Issue 03 Unit 6 Perrywood Business Park, Honeycrock Lane, Salfords, Surrey, RH1 5DZ, England, UK Telephone: Facsimile: Website:

2 Tinius Olsen Ltd _15 Issue 3

3 Contents 1. Introduction Preface Overview Major Options Strain (Aux.) Display Option(s) Navigator Specifications Load Frame Control System Force Measurement Extension Measurement Speed Control Hardware Options Dimensions Weight Power Supply Environmental CE Markings Manufacturer Installation Inspection Contents Location Connection to Power Supply Load Cell Connection to a PC Connection to auxiliary equipment (optional) Checks before powering up Power on Turn the machine On Check Machine Operation Operation Handset Handset Functions Special Key Functions Machine Protection Typical Settings Replacing Loadcells Tooling Attaching to the Machine Conducting a test Basic Operation Testing Using The Handset Testing Using Optional Software Safety Warnings Protective Screens Training Maintenance Electrical Calibration Lubrication Storage Appendix Dimensions...36 Tinius Olsen Ltd _15 Issue 3 Page 1

4 1. Introduction 1.1. Preface The purpose of this manual is to provide the user with sufficient information for installation, operation, care and maintenance of this test machine and its accessories. Therefore, it is recommended that the entire manual be read and understood before working with the machine. Questions that arise should be directed to Tinius Olsen or its authorised representative. A Calibration Certificate and Test Report are supplied for each Load Cell and Instrument provided with the machine. Re-calibration of the machine and instruments should be performed after installation and regularly at yearly intervals or as required. Tinius Olsen Ltd maintains a Calibration and Service Department. At a nominal cost to the customer, periodic calibration and servicing, as required, can be provided. Complete information on this service can be provided by our Service Department or our authorized representative upon request 1.2. Overview The Tinius Olsen H150KU Testing Machine with Strain Gauge Load Cell Weighing System is a modern precision Tension/Compression test machine designed for the Research Laboratory and/or Production Testing where the load requirements demand a machine with a large range of capacities. It is also designed for fast, accurate and convenient operation in the testing of various types of specimens. The first line of the 602 main display on the handheld will show the Force, measured by a strain gauge load cell and conditioner module (typically allocated to channel 1). The second line will show the crosshead position, measured by an incremental encoder and its conditioner module (allocated to channel 2). The third line of the display (Auxiliary) is not generally used unless an optional LVDT or strain gage based measuring instrument and its conditioner is to be used. Such a device may be used to measure strain (extensometer) or deflection (deflectometer) in the specimen. The H150KU testing machines with their versatile, easy-to-use software packages 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. The H150KU machines cater for capacities of up to 150,000N utilising a twin screw arrangement for high capacity. 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. See the accessory instructions provided for these options. Tinius Olsen Ltd _15 Issue 3 Page 2

5 2. Major Options 2.1. Strain (Aux.) Display Option(s) Test Lite is a software package that will allow the operator to have simple control of the machine and setup basic test parameters to gather data from a test. This data can then be printed or exported at the user s discretion. Please note that Test Lite does not calculate any test results. However, it will report maximum values and dimensions can be entered for flat or round specimens and report Stress units. Test Lite also includes the (password protected) Calibration program necessary to configure and calibrate the machine Navigator The software will control all the 602 Display settings. The software can start the test, control the speed of the machine, stop the machine after the test, and return the crosshead to its Start Test Position The Software will plot the test on the computer display, perform the calculations, and the operator can either reject or save the Test Results along with the Curve (Data Points). A printout of the Results and Curve can be made after a test and/or recalled later. When provided with an optional Printer, the printed curves can also be used to calculate results not reported by the software and multiple tests can be printed on one chart. Other options with the software include interfacing Digital Micrometers or Callipers, or other auxiliary devices. A simplified version of Test Lite is provided with the Navigator Software for operating the machine remotely. The Navigator software comes in three levels:- StanPac Version where the user must pick from a set of reports that cannot be changed. Standard Version where the user can edit or create reports, headings, simple results, etc. Plus Version where the user can create their own reports, headings, simple results, etc. In addition, the user can edit the formulas used for any customer defined results and expanded Import capability. NOTE These software packages require the use of a Windows (NT/2000/XP) computer with a vacant RS232 port. Should an RS232 port not be available, a USB port may be used in conjunction with an adaptor. A suitable computer and or adaptor is available from Tinius Olsen. For customers intending to supply their own computer, please ensure that it meets the minimum system requirements as stated in the quote for the software.. Tinius Olsen Ltd _15 Issue 3 Page 3

6 3. Specifications 3.1. Load Frame Designation Capacity Style Max Crosshead Travel Max Specimen Diameter Frame Stiffness Construction U Series 150kN (15,000kg) Floor Mounting 1200mm 650mm 200kN/mm at normal load points Solid steel -crossheads with sheet steel panelling Precision Anti-Backlash Ball Screws Ballscrew cover/protection bellows Pre-loaded Lead Screw Thrust Races Precision Brushless DC Servo Motor Programmable crosshead Limit Switches Emergency Stop Switch 3.2. Control System 602 Remote Handset 3.3. Force Measurement Load Cell Shear Web Type 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:- Unique ID and calibration for each load cell Max Force Limit = 1.09x FS Load (N). Force sampling rate typically 100 Samples/Second (Up to approx. 350 samples/sec possible with 2 channels and high speed computer running appropriate software) Load cell resolution 1 part 130,000 for +/- FS Digital Load Tear ±20% whilst maintaining full load cell capacity 3.4. Extension Measurement Extension Measurement by Precision optical encoder or optional external extensometer. Single measurement range 0 to 1200mm Resolution mm Accuracy 0.01mm/300mm 3.5. Speed Control 2 Pre-settable Speeds Under Manual Control Fully Variable Speeds Under Test Navigator Software Control 1 Return Speed Velocity Speed Range:- Testing 0.01 mm/min to 500 mm/min Return Speed 0.01 mm/min to 700 mm/min Speed Velocity Programmable in 0.01 mm/min steps Speed accuracy ±0.5% of full speed Drive system:- Brushless Servo Motor Automatic Over/Under Speed Alarms Motor Drive Alarms on Under/Over Voltage, Current, and Temperature Tinius Olsen Ltd _15 Issue 3 Page 4

