Q Operators Manual. Model: 100Q Firmware Version 0.5f-34. TestResources Inc. 680 Industrial Circle South Shakopee, MN

Transcription

1 Q Operators Manual Model: 100Q250-6 Firmware Version 0.5f-34 TestResources Inc. 680 Industrial Circle South Shakopee, MN

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3 1 FOREWORD TRI's Q systems have been designed and constructed with great care in every phase of assembly. In order to insure reliability, both the mechanical and electrical components have been built with the best available materials. Nevertheless, it has been proven that a thorough understanding of the machine, together with proper attention, will pay big dividends. The sections of this manual provide description and instruction on the operation and maintenance of the mechanical, electrical and software components. You as a customer are our most valued asset. We take pride in our systems and are proud that you have become an owner. We welcome your comments about our products. This is the only way that we can continue to build the best available test systems to satisfy your needs. Thank you for your support. This manual is intended to educate the customer on the capabilities, operation and maintenance of the Q Series Systems. Read this manual and become familiar with the controls of your test machine prior to operation. 1. TECHNICAL SUPPORT If a problem should occur with the testing machine: First, check that all external inputs are properly connected. Next, contact TestResources Inc. Technical Support (8:00 5:00 CT) Phone / Fax fax Mail Technical Support TestResources Inc. 680 Industrial Circle South Shakopee, MN USA support@testresources.com suggest@testresources.com service@testresources.com Technical support Product enhancement Order, status, maintenance contracts etc Web info@testresources.com Sales, pricing, and general information 1

4 2 DISCLAIMER AND WARRANTY 2.1 LIMITED WARRANTY TestResources Inc. (The Company) warrants that hardware and software/firmware products manufactured by The Company, when properly installed, used, and maintained, will be free from defects in material and workmanship. TestResources Inc. warrants a) the SOFTWARE/FIRMWARE will perform substantially in accordance with the accompanying written materials and b) the HARDWARE will be free from defects in materials and workmanship under normal use and service for a period of (1) one year from date of receipt. The Company s obligations under this warranty will be limited to repairing or replacing, at The Company s option, the part or parts of the hardware and software/firmware which prove defective in material and workmanship within one (1) year from the date of delivery, provided the buyer gives The Company prompt notice of any defect or failure and satisfactory proof thereof. Products may be returned to The Company s factory. The Company will deliver replacements for defective products to the Buyer, freight prepaid to the destination provided for in the original order. With respect to any product or part thereof not manufactured by The Company, only the warranty, if any given by the manufacturer thereof, will apply. It is the responsibility of the Buyer to determine the suitability and safety of this product for any particular purpose. The Company disclaims all liability for incidental or consequential damages. In no case will The Company s liability exceed the original purchase price. THE COMPANY MAKES NO OTHER OR FURTHER WARRANTY, EXPRESS OR IMPLIED, INCLUDING ANY WARRANTY OF FITNESSFOR A PARTICULAR PURPOSE OR WARRANTY OF MERCHANTABILITY. 2.2 HARDWARE/SOFTWARE LICENSE AGREEMENT This is a legal agreement between you, the end user, and TestResources Inc (The Company). By using the 100 Series test machine, you are agreeing to be bound by the terms of this agreement. 1.0 License Grant. The Company hereby grants the end user a personal, nontransferable and nonexclusive license to use one copy of the software/firmware and related documentation on a single indicating system. 2.0 Intellectual Property Rights. The Company is the sole owner of all right, title and interest to the 100 Series Indicating System and all copyrights, trademarks, and trade secrets therein. The Company is protected by United States copyright laws and international treaty provisions. Therefore, the end user must treat the software/firmware as any other copyrighted material and may not copy the written materials accompanying the 100 Series Indicator. 3.0 Restrictions. This Agreement and the Licensed Software/Firmware may not be assigned, Sublicensed or otherwise transferred by the Customer. The end user must not reverse engineer, decompile, or disassemble the Licensed Software/Firmware or attempt to do so. The Licensed Software/Firmware may not be modified without the written consent of The Company. 4.0 Termination. The Company may terminate the license contained in this Agreement by written notice upon any breach of any term by the end user. Upon termination, the end user shall immediately return the 100 Series System to the factory. Section 2.0 of this Agreement shall survive termination of this Agreement 5.0 Purchase by Governmental Agencies. If the end user is a federal, state or local governmental agency or unit, then as a matter of contract, the end user will accord The Company and the Licensed Program the same rights The Company would have had under the Copyright Act of 1976, as amended. 6.0 Governing Law. This Agreement shall be governed by and construed in accordance with the laws of the State of Minnesota. 7.0 COPYRIGHT NOTICE: The contents of this manual copyright (c) All rights reserved. Nothing in this manual may be reproduced in any manner, either wholly or in part for any purpose whatsoever without written permission from TestResources Inc. 2

