U-Series Instruction Manual 820-7001_15Issue_03

TINIUS OLSEN LTDH150KU Tensile Test Machine Instructions For Use Doc. Ref. 820-7001_15 Issue 03 Unit 6 Perrywood Business Park, Honeycrock Lane, Salfords, Surrey, RH1 5DZ, England, UK Telephone: +44 1737 765001 Facsimile: +44 1737 764768 Website: www.tiniusolsen.com © Tinius Olsen Ltd 820-7001_15 – Issue 3 Contents 1. 1.1. 1.2. 2. 2.1. 2.2. 3. 3.1. 3.2. 3.3. 3.4. 3.5. 3.6. 3.7. 3.8. 3.9. 3.10. 3.11. 3.12. 4. 4.1. 4.2. 4.3. 4.4. 4.5. 4.6. 4.7. 5. 6. 6.1. 6.2. 7. 7.1. 7.2. 7.3. 7.4. 7.5. 7.6. 8. 8.1. 9. 9.1. 9.2. 9.3. 10. 10.1. 10.2. 11. 12. 12.1. 12.2. 12.3. 13. 14. 14.1. Introduction...................................................................................................................................2 Preface .......................................................................................................................................2 Overview ....................................................................................................................................2 Major Options................................................................................................................................3 Strain (Aux.) Display Option(s)...................................................................................................3 Navigator ....................................................................................................................................3 Specifications ...............................................................................................................................4 Load Frame ................................................................................................................................4 Control System...........................................................................................................................4 Force Measurement ...................................................................................................................4 Extension Measurement ............................................................................................................4 Speed Control ............................................................................................................................4 Hardware Options ......................................................................................................................5 Dimensions.................................................................................................................................5 Weight ........................................................................................................................................5 Power Supply .............................................................................................................................5 Environmental ............................................................................................................................5 CE Markings...............................................................................................................................5 Manufacturer ..............................................................................................................................5 Installation.....................................................................................................................................6 Inspection ...................................................................................................................................6 Contents .....................................................................................................................................6 Location ......................................................................................................................................7 Connection to Power Supply......................................................................................................8 Load Cell ..................................................................................................................................10 Connection to a PC ..................................................................................................................11 Connection to auxiliary equipment (optional) ...........................................................................12 Checks before powering up ......................................................................................................13 Power on......................................................................................................................................14 Turn the machine On................................................................................................................14 Check Machine Operation........................................................................................................15 Operation.....................................................................................................................................17 Handset ....................................................................................................................................17 