7 3.6. Hardware Options 3.7. Dimensions 3.8. Weight Tinius Olsen range of Contact and Non-Contact Extensometers Tinius Olsen range of Displacement Transducers Tinius Olsen range of Grips and Attachments Tinius Olsen range of Guarding Options mm Inch Height 2, Width 1, Depth ,035 Kg 1,290 Kg Including Packaging 3.9. Power Supply 3 Phase 415+/-10% VAC Environmental Temperature Humidity Operating 0 C to 38 C Storage 10% to 90% Non-Condensing Wet Bulb Method CE Markings Manufacturer 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) Tinius Olsen Ltd 6 Perrywood Business Park Honeycrock Lane Salfords Redhill Surrey RH1 5DZ England Tinius Olsen Ltd _15 Issue 3 Page 5

8 4. Installation 4.1. Inspection After unpacking, thoroughly check the machine controls for any damage 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 H150KU Testing Machine Loadcell (Optional) This will normally be of a shear web type 150kN, other sizes & types may be specified Loadcell Bolt (Optional) Bolt with hexagonal head (41mm A/F) for securing the loadcell to the crosshead Nose Piece (Optional) Nose piece with 2 off locking collars for attaching tooling to the loadcell Nose piece with 2 off locking collars for attaching tooling to the base plate Grip Pin (Optional) 2 off supplied Pins to suit nose pieces specified PC Connection Lead D type 9 way socket RS232 Serial Port Lead for external computer control Manual Operating instruction manual and load cell calibration certificate Tinius Olsen Ltd _15 Issue 3 Page 6

9 Other Parts Additional parts may be supplied, which are not listed above and will depend on the system configuration Location Moving the Machine The machine will require a forklift truck or similar to move it. When moving the machine with a forklift truck, place protective materials (rubber sheet or cardboard) on the forks and lift the machine from the underside of the cross head Levelling The machine is designed to be placed on a flat level floor. If this is not available, jacking screw points are provided located at each corner. Level the machine by screwing an M20 screw into the jacking screw holes and then insert packing material between the feet and the floor. If desired the machine can be bolted to the floor using any combination of the 8 off holes located at the corners of the machine. See Appendix for bolt dimensions and positions Power Supply The machine requires to be hard wired to a suitable 3 phase supply, this is normally:15 Amp Cont. 30A Peak 415 V +/-10% ( ) 50/60Hz Tinius Olsen Ltd _15 Issue 3 Page 7

10 Other operating voltages may be used, please contact Tinius Olsen Ltd for further details The supply must be fitted with a power disconnect switch that is easy to operate and reach. The machine should be positioned as close as practical to the supply to avoid trailing leads and or conduit across the floor Connection to Power Supply Electrical connections must be made by qualified personnel and it is their responsibility for using the proper power disconnect along with the correct size and type of wire and conduit that conforms to all applicable local electrical codes when connecting the machine to the buildings main power. The machine must be earthed, Under no circumstance must the machine be operated without an earth connection Electrical Disconnect The electrical box must have a power disconnect switch that is easy to operate and easy to reach. It must also meet IEC and IEC standards. Recommended circuit breakers would be ones that are of the thermal magnetic type with characteristics suitable for large inductive loads (D-type trip characteristic). If fuses are used it is recommended that they are of the time delay type with dual elements. These recommendations should be followed to avoid nuisance tripping Cable Size The machine will require either a 4 core cable (3 power 1 earth) or individual cables 2 running in a trunking. The minimum wire gauge for the H150KU is 12 AWG (3.3mm ), the earth wire must be of the same size or greater Cable Entry A blanking plate is fitted to the side of the machine adjacent to the circuit breakers, this plate can be drilled to suit the required gland or conduit fitting. Tinius Olsen Ltd _15 Issue 3 Page 8

11 Connections Before the cables can be attached to the machine the gland plate, rear panel and MCB shield must first be removed. Rear Panel MCB Shield Gland Plate The cables must be connected as follows L1 L2 L3 Earth Tinius Olsen Ltd _15 Issue 3 Page 9

12 When connecting the earth, ensure that the both the first nut and lock nut are fully tightened Re Fit Panels IMPORTANT - Before applying power to the machine, ensure all covers are re-fitted 4.5. Load Cell The load cell is fixed to the underside of the crosshead using the bolt supplied. NOTE - Before mounting any load cell to the crosshead, always check to ensure that the contact surfaces are clean Loadcell Bolt Crosshead RJ45 Connector Loadcell Place the mounting bolt through crosshead and lift the loadcell into position. Screw the bolt into the load cell. Hold load cell in position ensuring it is parallel to the crosshead then fully tighten with a suitable spanner. WARNING High capacity loadcells are heavy. Assistance may be required to lift the loadcell Each loadcell is supplied with a strain module, this module must be used with the supplied loadcell. Strain modules hold identification & calibration information and are not interchangeable. Attach the strain module to the crosshead using the bracket supplied Connect the RJ45 plug connector into load cell socket located beneath and to the right of the moving crosshead. Connect the round connector into the socket on the loadcell and twist to tighten. Tinius Olsen Ltd _15 Issue 3 Page 10