5 TABLE OF CONTENTS 1 FOREWORD DISCLAIMER AND WARRANTY LIMITED WARRANTY HARDWARE/SOFTWARE LICENSE AGREEMENT INSTALLATION AND SYSTEM STARTUP SYSTEM UNPACKING AND ASSEMBLY SYSTEM REQUIREMENTS THE KEYS THE TEST METHOD KEY THE ENTER/START KEY THE ESC/STOP KEY THE JOG UP / JOG DOWN KEYS ( / ) THE ZERO KEY THE CONTROL KEY THE DATA ACQUISITION KEY THE ANALYSIS KEY THE UTILS KEY THE PRINT KEY THE ID# KEY THE MENU LAYOUT FUNCTION FLOWCHART OPERATION HOW TO SETUP A TEST DISPLAY RESOLUTION FOR LOAD AND DISPLACEMENT HOW TO PERFORM A TEST AND SAVE RESULTS TEST REPORTS GENERATED FROM STORED DATA EXPORT X-Y DATA CALIBRATION FORCE CALIBRATION VERIFICATION DETAILED DISPLACEMENT CALIBRATION DETAILED SPEED CALIBRATION PROBLEMS WITH THE CALIBRATION WHAT OCCURS DURING LOAD CALIBRATION

6 7 TEST SYSTEMS P/Q STANDALONE STANDARD FEATURES ADDITIONAL Q FEATURES OR OPTIONS INTERFACE MECHANICAL FRAME LOAD CELL GRIP OR TEST FIXTURE ELECTRICAL/MECHANICAL DATA USER CONNECTIONS LOAD CELL REPLACEMENT APPENDIX A GLOSSARY OF COMMON MATERIALS TESTING TERMS: APPENDIX B GLOSSARY OF COMMON MATERIALS TESTING TERMS: APPENDIX C TROUBLE SHOOTING AND PREVENTATIVE MAINTENANCE: APPENDIX C FACTORY PASSWORD: APPENDIX D ADDITIONAL PROJECT INFORMATION:

7 3 INSTALLATION AND SYSTEM STARTUP 3.1 SYSTEM UNPACKING AND ASSEMBLY To install your system, please follow these steps: Step 1. Unpack the frame and accessories. Retain the shipping container in case of a future desire to ship the frame back to TestResources for service or further upgrade. Frame Step 2. Confirm all parts have been received by comparing the parts received against the bill of materials specific to your project. If there is a shortage contact TestResources immediately. 1 4B A 7 1)Single column frame and Actuator 2)P/Q Controller 3)Load Transducer (Load Cell) 4A)Upper grip adapter 4B) Lower grip adapter 5)Grips 6)Grip/adapter pins 7)5mm T-hex tool 5

8 Step 3. Follow Steps for Frame Assembly Insert controller mounting rod into frame mount and tighten down set screw. Note: Make sure rod is fully inserted into the mount 6

9 Positioning Controller height: Loosen screws with T-hex tool and move controller assembly to desired height. Make sure to support assembly before loosening screws. Then tighten screws to lock assembly in place. 7

10 Step 4. Follow Steps for Load cell/grip Assembly Take the load cell, handle by the TestResources Logo and screw onto the crosshead of the actuator 8 Screw load cell until it secure to the bottom of the crosshead Note: Do not over tighten or twist load cell this may damage the load cell

11 Support load cell on the sides near the bottom of the load cell and screw adapter to bottom of the load cell. Note: Do not over tighten or twist load cell this may damage Lock adapter into place by tightening jam nut Note: Do not over tighten or twist load cell this may damage the load cell 9

12 Take one of the grips and insert into upper grip adapter. Line up pin holes and insert pin. Tighten down jam nut to secure grip 10

13 Q Series Systems Operation Manual Repeat previous steps to install grip on the lower grip adapter 11

14 Step 5. Step 6. Place test frame on a solid, level surface. Connect the serial port cable to your PC, load cell cable to controller, I/O cable to controller and power cable to controller. If you have other cables, match the descriptions on the cable to the corresponding connectors. For some systems, there are additional cables to connect. Match the connectors as indicated by the markings on or near the connector. Turn on the power. Optional. Insert the installation CD in your CD drive. Close and exit all applications open or in use. The install CD should automatically load contents and direct you through the process. Carefully read the instructions by the Install Wizard as you proceed. The Wizard will notify you when the setup is complete. If your CD does not automatically run then your PC s autorun feature may be turned off. Follow all steps as directed, including restarting the computer at completion of software installation. You will need to have one available serial port on your PC in order to use the application. Software Skills Prerequisite This manual assumes you have a working knowledge of the Microsoft Windows Operating System on the system computer. If you are not familiar with your operating system, it is recommended that you learn it prior to running Wincom or contact someone for assistance. 3.2 SYSTEM REQUIREMENTS The P/Q controller is designed to be used as in a standalone configuration or can be complimented with optional data collection software. If you would like to use the Wincom package the following requirements are needed: any currently supported Microsoft Windows operating system (2000/XP) Pentium 800 MHz or better. 256 MB RAM VGA monitor (640 X 480) 40 MB Hard drive space CDROM 12