Handset Functions ...................................................................................................................19 Special Key Functions..............................................................................................................21 Machine Protection...................................................................................................................21 Typical Settings ........................................................................................................................23 Replacing Loadcells .................................................................................................................24 Tooling.........................................................................................................................................25 Attaching to the Machine..........................................................................................................25 Conducting a test .......................................................................................................................28 Basic Operation........................................................................................................................28 Testing Using The Handset......................................................................................................28 Testing Using Optional Software..............................................................................................30 Safety ...........................................................................................................................................31 Warnings ..................................................................................................................................31 Protective Screens ...................................................................................................................32 Training........................................................................................................................................33 Maintenance ................................................................................................................................34 Electrical ...................................................................................................................................34 Calibration ................................................................................................................................34 Lubrication................................................................................................................................34 Storage ........................................................................................................................................35 Appendix .....................................................................................................................................36 Dimensions...............................................................................................................................36 © Tinius Olsen Ltd 820-7001_15 – Issue 3 Page 1 Introduction 1. Tinius Olsen Ltd maintains a Calibration and Service Department. such as Extensometers. A Calibration Certificate and Test Report are supplied for each Load Cell and Instrument provided with the machine. Questions that arise should be directed to Tinius Olsen or its authorised representative. There may be aspects of material testing not covered in this operation manual in particular the type of grips used and additional optional equipment. as required. Re-calibration of the machine and instruments should be performed after installation and regularly at yearly intervals or as required. measured by a strain gauge load cell and conditioner module (typically allocated to channel 1).1. The second line will show the crosshead position. measured by an incremental encoder and its conditioner module (allocated to channel 2). Complete information on this service can be provided by our Service Department or our authorized representative upon request 1. The H150KU machines cater for capacities of up to 150. Preface The purpose of this manual is to provide the user with sufficient information for installation. At a nominal cost to the customer. can be provided. Therefore. easy-to-use software packages are ideal for determining the mechanical and physical properties of materials in Tension. operation. © Tinius Olsen Ltd 820-7001_15 – Issue 3 Page 2 . Such a device may be used to measure strain (extensometer) or deflection (deflectometer) in the specimen. 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. The first line of the 602 main display on the handheld will show the Force. care and maintenance of this test machine and its accessories. periodic calibration and servicing.1.2. The H150KU testing machines with their versatile. accurate and convenient operation in the testing of various types of specimens. Flexure and Shear.000N utilising a twin screw arrangement for high capacity. it is recommended that the entire manual be read and understood before working with the machine. See the accessory instructions provided for these options. Compression. Many other physical properties may also be investigated. 