13 RJ45 Connector Strain Module 4.6. Connection to a PC The machine is connected to a PC using the supplied D type 9 way RS-232 Serial cable, this connection allows the computer to communicate with the testing machine s internal electronics. Before attempting to connect the RS-232 Serial cable, ensure that both Testing Machine and PC computer are SWITCHED OFF. NOTE - Only use the cable supplied with the machine The RS-232 Port is located on the right hand side of the machine towards the rear. 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 picture overleaf indicates the position of machine RS-232 Port. Tinius Olsen Ltd _15 Issue 3 Page 11

14 RS-232 Port RJ11 Connector The other end of the RS-232 serial cable connects to a Personal Computer RS-232 Com Port normally 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. If your computer does not have a vacant RS-232 port a USB port may be used in conjunction with an adaptor. A suitable adaptor is available from Tinius Olsen Connect the coiled lead between the handset and machine, the RJ11 connector is the uppermost connector on the side of the machine near to the RS-232 Serial Port. The handset rests on the bracket at the front of the machine. WARNING - Do not plug the RJ11 connector of the handset s cable into any of the RJ45 connectors for the modules or you will damage the handheld device 4.7. Connection to auxiliary equipment (optional) Auxiliary equipment (extensometers etc) suitable for use with this machine are available from Tinius Olsen Mechanical attachment methods vary according to the type of auxiliary equipment, these instructions will be supplied with the equipment To connect the equipment to the control system, slide the interface module, supplied with the equipment, into a vacant slot above the RS-232 port and plug the attached RJ45 connector from the module into its adjacent socket. NOTE Only use the module supplied with the auxiliary equipment as this contains identification & calibration data. Tinius Olsen Ltd _15 Issue 3 Page 12

15 5. Checks before powering up Before powering up the machine ensure the following:- The handset is plugged in. The power supply is attached and switched on. Both circuit breakers are on. These are located on the rear panel near the bottom of the machine. The breakers are on when the levers are facing upwards. NOTE There are 2 breakers, one 3 pole (3 phase supply) and one 2 pole (internal power supply) See below for location of Circuit Breakers. Circuit Breakers (shown in on position) The E-stop button is released. 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 Tinius Olsen Ltd _15 Issue 3 Page 13

16 6. Power on 6.1. Turn the machine On Apply power to the machine using the on/off switch on the front panel: When power is first applied to the test machine, the remote terminal should boot up after seconds. Whenever power is first applied to the 602 System, the handset display will show the following information Installed Version Number Firmware version and serial number are displayed Transducer details The display will indicate the attached conditioner modules, these will be:- Force Xducer on line 1 Position Xducer on line 2 Aux Xducer (if fitted) on line 3. If any of these modules are removed or replaced while the 602 system is displaying the main screen, the 602 system will recognize this and read in the data from the new module. NOTE - Power will be removed from the motor drive during the reading process, and return to the main screen. If any new modules are connected while the 602 is displaying one of the Menu Screens, the 602 will not be able to read in that module until exiting the Menu section Typical Boot up sequence is shown below Handset Boot Up Screen 1 Handset Boot Up Screen 2 Handset Boot Up Screen 3 Machine Ready Tinius Olsen Ltd _15 Issue 3 Page 14

17 6.2. Check Machine Operation The machine powers up in IDLE mode, the crosshead will not move unless the motor drive is enabled, to enable or disable the motor drive the keys HI CL or LO CL are used. NOTE - Hi Cl and Lo Cl perform the same function on this machine. Press the Hi Cl key once to activate it, again to deactivate it. Or press the Lo Cl key once to activate, again to deactivate it. The motor drive will be disabled when neither Hi nor Low is selected. Return Motor Enable Motor Enable Up Stop Down Enable drive Handset Controls To enable the motor drive you must first select either the [Hi Cl] or [Lo Cl] keys. Hi or Low will appear in the corner of the display Pressing the button a second time will disable the motor drive Move Crosshead Pressing one of the direction keys (Up or Down) after enabling the drive will move the crosshead in the relevant direction at the first set speed, pressing the button a second time will move the crosshead at the second set speed. Subsequent presses will toggle between the set speeds Pressing the stop key will stop the crosshead Pressing the Return key will move the crosshead either up or down at the set return speed until the position indicator returns to 0.00 IMPORTANT When using the return function ensure that there is sufficient space for the crosshead or anything attached to it to move to the zero position without colliding with anything placed on or attached to the machine. Tinius Olsen Ltd _15 Issue 3 Page 15

18 Travel limits The travel limits are set by releasing the blocks mounted on the alarm rod in front of the left hand cover and sliding them to the required position. To confirm function of the limit switch, run the crosshead upwards then pull the alarm rod up, the machine should stop. Next run the crosshead downwards and pull the alarm rod down, the machine should stop 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. IMPORTANT if the machine fails to stop when the limit alarm is tested DO NOT use the machine until the problem has been remedied. NOTE If the crosshead is allowed to contact the alarm block, the machine will stop, in this case in order to restart the machine, release and move the block away from the crosshead. If it is not possible to move the block away from the crosshead then the interlock override function must be used. (See 7.4.5) Emergency Stop Pressing the emergency stop button (located on the front panel) will immediately stop the machine and disable the drive. The button will remain down after being released, to reset the switch, rotate the top part of the switch clockwise (direction shown by arrows on top of switch), on rotation the top will spring upwards. If no upwards movement is felt the switch is already in its normal position. IMPORTANT if the machine fails to stop when the emergency stop switch is tested DO NOT use the machine until the problem has been remedied Load cell Press the ZERO FORCE key to zero the force displayed on the handset With the crosshead stationary, pull down and push up the underside of the load cell and check the force display on the handset. When the loadcell is pulled down, the load should be positive When the loadcell is pushed up, the load should be negative. IMPORTANT to prevent damage to the loadcell when using low capacity loadcells do not use excessive force Overload 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 100KN load cell is fitted the alarm would be triggered at 109kN 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 is indicated by the flashing load and position indication on the handset. The alarm can be cleared by backing the crosshead off in the opposite direction to reduce Tinius Olsen Ltd _15 Issue 3 Page 16