15 4 THE KEYS Front Panel 4.1 THE TEST METHOD KEY This <Test Method> key performs the following functions (Q controller only): Selects the different test profiles. Sets the absolute zero position for compression on springs, bottles, electrical components. This allows for the calculation of Free Height. 4.2 THE ENTER/START KEY The <ENTER/Start> key performs the following functions: Accepts/assigns the value in a data entry field to that field. Starts the test. 4.3 THE ESC/STOP KEY The <ESC/Stop> key performs the following functions: Backs up to the previous menu. Clears a data entry mistake by deleting the previously entered number in the data entry field. Stops the test and actuator if moving. 4.4 THE JOG UP / JOG DOWN KEYS ( / ) The <ARROW> or <Jog> keys allow the operator to scroll between menu items and jog the actuator up or down. 4.5 THE ZERO KEY The <Zero> key performs the following functions: Defines a new zero (tare) load. It also sets the home position of the crosshead. Places the Indicator Test Status in Ready Mode. Clears out the previous test results from the test buffer and initializes the indicator for the next test. Make sure the previous test result was stored prior to pressing Zero or it will be lost. 4.6 THE CONTROL KEY 13

16 Use the <ARROW> keys to scroll through the menu items. The following functions are provided in the Control Menu: <ESC>: Exit to Live Indicating Screen. Set Test Profile: Enter speed, control channel and end amount Direction: Toggle test direction (Tension/Compression) Post Test: Set desired action at completion of test (Stop/Home) Jog Rate: Enter manual actuator speed (jog switches) Home Location: Enter relative position to be HOME amount Home Rate: Enter HOME return speed Pre Load: Set load level of preload feature Pre Rate: Set control rate in displacement control (i.e. in/min) Control Gains: Change control gains for channels 4.7 THE DATA ACQUISITION KEY Use the <ARROW> keys to scroll through the menu items. The following functions are provided in the Data Acq Menu: <ESC>: Exit to Live Indicating Screen. Threshold: Once the load exceeds the user-defined threshold value, data logging will begin Sample Break: Enter value in percent to detect break (100% disables break detect). This is detected as a percentage drop from peak force. Specimen Type: Choose geometry that matches your specimen Round or Cylinder Beam Flat (dogbone) Area Log Rate: Enter data acquisition sampling rate. Set time to fit test length. Local Overload: Enter load level that the user does not want to exceed during this test Engineering Units: Set Engineering Units for force, stress,time and displacement, Rate Channel (Load or Position), Position (%,units of measure) 14

17 4.8 THE ANALYSIS KEY Selects different analysis parameters and toggle Auto Transmit results. Select Analysis: Choose analysis to perform on results. Toggle between ON/OFF Analysis P Q Max Load yes yes Max Ld/Width yes yes Max Stress yes yes Min Load yes yes AVG Ld1 <> Disp yes yes AVG Ld-Dp yes yes Load at Break yes yes Disp at Break yes yes Load at Disp yes yes Disp at Load yes yes Stiffness yes yes Energy <> Disp yes yes Free Height yes yes Percent Elongation yes yes Offset Yield yes yes Modulus of Elasticity yes yes Static Us no yes Kinetic Uk no yes Shear Modulus no yes Load1@Pct1 no yes Load2@Pct2 no yes Load3@Pct3 no yes Pct1@Load1 no yes Pct2@Load2 no yes Pct3@Load3 no yes Pct1@Load1 no yes Pct2@Load2 no yes Pct3@Load3 no yes A detailed description of each analysis can be found in the appendices Set Limits: Enter low and high limits for some analysis Auto Transmit Results: enable function to send data to RS232 port after test Calculate Results: recalculate the results after changes to parameters above 15

18 4.9 THE UTILS KEY Press the <UTILS> key from the Indicating Screen to enter the UTILS Menu. Use the <ARROW> keys to scroll through the menu items. The following items are found in the UTILS Menu: <ESC>: Exit to Live Indicating Screen. Clear Results: Clear tabled results in memory Store: Set auto store of results (Manual/Auto) Set Date/Time: Adjust the current date and time for system Stiffness Factor: Adjust stiffness/deflection of load cell (Unit Force/Unit of Measure) Install Defaults: Resets memory of system to factory defaults (only use with factory assistance) Diagnostics: Tool used to troubleshoot issues in the field Calibration: Adjustment of Load and Displacement transducer calibration files Supervisor: Mode used to lock down the changes to parameters used to run the test 4.10 THE PRINT KEY Press the <PRINT> key while in the Indicating Screen to enter the PRINT Menu. Use the Numbered keys to select the output and destination. The following functions are provided in the PRINT Menu: <ESC>: Exit to Live Indicating Screen. Press <1>: Current Res WC. Send the current result(s) to Wincom. Press <2>: XY Data WC. Send the last set of X-Y data (time, load, displacement) to Wincom. Press <3>: Stored Res WC. Send the tabled results to Wincom. Submenus to select from which test (1 thru 6) Press <4>: Current Res Com. Send the peak load results to the Com Port. Press <5>: Test Method WC. Send the all the test settings for current test to Wincom. Submenus to select from which test (1 thru 6) Press <6>: Calibration WC. Send the calibration table to Wincom. Press <7>: Baud Rate. Adjusts available baud rates for Com transfers THE ID# KEY Press the <ID#> key from the Indicating Screen to input the Specimen ID#. The Specimen ID# can be nine numerical characters long. Input the Specimen ID#. Press <ENTER> to accept the ID#. The Specimen ID# is displayed on test reports. 16