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. headings. A suitable computer and or adaptor is available from Tinius Olsen. 2. control the speed of the machine. Navigator The software will control all the 602 Display settings. Major Options 2. simple results. Plus Version where the user can create their own reports.2. and the operator can either reject or save the Test Results along with the Curve (Data Points). etc. However. Test Lite also includes the (password protected) Calibration program necessary to configure and calibrate the machine. etc. please ensure that it meets the minimum system requirements as stated in the quote for the software. When provided with an optional Printer.1. a USB port may be used in conjunction with an adaptor. and return the crosshead to its Start Test Position The Software will plot the test on the computer display.) 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. In addition. For customers intending to supply their own computer. This data can then be printed or exported at the user’s discretion. The software can start the test. Please note that Test Lite does not calculate any test results.2. A simplified version of Test Lite is provided with the Navigator Software for operating the machine remotely. Strain (Aux. the user can edit the formulas used for any customer defined results and expanded Import capability. headings. it will report maximum values and dimensions can be entered for flat or round specimens and report Stress units. simple results. © Tinius Olsen Ltd 820-7001_15 – Issue 3 Page 3 . or other auxiliary devices. A printout of the Results and Curve can be made after a test and/or recalled later. Standard Version where the user can edit or create reports. The Navigator software comes in three levels:• • • StanPac Version where the user must pick from a set of reports that cannot be changed. Should an RS232 port not be available. perform the calculations. Other options with the software include interfacing Digital Micrometers or Callipers. the printed curves can also be used to calculate results not reported by the software and multiple tests can be printed on one chart. . NOTE These software packages require the use of a Windows (NT/2000/XP) computer with a vacant RS232 port. stop the machine after the test. FS Digital Load Tear ±20% whilst maintaining full load cell capacity 3.000 for +/. Control System 602 Remote Handset 3.5% 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. Extension Measurement Extension Measurement by Precision optical encoder or optional external extensometer.01mm/300mm 3. Force sampling rate typically 100 Samples/Second (Up to approx.5.2. DIN 51221.09x FS Load (N). Specifications 3. Load Frame Designation Capacity Style Max Crosshead Travel Max Specimen Diameter Frame Stiffness Construction U Series 150kN (15.5% of full speed Drive system:.3. 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. and Temperature © Tinius Olsen Ltd 820-7001_15 – Issue 3 Page 4 .Brushless Servo Motor Automatic Over/Under Speed Alarms Motor Drive Alarms on Under/Over Voltage.4.01 mm/min to 700 mm/min Speed Velocity Programmable in 0.0001mm Accuracy 0. Force Measurement Load Cell – Shear Web Type Conforms to EN10002.01 mm/min to 500 mm/min Return Speed 0.000kg) 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 3.3.01 mm/min steps Speed accuracy ±0. Current. ISO 75001 Range 2% to 100% with Guaranteed Accuracy of 0. ASTM E4.1. 350 samples/sec possible with 2 channels and high speed computer running appropriate software) Load cell resolution 1 part 130. Single measurement range 0 to 1200mm Resolution 0. and conforms to the following specification. Hardware Options 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 3.290 Kg Including Packaging 3. Environmental Temperature Humidity Operating 0°C to 38°C Storage 10% to 90% Non-Condensing Wet Bulb Method 3.135 700 Inch 97 44. and conforms to the following Generic EMC specification for Commercial and Light Industrial products. Manufacturer Tinius Olsen Ltd 6 Perrywood Business Park Honeycrock Lane Salfords Redhill Surrey RH1 5DZ England © Tinius Olsen Ltd 820-7001_15 – Issue 3 Page 5 .10. EN 61010-1 (Safety requirements for Measurement. CE Markings EMC Directive 89/336/EEC.3. Power Supply 3 Phase 415+/-10% VAC 3.8. Control and Laboratory use) 3.11.12.035 Kg 1. Dimensions Height Width Depth mm 2.5 3.465 1.6.75 27.7. Emissions EN 50081-1 Immunity EN 50082-1 Low Voltage Safety Directive 73/23/EEC. Weight 1.9. 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 4. 4. H150KU Testing Machine 4.2.2. 4. Installation 4. other sizes & types may be specified 4. thoroughly check the machine controls for any damage. Grip Pin (Optional) 2 off supplied Pins to suit nose pieces specified 4. Contents The machines are shipped completely assembled except for the optional accessories .2. Manual Operating instruction manual and load cell calibration certificate © Tinius Olsen Ltd 820-7001_15 – Issue 3 Page 6 . 