19 7. Operation 7.1. Handset the applied force using the interlock override function (See 7.4.5). If the alarm persists it is possible that the load cell has been damaged. The user is able to set a lower load limit if desired The handset will always show Force on the top line of the main display. This reading comes from a strain gage load cell and its conditioner module (typically channel 1). The second line indicates crosshead position. It comes from an incremental encoder and its conditioner module (channel 2). The third line may be blank or it may display the reading from an Auxiliary device like an extensometer or deflectomer. Tinius Olsen supplies LVDT and strain gage based strain devices which, in conjunction with the appropriate module, may be selected The bottom two lines will display Status information. The second to last line will show SBD on the left if the Sample Break is ON, HI or LOW in the middle to show which Clutch Range is selected, and PK= on the right if Peak Hold (for Force) is on. The last line will show the current mode of operation on the left, this will be IDLE when the system is first booted or when leaving a Menu screen, READY once the [Test/Clear] key is pressed, TEST while a test is running, HOLD when the [Stop] key is pressed, and an Error message when an error is detected. The right side of the last line will show the speed setting or current speed during a test. If the 602 is not running a test then pressing Up or Down will show on the last line. NOTE The user should first press the [STOP] key before pressing [TEST/CLEAR] to ensure that the crosshead does not drift whilst in the Ready mode. Before testing, select the drive by pressing either Hi or Low Clutch and then press Stop (Hold). Then press Test/Clear (status shows Ready) and then press either Up or Down to start the crosshead moving and begin the Test. The Peak Hold and Sample Break (if selected) will only work in the Test mode Tinius Olsen Ltd _15 Issue 3 Page 17

20 Handset Menu 602 Display Main Menu Selections 1. Machine Control 1. Speeds The two Test Speed Settings. Return Speed & Proportional Gains can be displayed and edited. 2. Position Control The HOME Position, Threshold and the HOLD Gains can be displayed and edited. 3. Limits The FORCE, POSITION & DAC Limits can be displayed and edited. 4. Sample Break Detect The Sample Break Detector is set to Stop/Return on Break or is turned OFF. 5. Sample Break Set The Force Start Load (%fs) & Dropoff (%pk) are set for the Sample Break Detector. 2. Display 1. Units The Force, Position, Auxiliary Channel & Speed Units can be changed. 2. Peakhold The 602 Force Peak Hold Function can be turned ON or OFF. 3. Backlight The 602 Display Backlight can be turned ON, OFF or set to a 10 minute timed delay. 4. Contrast The contrast of the 602 Display can be adjusted from Language The operator will be able to choose the language for the Menu Screens. 3. Configuration 1. Force The operator can select which force transducer to direct to the main Force Display. 2. Position The operator can select which position transducer to direct to the Position Display. 3. Auxiliary The operator can select which module to direct to the Auxiliary Display. 4. CPU This will bring up the Title Screen with the 602 Version. 4. Protected* 1. Interlock This will bring up a Screen on a Mechanical Machine to override the Crosshead Limit Switches. 2. Lock/Unlock This will lock and unlock the 602 Machine Control & Configuration Menus. 3. Bootloader This is used when flashing a program into the 602 CPU. Power must be removed to get off this screen. 4. DAC Test This screen will allow the operator to select certain DAC output levels for testing the DAC Signal. 5. Filter This will display the Bandwidth & Delta settings for the three 602 Display Channels Force, Position & Aux. 6. Additional Sets the Hold Rate & Sampling Rate. The 602 will re-boot after exiting. 5. Refresh This will refresh the 602 display. This is only needed for older handsets * - A general Passcode (602602) is needed to enter the Protected Menu Selections. The Stop key is used as an [Enter] key when on a Menu Screen. Tinius Olsen Ltd _15 Issue 3 Page 18