19 THE MENU LAYOUT FUNCTION FLOWCHART Control Panel Test Method 1-6 Set ABS Zero Pos ABS ZERO FUNC will Load in Tension ESC) Exit ENT) Continue ABS Rate (in/min): ABS (lbf): METHOD) Continue Test Method Threshold (Lbf) Sample Break (%) 1) None, Round, Flat, Beam Ctr, Beam 3Pt, Beam Ctr-Rec. Tube, Area, Width ENT) Set Specimen Type ESC) Exit 16sec Hz Data Acq Log Rate Local Overload (Lbf) 1) Test Len: Log Rate: 2) Live XY Data - On/Off ESC) Exit 1) Force: (Lbf, N, KN, mn, gf, Kgf, ozf) 32sec Hz 64sec Hz 128sec Hz 256sec 63.97Hz 512sec 31.99Hz 1024sec 15.99Hz 2049sec 8.00Hz Engineering Units 2) Stress: (psi, MPa, KPa, ksc) 3) Length: (in, mm, cm) 4098sec 4.00Hz 8195sec 2.00Hz 16390sec 1.00Hz 4) Time: (sec, min) 32781sec 0.50Hz 65561sec 0.25Hz 17

20 Control Panel Select Analysis ENT) Param ESC) Exit Set Limits Auto XMit Res-On/Off Calculate Results Max Load On/Off Max Ld/Width On/Off Max Stress On/ Off Min Load On/Off Analysis Control Control Gains PASSWORD: Proportional: Position Integral: Position Channel Derivative: Position Channel Proportional: Load Channel Integral: Load Channel Derivative: Load Channel Max Load Low:/High: AVG Ld1<>Disp Low:/High: AVG Low:/High: Set Test Profile Dir Tension/Compression Post Test - Home/Stop Jog Rate (in/min) Home Location (in) Home Rate (in/min) Pre Load (Lbf) Pre Rate (in/min) CONTROL CH SegA 1) Position, Load SegA (in, Lbf/min): END CH SegA 1) Position, Time, Load ENT) Continue END AmtA(in/sec/lbf) 0=CONTINUE TO BRK CREATE SegB? Yes/No CONTROL CH SegB 1) Position, Load SegA (in, Lbf/min): END CH SegB 1) Position, Time, Load ENT) Continue END AmtA(in/sec/lbf) 0=CONTINUE TO BRK Cycle Btwn Seg ON/OFF AVG Ld1<> Disp On/Off AVG Ld2@Ld-Dp On/ Off Load At Break On/ Off Disp At Break On/ Off Percent Elong On/ Off Load At Disp On/ Off Disp At Load On/ Off Stiffness On/ Off Energy<>Disp On/ Off Free Height On/ Off Mod Elast On/ Off Static Us On/ Off Kinetic Uk On/ Off Shear Modulus On/ Off Load1@Pct1 On/ Off Load2@Pct2 On/ Off Load3@Pct3 On/ Off Pct1@Load1 On/ Off Pct2@Load2 On/ Off Pct3@Load3 On/ Off 18

21 Control Panel 1) Current Method 2) ALL Methods Clear Results ESC) Exit 1) Set Store Auto/Manual Set Date/Time Stiffness Fact (Lbf/in) Install Defaults 2) Set ESC) Exit PASSWORD Month (MM): Day (DD): Year (YY): Hour (HH): Minute (MM): Install Defaults ESC) Utils Diagnostics AD: Load Cell Counts ENC: Encoder Counts InBy IN3 0 (0-7) OutBy -7 (8) DAC 1) Load Calibration Password C1 Full Scale (Lbf): C1 Shunt (Lbf): C1 Resolution (Lbf): Serial No: 2) Position Pulses per in: Max Spd (in/min): Max Tach Gain: Calibrate Transducer Unload Machine ENT) Continue Zero Reading Taken Span Reading Taken Calibration Successful Supervisor On/Off 19

22 Control Panel Store Writing Result 1 (2,3,4,...) 1) Current Res -> WC 2) XY Data -> WC Print 3) Stored Res -> WC 4) Current Res -> COM 5) Test Method -> WC 6) Calibration -> WC 7) Baud Rate: (0) Zero (-) Home (.) Freeze 1) Both 2) Load 3) Position 4) Cal Load ESC) Exit Calibrate Transducer Unload Machine ENT) Continue Zero Reading Taken Span Reading Taken Calibration Successful ESC Stop ENT Start Jog Up Jog Down ID# 20