4.2. please ensure that these are included for the installation.2. Loadcell Bolt (Optional) Bolt with hexagonal head (41mm A/F) for securing the loadcell to the crosshead. 4.2. Loadcell (Optional) This will normally be of a shear web type 150kN.2.1. Inspection After unpacking.2.6.7.4.4. PC Connection Lead D type 9 way socket RS232 Serial Port Lead for external computer control.1.2.5. The basic machines are supplied with the following items.3. When moving the machine with a forklift truck. 30A Peak 415 V +/-10% (374 – 456) 50/60Hz © Tinius Olsen Ltd 820-7001_15 – Issue 3 Page 7 . Location 4. If this is not available. Moving the Machine The machine will require a forklift truck or similar to move it. Levelling The machine is designed to be placed on a flat level floor.3. Other Parts Additional parts may be supplied.2. which are not listed above and will depend on the system configuration. 4. this is normally:15 Amp Cont.2. Power Supply The machine requires to be hard wired to a suitable 3 phase supply. 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.3.1.8. Level the machine by screwing an M20 screw into the jacking screw holes and then insert packing material between the feet and the floor. place protective materials (rubber sheet or cardboard) on the forks and lift the machine from the underside of the cross head 4. See Appendix for bolt dimensions and positions 4.3.3. jacking screw points are provided located at each corner.4.3. These recommendations should be followed to avoid nuisance tripping.4.2.4. this plate can be drilled to suit the required gland or conduit fitting. 4. It must also meet IEC 60947-1 and IEC 60947-3 standards. © Tinius Olsen Ltd 820-7001_15 – Issue 3 Page 8 . Recommended circuit breakers would be ones that are of the thermal magnetic type with characteristics suitable for large inductive loads (D-type trip characteristic). 4.1.4. Under no circumstance must the machine be operated without an earth connection 4. The machine must be earthed. Cable Entry A blanking plate is fitted to the side of the machine adjacent to the circuit breakers. 4. the earth wire must be of the same size or greater. 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. Electrical Disconnect The electrical box must have a power disconnect switch that is easy to operate and easy to reach.3mm ). The minimum wire gauge for the H150KU is 12 AWG (3. If fuses are used it is recommended that they are of the time delay type with dual elements.4.3. Cable Size The machine will require either a 4 core cable (3 power 1 earth) or individual cables 2 running in a trunking.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. 4. Connections Before the cables can be attached to the machine the gland plate.4. rear panel and MCB shield must first be removed.4. Rear Panel MCB Shield Gland Plate The cables must be connected as follows L1 © Tinius Olsen Ltd L2 L3 820-7001_15 – Issue 3 Earth Page 9 . 1. 820-7001_15 – Issue 3 Page 10 . Strain modules hold identification & calibration information and are not interchangeable.When connecting the earth.5.5. Connect the round connector into the socket on the loadcell and twist to tighten.Before mounting any load cell to the crosshead.5. always check to ensure that the contact surfaces are clean Loadcell Bolt Crosshead RJ45 Connector Loadcell 4. Place the mounting bolt through crosshead and lift the loadcell into position. Hold load cell in position ensuring it is parallel to the crosshead then fully tighten with a suitable spanner. 4. Each loadcell is supplied with a strain module. • • • © Tinius Olsen Ltd 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. ensure all covers are re-fitted 4. Assistance may be required to lift the loadcell 4.4. Re Fit Panels IMPORTANT . WARNING – High capacity loadcells are heavy.2. this module must be used with the supplied loadcell. Screw the bolt into the load cell. NOTE .5.Before applying power to the machine. Load Cell The load cell is fixed to the underside of the crosshead using the bolt supplied. ensure that the both the first nut and lock nut are fully tightened. 6. ensure that both Testing Machine and PC computer are SWITCHED OFF. NOTE . 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. The RS-232 Port is located on the right hand side of the machine towards the rear. this connection allows the computer to communicate with the testing machine’s internal electronics. © Tinius Olsen Ltd 820-7001_15 – Issue 3 Page 11 . Simply align the 9 way D type cable socket connectors to its mating plug on the machine.RJ45 Connector Strain Module 4.1.Only use the cable supplied with the machine 4. taking care not to bend any pins. Before attempting to connect the RS-232 Serial cable.6. Connection to a PC The machine is connected to a PC using the supplied D type 9 way RS-232 Serial cable. Connect the coiled lead between the handset and machine. The handset rests on the bracket at the front of the machine.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. If your computer does not have a vacant RS-232 port a USB port may be used in conjunction with an adaptor.RS-232 Port 4.7. 4.2. 4.6.3.7.6.3. 