21 7.2. Handset Functions Zero Channel Keys These function keys are used to zero the three display channels between tests while on the Live Screen. Pressing the [Zero Force] key will zero the force reading on the first line. This should be done before inserting the specimen in the grips or holders. Pressing the [Zero Pos.] key will zero the position reading on the second line. This should be zeroed when the crosshead is at the Start Test position. This zero position is where the crosshead will go to when the [Return ] key is pressed. Pressing the [Zero Aux.] key will zero the reading on the auxiliary line. When using an extensometer, it should be zeroed after clamping it on the specimen just prior to starting a test. Pressing one of these keys for any given channel causes the display value for that channel to be automatically zeroed. If the transducer is mechanically so far off zero that it cannot be electrically zeroed, the display will not change. The transducer should then be checked and/or adjusted, and the "zero" key pressed again. Strain Gauge Conditioner Modules will zero up to ±20%, LVDT Conditioner Modules will zero up to ±50%, and Encoder Modules will zero any value. The zero keys WILL WORK during a test but SHOULD NOT BE USED unless intended Menu Key Pressing the [Menu] key will bring up the 602 Main Menu Screen. From this menu, the operator can press a number key for one of the choices or press the [Menu] key to exit the menu mode. Refer to the 602 Instructions provided after this booklet for the Menus and their functions Drive Enable or Pressing the [HI CL] or [LO CL] will ready the motor drive, once an instruction to move has been given the drive will enable and remain enabled until the button is pressed a second time. These are also the [4] & [7] keys when using the Menu Screens Return Crosshead Key Pressing the [Return ] key will activate the return function of the 602 system. If the crosshead is beyond the threshold value, the crosshead will attempt to return at the Speed set on the Speeds Menu 1-1. As the crosshead is returning, the lower left hand corner of the 602 remote will show RETURN. As the crosshead approaches the threshold value, the 602 will switch to a HOLD Segment as set up on the Position Control Menu 1-2. The bottom status line will show the system in a HOLD Mode while at the home position. This key can be pressed at anytime; if a test is being conducted, it will end the test. This is also the [8] key when using the Menu Screens Tinius Olsen Ltd _15 Issue 3 Page 19

22 Max Key The [Max.] key will display the maximum value obtained for each display Channel during the last test performed until the [Test/Clear] key is pressed for the next test. Pressing the [Test/Clear] key after a test will reset the current maximum values. If higher values are obtained after the test has been ended by the operator pressing the [Stop ] key or by the Sample Break Detector, they will not register as maximum values. The [Max.] key can pressed during a test but will continue to update while pressed. This is also the [9] key when using the Menu Screens Test / Clear Key Pressing the [Test/Clear] key resets the stored maximum values from the last test, resets the Sample Break Detector (if enabled), resets any overload errors and places the display into a "READY" Mode for the next test as shown on the bottom status line. Do not press this key until the maximum values are recorded for the prior test, as it will clear those values Upper Directional Key Pressing the raise [ ] once will start to run the crosshead up at the Speed 1 setting on the Speeds Menu 1-1. Pressing this same key again will advance the machine to the Speed 2 setting on the Speeds Menu 1-1. This key will not do anything unless the drive is enabled and the 602 display is in the IDLE or HOLD Mode Lower Directional Key Pressing the lower [ ] once will start to run the crosshead down at the Speed 1 setting on the Speeds Menu 1-1. Pressing this same key again will advance the machine to the Speed 2 setting on the Speeds Menu 1-1. This key will not do anything unless the drive is enabled and the 602 display is in the IDLE or HOLD Mode Stop (Hold) Directional Key On the Live Screen, the [Stop ] key will stop the crosshead by immediately executing a Position Hold (as shown on the bottom Status Line) on the current position. Depending on the speed that the crosshead is running, the crosshead will stop and return a little to the position value at the time the [Stop ] key was pressed. This key will also end a test, if in the TEST Mode. In the Menu Mode, it s the [Enter] key to accept an entry Speed Increase Adjust Key When running a speed (Speed1 or Speed2) pressing the [Speed ] key once will cause the current speed setting to be incremented and momentarily show the change in the setting. Pressing and holding this key will continue to increase the selected speed in greater increments. After showing the setting change, the bottom line of the 602 display will return to the current rate display. This is also the [0] key when on one of the Menu Screens. Tinius Olsen Ltd _15 Issue 3 Page 20

23 Speed Decrease Adjust Key When running a speed (Speed1 or Speed2) pressing the [Speed ] key once will cause the current speed setting to be decremented and momentarily show the change in the setting. Pressing and holding this key will continue to decrease the selected speed in greater increments. After showing the setting change, the bottom line of the 602 display will return to the current rate display. This is also the decimal [.] key when on one of the Menu Screens Non-Function Keys These six keys have no function except when on a Menu Screen for entering the number on the key or the minus (-) sign for entering negative values Special Key Functions Force Calibration Check Number Pressing the [Menu] key, the [Zero Force] key and the [Menu] key in sequence will activate or deactivate the Cal-Check for that pressure transducer or load cell directed to the Force Channel. The Cal-Check number will be shown on the first 602 channel and the left side of the bottom status line will show Cal-Check. Repeat the key sequence again to deactivate the cal-check. The force display line must first be properly zeroed before reading the cal-check number. This only works with Strain Gauge Conditioner Modules. This value is recorded at Calibration and noted on the Report and/or sticker. This value should not change by more than 1% for any given Load Cell. It is an indication that the system's electronics are operating properly but is not a substitution for verification of the system's accuracy to approved standards. NOTE - The Cal Check number changes if the initial conditions change. The best way to use this function is to let the load cell warm up, remove any weight such as grips, zero the Force, then activate the Cal-Check and record this number 7.4. Machine Protection Zero Motion Detect Should the machine detect no change in position when the crosshead should be moving after a certain amount of time then the drive will be disabled and the error Pos will be displayed on the handset. This protects the machine should the encoder be disconnected or faulty. Pressing [Test/Clear] will clear this condition Travel Limits Damage to the load cell, tooling etc. caused by overtravel of the crosshead can be prevented by the operator properly setting the Adjustable Limit Switch Blocks located on the long rod on the left hand side of the machine. When one of the Position Limit Switches is activated, the 602 display will flash and the proper error message UprLmt or LwrLmt will be shown in the lower left hand corner. This will also disable the motor drive. To clear this alarm, the operator can manually move the adjustable block on the limit switch rod if possible and then run the machine away from the limit switch collar. If the collar cannot be moved anymore, there is an Interlock Override feature on the 602 that will allow the operator to force the crosshead to move regardless of the Limit Switch. (See 7.4.5) Tinius Olsen Ltd _15 Issue 3 Page 21