23 5 OPERATION Section 5.1 describes how to setup a test. Section 5.3 describes how to perform a test and store the results to memory. Section 5.4 describes how to generate test reports. Section 5.5 describes how to download the stored test results to a remote PC. 5.1 HOW TO SETUP A TEST Step 1: Turn on controller, and ZERO position and load by pressing <1)Both> Step 2: Press <Utils> from the Indicating Screen. Press <8)Supervisor> to turn ON supervisor mode. Press <ESC> to return to Indicating Screen. Step 3: Press <Control> from the Indicating Screen. Step 4: Press <1)Set Test Profile> and set the following: Press <1> to toggle between Position and Load control. Press <ENT> to continue. Enter test speed (in/min or Lbf/min) Press <1> to toggle between position, load and time to set as END CHANNEL (Select position to end test at a certain displacement, Select load to end test at a certain force, or Select time to end test after a certain amount of time). Press <ENT> to continue. Enter End amount (this will define the maximum amount before it stops) Enter 0 to continue until break Select to create Segment B. Repeat Step 4 for Segment B Step 5: Press <2> to Select the Direction for Compression or Tension Step 6: Press <3> to Select POST TEST Action (STOP/HOME) Step 7: Set the jog rate, home rate and preload levels if desired Step 8: Press <DATA ACQ> from the Indicating Screen. And change the following: Threshold: 1.0 lb (other values may be necessary) Sample Break: 50% (other values may be necessary) Specimen type: (match to your sample & set geometry) Log Rate: Set depending on length of test. Choose 64 hz for ~256 seconds Local Overload: set maximum amount of load you want to place on sample. Test will stop when it reaches this level. Set engineering units as desired. Step 9: Press <Analysis> from the Indicating Screen and choose analysis you want to have on. Step 10: Press <UTILS> from the Indicating Screen. Clear results from memory. Note: If the stored results are important, print before clearing. See Section 3.3 for more information. Step 11: Press the <ID#> from the Indicating Screen. Input the Specimen ID# and other specimen information. 5.2 DISPLAY RESOLUTION FOR LOAD AND DISPLACEMENT The display resolution for both the load and the position are factory default. The load resolution is 1 part in 100,000. For a 10 lb load cell, the resolution would be For the display resolution, we use factory default multiplier factor of 200. For the 10 lb load cell, the display resolution would be The resolution for the position is factory default at To manually adjust the resolution refer section 7.1 step

24 5.3 HOW TO PERFORM A TEST AND SAVE RESULTS If the steps in Section 5.1 were followed, you are now ready to perform a test. The current test settings are saved in permanent memory (Test Methods) and will not change unless they are modified by the operator. Up to six Test Methods can be saved. Turn off Supervisor mode to prevent inadvertent changes. Step 1: Select appropriate Test Method (1-6) for test to be completed. Step 2: Insert the specimen in the machine and move the crosshead to the desired starting position using the JOG toggle switch. Step 3: Place the Indicator Status in READY Mode and tare any residual load by pressing the <ZERO> key. See Section The Indicator Status. Step 4: Push the Start/Home toggle switch to START to begin loading the specimen. Once the load exceeds the THRESHOLD value, the Test Status will change to TESTING and the Sample Break detector is armed. This can be observed by watching the Indicator Status change from "RT or RL" to TT or TL. Step 5: Once the end of test condition is detected, the test is complete and the Test Status will change to DONE ("D" will appear in the display). If Auto Store is turned ON, the results will be saved to memory and/or printed automatically. If Auto Store is turned OFF, press <STORE> to save the current test results. Note: If AUTOSTORE is not enabled and you do not press <STORE> before pressing <ZERO> the test results will be lost. To continue running tests, repeat Steps The Indicator Status Indicator Status: The two letters in the lower left hand side of the display. 1 st Letter Values: 2 nd Letter Values: D P R A T B X H C S st Letter (Test Status) 2 nd Letter (Servo Status) D=Done P=Pre Function R=Ready A=Segment A T=Testing B=Segment B X=Buffer Full H=Moving Home C=Calculating S=Stop +=Jogging Up -=Jogging Down 22

25 5.4 TEST REPORTS GENERATED FROM STORED DATA If the steps in Section 5.3 were followed, a test report containing all of the results stored to memory can be obtained. Step 1: Press <PRINT> from the Indicating Screen. Step 2: Ensure cables are connected as described in Section 3 and you have also initiated upload from Wincom/Wincom Plus and Baud Rate is same on controller and Wincom/Wincom Plus. Step 3: Press the <3> numeric key (Stored Res) to send tabled results to RS232 port 5.5 EXPORT X-Y DATA If the steps in Section 5.3 were followed, an output containing the X-Y data from the test run can be obtained. Step 1: Press <PRINT> from the Indicating Screen. Step 2: Ensure cables are connected as described in Section 3 and you have also initiated upload from Wincom/Wincom Plus and Baud Rate is same on controller and Wincom/Wincom Plus. Step 3: Press the <2> numeric key (XY Data) to export XY data to RS232 port. Note: Data is transferred over an RS232 port. RS232 is specified for transfer distances up to approximately 50ft. Cable runs over 200 ft. have been installed and have worked successfully. Much of this is dependent on the equipment's environment. 23