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.1. Mechanical attachment methods vary according to the type of auxiliary equipment.7. © Tinius Olsen Ltd 820-7001_15 – Issue 3 Page 12 . A suitable adaptor is available from Tinius Olsen. NOTE – Only use the module supplied with the auxiliary equipment as this contains identification & calibration data. the RJ11 connector is the uppermost connector on the side of the machine near to the RS-232 Serial Port. Connection to auxiliary equipment (optional) 4. The method is the same as used on the machine by aligning the 9 way D-type connectors then tighten the two jack screws.2. into a vacant slot above the RS-232 port and plug the attached RJ45 connector from the module into its adjacent socket. supplied with the equipment. 4. these instructions will be supplied with the equipment.7. Auxiliary equipment (extensometers etc) suitable for use with this machine are available from Tinius Olsen. WARNING . To connect the equipment to the control system. slide the interface module. If the switch had been previously activated. NOTE – There are 2 breakers. • 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. 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 no upwards movement is felt the switch is already in its normal position © Tinius Olsen Ltd 820-7001_15 – Issue 3 Page 13 . on rotation the top will spring upwards. one 3 pole (3 phase supply) and one 2 pole (internal power supply) See below for location of Circuit Breakers. • The power supply is attached and switched on. Circuit Breakers (shown in “on” position) • The E-stop button is released. Checks before powering up Before powering up the machine ensure the following:• The handset is plugged in.5. Power on 6.6. 6.Power will be removed from the motor drive during the reading process.1. the remote terminal should boot up after 10 .1.1. 6. these will be:• Force Xducer on line 1 • Position Xducer on line 2 • Aux Xducer (if fitted) on line 3. the 602 will not be able to read in that module until exiting the Menu section Typical Boot up sequence is shown below © Tinius Olsen Ltd Handset Boot Up Screen 1 Handset Boot Up Screen 2 Handset Boot Up Screen 3 Machine Ready 820-7001_15 – Issue 3 Page 14 . Installed Version Number Firmware version and serial number are displayed. and return to the main screen.20 seconds. 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. Transducer details The display will indicate the attached conditioner modules. Whenever power is first applied to the 602 System. NOTE . If any new modules are connected while the 602 is displaying one of the Menu Screens. the 602 system will recognize this and read in the data from the new module.1.2. If any of these modules are removed or replaced while the 602 system is displaying the main screen. the handset display will show the following information. Return Motor Enable Up Motor Enable Stop Down Handset Controls 6. Or press the Lo Cl key once to activate. The motor drive will be disabled when neither Hi nor Low is selected. pressing the button a second time will move the crosshead at the second set speed.2. Enable drive To enable the motor drive you must first select either the [Hi Cl] or [Lo Cl] keys.6. Hi or Low will appear in the corner of the display Pressing the button a second time will disable the motor drive. again to deactivate it. 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 0.2. the crosshead will not move unless the motor drive is enabled. NOTE . • © Tinius Olsen Ltd 820-7001_15 – Issue 3 Page 15 .2. 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. to enable or disable the motor drive the keys “HI CL” or “LO CL” are used.1. Press the Hi Cl key once to activate it.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.Hi Cl and Lo Cl perform the same function on this machine. Check Machine Operation The machine powers up in “IDLE” mode. again to deactivate it. 6.2. If it is not possible to move the block away from the crosshead then the “interlock override” function must be used. The alarm can be cleared by backing the crosshead off in the opposite direction to reduce © Tinius Olsen Ltd 820-7001_15 – Issue 3 Page 16 . NOTE – If the crosshead is allowed to contact the alarm block.2. Load cell Press the “ZERO FORCE” key to zero the force displayed on the handset With the crosshead stationary. If no upwards movement is felt the switch is already in its normal position. the machine should stop Release Upper Limit Switch. This system should not be relied on to protect the machine or operator. in this case in order to restart the machine.5) 6. IMPORTANT – if the machine fails to stop when the limit alarm is tested DO NOT use the machine until the problem has been remedied. release and move the block away from the crosshead.2.4.6. 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. When the loadcell is pulled down.4. to reset the switch. the machine should stop.2. Overload alarm A load limit alarm is flagged when the machine or load cell capacity is exceeded either in tension or compression. 