24 CAUTION: When using the Interlock Override be sure that the Crosshead is moved in the OPPOSITE direction AWAY from the activated Limit Switch Collar. DO NOT MOVE the Crosshead in the same direction as it will go through the limit switch and will damage the Limit Switch Arrangement. Overtravel may also damage the loadcell and tooling. Should this occur please contact Tinius Olsen for advice before continuing to use the machine Loadcell Overload The maximum force limit is 1.09 x FS capacity (N). The Positive and Negative Limits must be set for their respective limits. The user may enter smaller limits if desired. Should the loadcell be subjected to excessive load, the lower left hand corner of the remote will show Ovrld, the display will flash and the drive will be disabled. If the load can be removed or reduced then pressing the [Test/Clear] button will re-set the display. If it not possible to remove the load, the crosshead can be backed off using the override feature. (See 7.4.5) CAUTION: When using the Interlock Override be sure that the Crosshead is moved in the OPPOSITE direction AWAY from the applied load. DO NOT MOVE the Crosshead in the same direction as damage will be caused to the loadcell Position Limit The position limit is set using the Menu [1] [3], this limit is normally set to +/-1199mm. Should the limit be exceeded, the lower left hand corner of the remote will show Pos, the channel displays will flash and the drive will be disabled. The machine crosshead can be moved back into a valid position by simply re-zeroing the position or using the override feature (See 7.4.5) Operation of Interlock Override To get to the Interlock Override press:- The [Menu] key The [4] key for the Protected Mode Type the Passcode ( ) The [1] key for Interlock Override The following menu will display. Interlock Override Use up and down arrow Keys to move crosshead. Press Menu key to exit. Use Caution when moving Crosshead. Once the crosshead has moved enough to clear the fault position press the [Menu] key to exit back to the live screen. It may be necessary to press [Test/Clear] to clear out the old fault status. Tinius Olsen Ltd _15 Issue 3 Page 22

25 7.5. Typical Settings When set at the factory, the handset will typically display the following settings. Settings highlighted should not be altered under normal circumstances and may be locked on the handset (see Error! Reference source not found. [Menu # 4 2]) Speed [Menu # 1 1] Speed mm/min Speed mm/min Return Speed mm/min * Gain Gain Gain Return 0.25 (*) Max speed will depend upon supply voltage Position Control [Menu # 1 2] Home 0 Threshold 2 Hold P Gain 0.25 Hold I Gain Limits [Menu # 1 3] + Force N * - Force N * + Position mm - Position mm + DAC DAC (*) Force limit will depend upon loadcell fitted Units [Menu # 2 1] Force N Position mm Speed mm/min Hold / Sample Rate [Menu# 4 1 6] Hold Rate 1000 Sample Rate 100 Tinius Olsen Ltd _15 Issue 3 Page 23

26 7.6. Replacing Loadcells Fitting To change Load Cells, the primary load cell must be removed and the new Load Cell mounted (See 4.5.1) With each load cell there must a cable with a Strain Gauge Conditioner Module. Mount the module onto the crosshead and plug the 8-pin RJ45 jack into the receptacle on the side. The 602 will read in the new module and the Configuration Screen for that module will be shown and then return to the live screen. DO NOT PLUG ANY NEW MODULES DURING A TEST BECAUSE THE 602 WILL STOP THE DRIVE DURING THE READ IN PROCESS Selecting Device Once the read in process is done, the operator must direct the new Load cell to the Force Display (top line) by pressing [Menu], the [3] key on the Main Menu for Configuration, the [1] key on the Select Channel Menu for Force, and then [1] on the Xducer Menu for Select Transducer. The 602 will show a list of any connected Force Modules by description. Press the number for the description of the new Load cell to be used. If the desired cell is not listed, check that it is connected correctly. The 602 will exit back to the live screen. Press the [Zero Force] key to zero the load cell, then manually push up on the base of the loadcell and check that the Force Display shows an appropriate response. If optional software is being used, this can be done by the software settings and the operator doesn t have to use the 602 menus. NOTE - Only modules that are intended to be used should be plugged in to the RJ45 connectors. That is because any device with the RJ45 connectors plugged in is considered active by the 602. Too many connected devices reduces the bandwidth of the system, particularly at higher sample rates. It is recommended that the total number of connected devices be limited to 3 or Setting Force Limits Note that for the Force Limits to apply, the load cell must be directed to the first (Force) line on the 602. When a lower capacity load is read into the 602, the Force Limit Settings will be rewritten 1.09 x FS capacity (N), but when adding a higher capacity load cell the operator MUST enter the higher limits manually or have them entered in the software settings and let it load them in. Tinius Olsen Ltd _15 Issue 3 Page 24

27 8. Tooling Tinius Olsen manufacture a wide range of sample tooling, please contact Tinius Olsen or local authorised distributors to discuss your requirements Attaching to the Machine A large proportion of tooling uses the same method of attachment to secure the tooling to the machine / load cell. In general this comprises:- Nose Piece Locking Collar (X 2) Grip pin The diagram below indicates attachment parts Nose pieces have a threaded section to screw into the loadcell / machine and a parallel section to fit inside the tooling. The parallel section includes a hole for a grip pin to be inserted to attaching to the tooling. The size of the nose piece is determined by the maximum load to be applied as follows:- Load (kn) Nose Piece Dia Grip Pin Dia /8 inch (15.875mm) 5/16 inch (7.9375mm) /4 inch (19.05mm) 3/8 inch (9.525mm) mm 1/2 inch (12.7mm) mm 16mm mm 20mm mm 24mm The attachment fixing threads range from M6 to M42, depending on the capacity of load cell used. The tooling attachment for the fixed crosshead is M36 and standard loadcell is M33, an adaptor is available to reduce this if required 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 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 M33 fixing thread tooling attachment. The diagrams below indicate tooling attachments for load cell and fixed crosshead. Tinius Olsen Ltd _15 Issue 3 Page 25