26 6 CALIBRATION 24 Calibration of the Test System is the responsibility of the end user. The Q System has been constructed with great care. Proper handling of equipment should maintain calibration over the life of the equipment. Some adjustment of the calibration may be needed at intervals defined by the user based on the needs of the user. Load cells for the 100 Series controller contain all the calibration data. With the power off, disconnect the load cells and reconnect the new load cell. Power ON the system and confirm load readings before beginning the testing protocol. 6.1 FORCE CALIBRATION VERIFICATION The following procedure is based on ASTM E-4. Load cells carry calibration data within each configuration. Changing of load cells will reset the calibration data to match the load cell connected. Industry standard is tension positive. A 50 lb calibration kit is available from the factory. Please contact us for more information. Other solutions are available on request. Equipment Needed: 3/16 hex key, compression platen, compression base, calibrated dead weights or appropriate test frame and reference cell. Step 1. Turn on the 100 series system and allow it to run for 10 minutes before calibrating. Step 2. Compression Calibration: Remove the load cell from the upper crosshead and attach to the compression base. Mount the compression platen to the post adapter. Tension Calibration: Remove the load cell from the upper crosshead and attach appropriate support and grip to perform dead weight calibration. If an independent reference cell is being used for calibration, a separate load frame may be required. Consult the factory. Step 3. Zero the reading and physically add weights on to the platen at values of 20, 40, 60, 80, and ~95% of full scale. (For a 50 lb full scale that would be 10, 20, 30, 40, 48 lbs) and record the Live load reading from the display. Step 4. If all values are within 1% of reading, then no adjustment is necessary. Repeat Step 3 above to record and verify the first set of numbers is consistent. Step 5. If any values in Step 3 and Step 4 are out of tolerance and not due to operator bias, proceed to Step 6. Step 6. Press <Utils> from the Indicating Screen. Step 7. Press <7> to enter the load calibration function. Step 8. Enter the password. Call your equipment manufacturer if you have lost the password. Step 9. Press <1> to enter load cell calibration Step 10. Input the Full Scale Range of load cell or desired range, the capacity of the machine, or accept the range supplied. The range should be input in the currently active engineering units. Step 11. Change the Shunt value by % error in reading. Step 12. Input the resolution or minimum load increment. (0.01 or appropriate) Step 13. Input Serial Number of the Load Cell DONE! READY TO VERIFY CALIBRATION by repeating Step 3

27 Step 14. After successful calibration, print out the cal report to printer and store with calibration data. Step 15. Turn off Supervisor Mode and return to desired test. 6.2 DETAILED DISPLACEMENT CALIBRATION Adjustment is able to be made to the displacement transducer. Typically there is little need to perform field adjustment. Equipment Needed: calibrated rule or dial indicator Step 1. Step 2. Step 3. Step 4. Step 5. Step 6. Step 7. Step 8. Turn on the 100 series system and allow it to run for 10 minutes before calibrating. Attach a calibrated rule vertically next to the crosshead. A dial indicator may be used instead. Adjust the jog speed in the setup menu to be relatively slow, 2 to 5 inches per minute and set the desired units to match the standard being used. Using the jog switch, move the crosshead a particular reference point on the rule like 12 inches. Press <Zero> to zero out the live readings. Move the crosshead a fixed amount (0.5, 1.0, 5.0, or 10.0) and measure the corresponding displacement. Other displacement values can be taken based on the end users need. If error in reading is less than 1% along the full range of desired displacement, unit is acceptable. Repeat the above step twice for repeatability If the error is greater than 1% along the full range of desired displacement, multiply the current pulses per unit amount by 100% + % error. Repeat as needed. 6.3 DETAILED SPEED CALIBRATION Control of the speed of movement can be adjusted slightly by adjusting the PID parameters for position. No adjustment from factory settings should be made unless required in order to meet the needs of your specific application. Adjustment of these parameters typically affects how quickly the machine responds to a change in velocity. Equipment Needed: calibrated rule or dial indicator, calibrated stop watch or timer. Step 1. Step 2. Step 3. Step 4. Step 5. Turn on the 100 series system and allow it to run for 10 minutes before calibrating. Attach a calibrated rule vertically next to the crosshead. Adjust the jog speed in the setup menu to be a desired speed of interest. Using the jog switch, move the crosshead a particular reference point on the rule like 12 inches. Press <Zero> to zero out the live readings. 25

28 Step 6. Step 7. Step 8. Move the crosshead a fixed amount (1.0, 5.0, or 10.0 depending on the rate setting) and measure the corresponding displacement and time. Other displacement values can be taken based on the end users need. Divide the displacement by the time recorded and verify this against the rate set. For faster rate settings, longer crosshead displacements are required to compensate for human bias of starting and stopping of the timer. 6.4 PROBLEMS WITH THE CALIBRATION The calibration will have to be repeated if there is a mistake (i.e. incorrect number input) made during the measurement mode. Contact the factory if any of the voltage readings exceed the capacity of the indicator. 6.5 WHAT OCCURS DURING LOAD CALIBRATION The calibration slope is defined by the entered shunt value to set a two point calibration. Verification is used throughout the range of interest to confirm measured readings match standard and traceable weights. 26

29 7 TEST SYSTEMS Each 100 Series P/Q System is a digital DC servo-controlled electromechanical test system for universal mechanical testing applications such as tensile and compression testing. The system features a mechanical load frame and a load cell sized to produce loads to the users test requirements. The system can be calibrated from the full load cell capacity down to as low as 0.25% of cell range and still produce test data matching ASTM E4 specifications for accuracy. Each system is uniquely configured to match specific client requirements, even though major components are standard. The 100 series is part of a family of next generation test machines designed and manufactured by TestResources Inc. for tension and compression testing. The 100 P/Q features high resolution, high accuracy, and large data storage capability and is designed for high reliability and ease-of-use. 7.1 P/Q STANDALONE STANDARD FEATURES Indicate Live Load, Max Load, and Load Rate and other selected analysis. Select engineering units of Lb, N, Kgf, gf, ozf, KN, mn, in, cm, or mm. Display resolution up to on Position and on Load. Store up to 50 test results per profile (300 total records) to permanent memory. Results include Date, Time, Specimen ID#, Max Load, Avg Load, Displacement at Break (Dsp@Brk), and a statistical summary of the data. Generate a hardcopy printout of the results. Calibration accuracy exceeds ASTM E4 standards and in general is greater than 0.5% from 1% to 100% of full scale. Activate Auto-Store to automatically store the results of each test. Activate Auto-Print to automatically print the results of each test. Define and detect the end of test with the Sample Break Detector. Provide average load over predetermined length of the test. Supervisor Mode prevents changing of test parameters. Download stored test results to a remote computer through the RS-232 port. The data can be transmitted and then exported in ASCII delimited format for easy import into many common spreadsheet and database programs such as Microsoft Excel. (additional software required) 7.2 ADDITIONAL Q FEATURES OR OPTIONS Machine can be controlled to a static load or position and hold. Six discrete test profiles to readily transition between different test needs. Download up to data points consisting of time, position, and force after each run to a remote computer through the RS-232 port. Data acquisition rate is user selectable from 0.12 to Hz. Enhanced analysis options, such as peak stress, displacement at break, stiffness, energy, free height. Cycle between Test sequences Remote Home Switch (additional hardware required) 27