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. the machine will stop.2. Next run the crosshead downwards and pull the alarm rod down. IMPORTANT – to prevent damage to the loadcell when using low capacity loadcells do not use excessive force. The button will remain down after being released. rotate the top part of the switch clockwise (direction shown by arrows on top of switch). If a 100KN load cell is fitted the alarm would be triggered at 109kN in tension or compression.5. on rotation the top will spring upwards. slide limit switch to crosshead striker. Emergency Stop Pressing the emergency stop button (located on the front panel) will immediately stop the machine and disable the drive. 6.3. run the crosshead upwards then pull the alarm rod up. re-tighten. E. pull down and push up the underside of the load cell and check the force display on the handset. The value of the alarm depends upon the load cell fitted and is approximately 9% greater than load cell capacity. The alarm is indicated by the flashing load and position indication on the handset. (See 7.g. To confirm function of the limit switch. re-tighten Release Lower Limit Switch.6. the load should be positive When the loadcell is pushed up. move crosshead to new position. as the machine’s ability to stop prior to damage is greatly reduced at high crosshead speeds. the load should be negative. 6. move crosshead to new position. slide limit switch to crosshead striker. The Peak Hold and Sample Break (if selected) will only work in the Test mode © Tinius Olsen Ltd 820-7001_15 – Issue 3 Page 17 . The second to last line will show “SBD” on the left if the Sample Break is “ON”. select the drive by pressing either Hi or Low Clutch and then press Stop (Hold). The third line may be blank or it may display the reading from an Auxiliary device like an extensometer or deflectomer. this will be “IDLE” when the system is first booted or when leaving a Menu screen. Operation 7. “HOLD” when the [Stop ] key is pressed. “READY” once the [Test/Clear] key is pressed. If the 602 is not running a test then pressing Up or Down will show on the last line. The right side of the last line will show the speed setting or current speed during a test. and an Error message when an error is detected. in conjunction with the appropriate module. Handset The handset will always show Force on the top line of the main display. “TEST” while a test is running. “HI” or “LOW” in the middle to show which Clutch Range is selected. It comes from an incremental encoder and its conditioner module (channel 2).the applied force using the “interlock override” function (See 7. Tinius Olsen supplies LVDT and strain gage based strain devices which. If the alarm persists it is possible that the load cell has been damaged. 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.4. This reading comes from a strain gage load cell and its conditioner module (typically channel 1). The second line indicates crosshead position. Then press Test/Clear (status shows Ready) and then press either Up or Down to start the crosshead moving and begin the Test. may be selected The bottom two lines will display “Status” information. The user is able to set a lower load limit if desired 7.1.5). and “PK=” on the right if Peak Hold (for Force) is on. Before testing. The last line will show the current mode of operation on the left. 1. 2. POSITION & DAC Limits can be displayed and edited. 1. DAC Test – This screen will allow the operator to select certain DAC output levels for testing the DAC Signal. 5. Position. 602 Display Main Menu Selections 7. CPU – This will bring up the Title Screen with the 602 Version. 4. Language – The operator will be able to choose the language for the Menu Screens. Auxiliary – The operator can select which module to direct to the Auxiliary Display. Power must be removed to get off this screen.1. Refresh – *- 1. The 602 will re-boot after exiting. Auxiliary Channel & Speed Units can be changed. This will refresh the 602 display. “OFF” or set to a 10 minute timed delay. 3. 4. 3. 5. 6. Return Speed & Proportional Gains can be displayed and edited. Sample Break Detect – The Sample Break Detector is set to Stop/Return on Break or is turned “OFF”. Units – The Force. Threshold and the HOLD Gains can be displayed and edited. Handset Menu Page 18 . Additional – Sets the Hold Rate & Sampling Rate. 2.1. Backlight – The 602 Display Backlight can be turned “ON”. Machine Control – Speeds – The two Test Speed Settings. Display – The Stop key is used as an [Enter] key when on a Menu Screen. 3. Position & Aux. Peakhold – The 602 Force Peak Hold Function can be turned “ON” or “OFF”. Protected* – 5. 4. Lock/Unlock – This will lock and unlock the 602 Machine Control & Configuration Menus. Position – The operator can select which position transducer to direct to the Position Display. 1. Contrast – The contrast of the 602 Display can be adjusted from 1 – 16. 3. 2. 2. Force – The operator can select which force transducer to direct to the main Force Display. Sample Break Set – The Force Start Load (%fs) & Dropoff (%pk) are set for the Sample Break Detector. 5. 2. This is only needed for older handsets 3. 