28 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. 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 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. Tinius Olsen Ltd _15 Issue 3 Page 26

29 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 _15 Issue 3 Page 27

30 9. Conducting a test 9.1. Basic Operation These are some typical precautions to be observed when operating a Tinius Olsen H150KU Testing Machine. The Load Cell Weighing System of the H150KU is considered a very "HARD" type of weighing system. The force-measuring element (Load Cell) will only deflect approximately 0.1mm at the full rated capacity. This "HARD" weighing system permits extremely sensitive and accurate load indication. The following information is included to caution the operator as to unintentional misuse and resulting damage to the load cell Overloads The Load Indicating System of this test machine is provided with protective Overload Limit Switch Circuitry that removes power from the drive motor whenever the load exceeds full scale. The purpose of this feature is to prevent damage that can be caused by exceeding the capacity of the weighing system or the tooling being used for the test. However, the overload protection is only effective when the machine is being operated within the response capabilities of the load indicator. Obviously, the overload protection cannot prevent overloading and the resulting damage if a rigid specimen is impacted at a high rate of speed Clearance Care must be taken whenever running the crosshead up or down, that the Load Cell and any attached tooling or specimens do not contact any part of the machine or any tooling, specimens, etc Mounting of Specimens Care must be taken to insure that the specimen is always cantered in the grips, etc., when testing in tension or centred between the compression platens when testing in compression. Off centre loading can result in an erroneous load reading and possible damage to the load cell or tooling Use of Low Capacity Loadcells The load cells are designed for some overloading, but if the load exceeds 150% of the rated capacity this can result in zero shift, span changes and possible damage or breakage. EXTREME CARE should be taken when using low capacity load cells that they are not dropped or overloaded when mounting tooling. Overloading a load cell will usually result in the inability to zero the load cell or an offscale reading. As load cell damage can be difficult to see visually and where load cells may be damaged, the extent and responsibility is to be determined solely by the manufacturer Testing Using The Handset The following assumes that the machine is set up, all grips are fitted and all handset settings have been made. See this manual for further details. CAUTION: DURING A TEST, ALWAYS CHECK THE CLEARANCES IN THE AREA AROUND THE CROSSHEAD. IF INSUFFICIENT, STOP THE TEST BEFORE THE TRAVEL OF THE CROSSHEAD CAN CAUSE DAMAGE Preparing the Machine With the proper grips or holders installed, run the crosshead to the desired starting position and press the [Zero Pos] key to zero the Position Channel at this position. The Force Channel can also be zeroed now by pressing the [Zero Force] key. Tinius Olsen Ltd _15 Issue 3 Page 28

31 Mount Specimen Secure the specimen properly in the grips or holders. When securing a specimen there might be some amount of ±preload applied to the specimen. The operator can start the test with a small preload on the specimen, or they can run the crosshead slowly in the proper direction until zero force is displayed. DO NOT USE THE FORCE CHANNEL ZERO TO ELIMINATE PRELOAD ON A SPECIMEN Mount Aux Instruments (if applicable) If Strain data is to be recorded, mount the Strain Instrument following the instructions provided for the instrument, the Strain System and/or Computer being used. Mount the module into the rack at the rear of the machine and plug the adjacent 8-pin RJ45 jack. The 602 will read in the new module and the Configuration Screen for that module will be shown and then return to the live screen. DO NOT PLUG ANY NEW MODULES DURING A TEST BECAUSE THE 602 WILL STOP THE DRIVE DURING THE READ IN PROCESS Once the read in process is done, the operator must direct the new instrument to the Aux Display (third line) by pressing [Menu], the [3] key on the Main Menu for Configuration, the [3] key on the Select Channel Menu for Aux, and then [1] on the Xducer Menu for Select Transducer. The 602 will show a list of any connected Aux Modules by description. Press the number for the description of the new instrument to be used. If the desired cell is not listed, check that it is connected correctly. The 602 will exit back to the live screen. NOTE - Only modules that are intended to be used should be plugged in to the RJ45 connectors. That is because any device with the RJ45 connectors plugged in is considered active by the 602. Too many connected devices reduces the bandwidth of the system, particularly at higher sample rates. It is recommended that the total number of connected devices be limited to 3 or Install Protective Devices (if applicable) If necessary, install protective devices around the test specimen or test machine to prevent injury to the operator or personnel in the area. (See 10.2) Set Speeds The machine uses the programmable Speeds on the Speeds Menu # 1-1 or optional Software to set the speed(s) of the test. Set a crosshead speed or rate that meets the applicable test specification; in some cases, it may be necessary to calculate the loading speed from known or given data. In the absence of a testing specification, a good rule to follow is to select a loading speed (rate) slow enough that the force display can be accurately read at any time. NOTE - typically Speed 1 is set for a slow speed (e.g. pre-yield speed) and Speed 2 is set for a faster speed (e.g. post-yield speed or jog speed) Start Test Ensure that the drive is enabled by pressing [Hi] or [Low] Press [STOP] to keep the 602 in Hold mode Before starting the test, the [Test/Clear] key must be pressed, placing the 602 into a "READY" Mode. If the 602 remote is not in the READY Mode before starting a test, the Peak Hold and Maximum Values will not be retained, and the Sample Break Detector is not active. Press either the lower directional key (compression test) or upper directional key (tension test) once to start running a test at the programmed Speed #1 and the 602 display should show TEST in the bottom left corner of the display. If needed, press the directional key a second time to go to Speed #2. The operator can see the actual crosshead rate in the bottom right corner of the 602 display. Tinius Olsen Ltd _15 Issue 3 Page 29