30 7.3 INTERFACE P/Q controllers are standalone systems with LCD display, keypad, and operation switches. The P/Q controller is an intelligent device with local firmware, signal conditioning for transducers. The controller provides an analog command signal to the power amplifier, which drives the DC motor. It also interfaces to the encoder, system interlocks and transducers. Each enclosure includes a control console with the following operator buttons and switches: System ON System OFF Jog Head UP Jog Head DOWN START Test Return moving actuator to HOME EMERGENCY STOP LCD 4 line Display Durable overlay keypad 7.4 MECHANICAL FRAME Each test system includes mechanical reaction frame, precision ball-screw drive mechanism, DC servomotor, precision encoder, mechanical limit switches, electronics enclosure and mechanical and electrical interfaces to other components. For the purpose of distinguishing your frame from other models, we include a summary of standard products as of product manual release date contact us for an updated summary listing. Model Maximum Load Capacity Head/Actuator Travel Max Rate of Travel 100X Pounds (1.1 kn) 6 or 12 w/ manual adjustment to 30 25ipm (635mm/min) 100X Pounds (2.2 kn) 6 or 12 w/ manual adjustment to ipm (195 mm/min) 100X Pounds (4.4 kn) 6 or 12 w/ manual adjustment to ipm (55 mm/min) 100X Pounds (4.4kN) 6 or 12 w/ manual adjustment to 30 15ipm (381 mm/min) 100X Pounds (6.2kN) 6 or 12 w/ manual adjustment to ipm (22mm/min) *X controller type: P or Q 7.5 LOAD CELL TestResources load cells are available from 2000 lbs to 0.1 lbs (500 N to 0.5N) load capacity. Optional metric or mechanically overload protected load cells are available. All TestResources load cells meet industry standards. Load cells are readily available for replacement or to expand the measurement capabilities of your test system as your needs change. Please contact TestResources (page 1) for a load cell to fit your requirements. Ordering information is located in table footnotes. Load cells listed are for 100/200 series frames as well as 650/1000 series. Please contact TestResources for replacement models on other frame styles. 28

31 Standard Load Cells: Load Capacity Matching Grip Adapter 2000 Pounds B 1000 Pounds B 500 Pounds B 250 Pounds A 100 Pounds A 50 Pounds A 25 Pounds A 10 Pounds A Order part number: SM-x-294 Where x = load capacity required. A is G adapter; B is G adapter. To use 250 lb capacity load cells on 650/1000 series frames requires additional adapters. Please contact the factory. Overload Protected Load Cells: Load Capacity Matching Grip Adapter 450 Pounds 5X Overload B 225 Pounds 5X Overload B 112 Pounds 5X Overload B 56 Pounds 10X Overload A 22 Pounds 10X Overload A 11 Pounds 10X Overload A 5.6 Pounds 10X Overload A 2.2 Pounds 10X Overload A 1.1 Pounds 10X Overload A Order part number: SMTn-x-294 Where n = 1 for capacities 56 Lbs, n = 2 for capacities 112 Lbs And where x = load capacity required. A is G adapter; B is G adapter. 7.6 GRIP OR TEST FIXTURE Almost 100 different grips and fixtures are displayed for selection and fit for different tests at System-to-Grip Universal Adapters are optional accessories that enable the rapid changeover of different grips and fixtures from test to test. The frame base plate or actuator and load cell come with nominal ¼-28UNF threads that is available for attaching fixtures to. Our adapters follow various industry standards for dimensional consistency. You can probably adapt your existing grips to our frame with the right adapters. 29

32 8 ELECTRICAL/MECHANICAL DATA 8.1 USER CONNECTIONS A B C D ON/OFF Figure 1. User Connections Load Cell Port (A) RS232 Serial Port (B) The RS232 Serial Port is used to download test results to a remote AT compatible computer. This port interfaces with a female DB9 null modem cable/connector. Communication Settings: selectable baud rate, N I/O Connection (C) This connection runs to the actuator to control limits and motor functions Power Input (D) The 100 Series System features a 24VDC, 4A power supply for the control board. This may be used with VAC (3A) power input. Use of transformer other than supplied with machine will void warranty. 30

33 8.1.5 Load Cell and Strain Connections Figure 2. Pin Out on Machine Table 1 Connector Connections Function Pin Comments + Analog excitation 9 5 VDC standard applies to both channels - Analog excitation 10 Analog ground + signal input to controller signal input 1 Ground shield 10 Analog shield connects to Dsub Shell 2 Standard input range up to 4.5 mv/v tie pin 4 to pin 12 Optional input range up to 2.5 mv/v tie pin 3 to pin LOAD CELL REPLACEMENT 100 series systems normally are supplied with load cells that have a nominal output of 3 mv / V. In that case, we include a short jumper cable tying pin 4 to pin 12. If the replacement cell has different output sensitivity, such as 2 mv / V, then the jumper should then be changed to tie pin 3 to pin 12. Factory replacement Load cells come setup to match the configuration for your machine. Please include your serial number with your order. Ed. Note These are standard settings. Please contact Factory if options have been added to your machine. 31

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35 APPENDIX A Glossary of Common Materials Testing Terms: Compressive Strength (psi) Maximum Compressive Stress. Elongation (%) The increase in gage length divided by the original gage length. Extensometer A device for measuring linear Strain. Gage Length (in) The original length of that portion of the specimen over which Strain or change of length is determined. Modulus of Elasticity The slope of the Stress-Strain curve in the elastic region. Proportional Limit (psi) The greatest Stress the material is capable of sustaining without any deviation from proportionality of Stress to Strain. The end of the elastic region. Strain (in, in/in, %) (also Extension) The change is size, due to force, referred to the original size. Stress (psi) Load (force) divided by original cross sectional area of the specimen. (Engineering Stress) Tensile Strength (psi) Maximum tensile Stress (Peak Load divided by initial Area). Total Elongation (in) The elongation determined after fracture by manually realigning and fitting together of the broken ends of the specimen. Yield Point (psi) Stress value where Strain increases in a non-linear relationship with an increase in Stress. 33

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37 APPENDIX B Q CONTROLLER: Glossary of Common Materials Testing Terms: Max Load Greatest Load during test. Max Ld/Width Peak Load over a user-specified width. Max Stress Peak Load divided by specimen area. Min Load Smallest Load during test. AVG Ld1<>Disp Average Load over a certain displacement window. AVG Ld2@Ld-Dp Average Load at a specified load. Load At Break The Load at Break. Disp At Break The Displacement at Break. Load At Disp The Load at a user-defined Displacement. Disp At Load The Displacement at a user-defined Load. Stiffness (lbf/in) Sample stiffness calculation based upon user-defined displacements. Energy<>Disp Area beneath force displacement curve between two specified displacements Free Height Cross head position at threshold relative to ABS zero Percent Elongation The elongation of the test specimen expressed as a percentage of the gage length. Static Us Static coefficient of friction Kinetic Uk Kinetic coefficient of friction Shear Modulus The ratio of shearing stress to shearing strain within the proportional limit of the material. Load1@Pct1 Specify a position percentage (of gage length) offset and the software reports the corresponding load point on the curve. 35

38 Specify a position percentage (of gage length) offset and the software reports the corresponding load point on the curve. Load3@Pct3 Specify a position percentage (of gage length) offset and the software reports the corresponding load point on the curve. Pct1@Load1 Specify a load value and the software reports the corresponding position percentage ((of gage length)) offset on the curve. Pct2@Load2 Specify a load value and the software reports the corresponding position percentage ((of gage length)) offset on the curve. Pct3@Load3 Specify a load value and the software reports the corresponding position percentage ((of gage length)) offset on the curve. 36

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40 APPENDIX C Trouble Shooting and Preventative Maintenance: Status Message Over Range Positive/Negative Limit exceeded No Power or Machine will not turn on Symptom Possible Cause Action - Load reading saturated at full scale - No change in force on load cell with no load - only one direction of jog switch works - only one direction of jog switch works - test stops prior to completion - Machine will not power on - load cell disconnected - Load Cell has been Overloaded 1 - Travel of machine at maximum - Test reached maximum load/strain as set by calibration - Connect Load cell - Replace Load cell - Manually jog away from limit switch - Verify maximum range for active channel in calibration area - No Power to machine - Verify connection to - Fuse blown 2 proper power source - Check and replace fuse 2 ESTOP - Machine is frozen - E-Stop button is - Release E-Stop button pressed 1) If the load cell has been overloaded, mechanical damage has been done that is not repairable, because overloading results in permanent deformation within the flexural element and gages, destroying the carefully balanced processing that results in performance to specifications. 2) There is an internal fuse to protect the controller. If you need to replace the fuse, please contact Test Resources. Preventative Maintenance: The equipment you have as been designed to provide many years of service. On occasion, some items will need attention to ensure proper operation. Depending on the environment and testing conditions, most maintenance can be verified at the time of calibration. For more information, contact the factory. Remove debris from the 100P/Q actuator and add white lithium grease as necessary. A soft cloth should be used to remove debris and material from the surface of the equipment. The unit is not water tight. Avoid spraying or spills onto the test frame and/or control box. Promptly remove liquid from surfaces. 38

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42 APPENDIX D Factory Password: Factory Password: 268 Supervisor Password: 157 Suggestion: Remove this page from the manual and place it in a secure place. 40

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44 APPENDIX E Additional Project Information: 42

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