32 End Test The test can be ended and the crosshead returned to its start test position automatically by the Sample Break Detector if there is a detectable drop-off in force. If there is no drop-off or failure during a test, the operator must end the test manually using the [Stop ] key. The 602 display will then go to HOLD Mode and hold that crosshead position. When you are ready to return the crosshead to it s starting position press the [Return ] key. For tensile testing, the Sample Break Detector is normally set to trigger at a large amount of "drop off in load" such as 75% to ensure that the specimen has broken completely. NOTE - A small Start Load % of Full Scale (typically 1-10 % FS) is required to prevent false triggering of the Sample Break Detect Record Results Record the test data required the Peak Force will be shown on the right side of the second to last line on the 602 or the maximum values for three Display Channels can be recalled by pressing the [Max.] key. Remove the tested specimen, then press the [Test/Clear] key on the 602 remote to clear the maximum values being held, reset the 602 Display and Sample Break Detector, if enabled, for the next test. NOTE - Do not press the [Test/Clear] key until the results from the prior test are recorded, because once the [Test/Clear] key is pressed the prior results are cleared Next Test The machine should always be left in its Start Test (Home) Position until the next test is ready to be started. If the 602 display in the READY mode simply press the directional key to start the next test. The user must press [Test/Clear] to clear the old results and re-arm the 602 for the next Test 9.3. Testing Using Optional Software For machines provided with optional Tinius Olsen Test Software, the computer will send all the needed information to the 602 Display to run the test remotely. In addition, all the controls on the 602 are available on the Top Tool Bar in the Software. Setup the test the same as described in section 9.2, but start the test in the software instead using the directional key. Once the test has started, the program monitors the test and advances the segments according to the program and the Machine Control Settings being used for that test. After the test is over, and the results are saved, etc., the program will prompt the operator to choose whether to have the 602 automatically return the crosshead or to return it manually by using the [Return ] key. WARNING - the user must take care if using the handheld in conjunction with the computer because of possibility of conflict. When using a computer, it is best to configure the system and run the machine entirely from the computer to avoid potential conflicts Tinius Olsen Ltd _15 Issue 3 Page 30

33 10. Safety Warnings 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. When left unattended always disable the drive by pressing the E-Stop or taking it out of Hi/Low clutch mode. Do not rely on the simply pressing [STOP] as the drive is still active Installation of the machine must be carried out as described in section 4 of this manual. Only trained operators should use the machine. (Including operation of software) Operator must wear appropriate clothing. (No loose clothing) Eye protection must be worn at all times when operating the machine. Operator must not place any part of their body within the test area when the machine is moving. Mains Supply isolator must not be obstructed and be within 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 Tinius Olsen Ltd _15 Issue 3 Page 31

34 10.2. Protective Screens Standard machines are not supplied with protective screens. Depending on the type of material being tested a protective screen may be required. Please contact Tinius Olsen if you require screens for your application Prior to conducting any testing, the operator must assess the type of sample failure likely to occur. This assessment will enable the correct protective screen to be selected. As a general rule, if there is any possibility of fragments being ejected from the machine when a sample fails then a protective screen should be fitted. Where high loads and large extensions are required to break a sample failure often becomes more violent, in this case interlocked screens should be fitted. In case of doubt or for more advice on protective screens please contact Tinius Olsen or your local authorised distributor to discuss your requirements. Illustration shows a fully enclosed guarding solution. Tinius Olsen Ltd _15 Issue 3 Page 32

35 11. 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. For details of your nearest distributor, please check our website at Tinius Olsen Ltd 6 Perrywood Business Park Honeycrock Lane Salfords Redhill Surrey RH1 5DZ England Tinius Olsen Ltd _15 Issue 3 Page 33

36 12. 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 qualified service personnel and should not be attempted by the customer unless instructed on how to do the required service Electrical Supply The H150KU machine operates from a 3ph phase 415V +/- 10% 50/60 Hz 15Amp Continuous, 30A peak Electronics All the electronics in the machine are solid state and do not require any maintenance Circuit Breakers Calibration To protect the machine two circuit breakers have been incorporated at the rear of the machine. In the event of either circuit breaker repeatedly tripping please contact Tinius Olsen or one of our authorised distributors 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 calibrated conditioner module. All the load cells supplied will already be calibrated and a calibration certificate 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 Lubrication For details of your nearest distributor, please check our website at Bearings Bearings are pre-packed with grease on assembly and should not require additional lubrication Guide columns The columns (adjacent to the ballscrews) use DU dry self lubricating bearings. If required the shaft can be lubricated using most lubricating oils that do not chemically attack the PTFE/Lead overlay or the porous bronze interlayer Ballscrews The ballscrew nuts require a lithium soap based grease Number 2. They will require approximately 2cc of grease per 12,000-15,000m of travel. Tinius Olsen Ltd _15 Issue 3 Page 34

37 13. Storage Long Term Storage If the machine is not to be used for some time ensure that it is unloaded and the mains power is disconnected. To help to keep the machine clean cover 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 _15 Issue 3 Page 35

38 14. Appendix Dimensions Tinius Olsen Ltd _15 Issue 3 Page 36