4. Filter – This will display the Bandwidth & Delta settings for the three 602 Display Channels – Force. Position Control – The HOME Position. Bootloader – This is used when flashing a program into the 602 CPU. A general Passcode (602602) is needed to enter the Protected Menu Selections. Limits – The FORCE. Configuration – 4. Interlock – This will bring up a Screen on a Mechanical Machine to override the Crosshead Limit Switches.© Tinius Olsen Ltd 820-7001_15 – Issue 3 1. the 602 will switch to a HOLD Segment as set up on the Position Control Menu 1-2.] key will zero the position reading on the second line. The zero keys WILL WORK during a test but SHOULD NOT BE USED unless intended. As the crosshead approaches the threshold value. This key can be pressed at anytime.2.2. From this menu. The transducer should then be checked and/or adjusted.2. This is also the [8] key when using the Menu Screens © Tinius Olsen Ltd 820-7001_15 – Issue 3 Page 19 .3. This should be zeroed when the crosshead is at the “Start Test” position. if a test is being conducted. If the transducer is mechanically so far off zero that it cannot be electrically zeroed. Pressing the [Zero Pos. Return Crosshead Key Pressing the [Return

] key will activate the return function of the 602 system. 7.7. Drive Enable or Pressing the [HI CL] or [LO CL] will ready the motor drive. LVDT Conditioner Modules will zero up to ±50%. once an instruction to move has been given the drive will enable and remain enabled until the button is pressed a second time. it will end the test. the operator can press a number key for one of the choices or press the [Menu] key to exit the menu mode. Zero Channel Keys These function keys are used to zero the three display channels between tests while on the Live Screen. This should be done before inserting the specimen in the grips or holders.4. the crosshead will attempt to return at the Speed set on the Speeds Menu 1-1. Pressing the [Zero Aux. it should be zeroed after clamping it on the specimen just prior to starting a test. When using an extensometer.2. and the "zero" key pressed again. These are also the [4] & [7] keys when using the Menu Screens 7. the display will not change. Strain Gauge Conditioner Modules will zero up to ±20%. As the crosshead is returning. Menu Key Pressing the [Menu] key will bring up the 602 Main Menu Screen. and Encoder Modules will zero any value. Pressing the [Zero Force] key will zero the force reading on the first line.2. Handset Functions 7. Refer to the 602 Instructions provided after this booklet for the Menus and their functions 7.2.] key will zero the reading on the auxiliary line.1. This zero position is where the crosshead will go to when the [Return

] key is pressed. the lower left hand corner of the 602 remote will show “RETURN”. If the crosshead is beyond the threshold value. Pressing one of these keys for any given channel causes the display value for that channel to be automatically zeroed. The bottom status line will show the system in a HOLD Mode while at the home position. the [Stop  ] key will stop the crosshead by immediately executing a Position Hold (as shown on the bottom Status Line) on the current position.2. resets any overload errors and places the display into a "READY" Mode for the next test as shown on the bottom status line. Stop (Hold) Directional Key On the Live Screen.6.7. The [Max. as it will clear those values 7. 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.2.2. This is also the [0] key when on one of the Menu Screens. Pressing the [Test/Clear] key after a test will reset the current maximum values. In the Menu Mode.9.2. it’s the [Enter] key to accept an entry 7. Test / Clear Key Pressing the [Test/Clear] key resets the stored maximum values from the last test. the bottom line of the 602 display will return to the current rate display.8. 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. they will not register as maximum values. Pressing and holding this key will continue to increase the selected speed in greater increments. the crosshead will stop and return a little to the position value at the time the [Stop  ] key was pressed. If higher values are obtained after the test has been ended by the operator pressing the [Stop  ] key or by the Sample Break Detector. 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.] 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. 7.7. if in the “TEST” Mode. This key will also end a test. © Tinius Olsen Ltd 820-7001_15 – Issue 3 Page 20 . This key will not do anything unless the drive is enabled and the 602 display is in the “IDLE” or “HOLD” Mode 7. resets the Sample Break Detector (if enabled).5. After showing the setting change. Do not press this key until the maximum values are recorded for the prior test.2. Max Key The [Max.] key can pressed during a test but will continue to update while pressed.10. This is also the [9] key when using the Menu Screens. 7. Depending on the speed that the crosshead is running. Pressing this same key again will advance the machine to the Speed 2 setting on the Speeds Menu 1-1. Upper Directional Key Pressing the raise [ ] once will start to run the crosshead up at the Speed 1 setting on the Speeds Menu 1-1.2. 3.7. (See 7. When one of the Position Limit Switches is activated. The force display line must first be properly zeroed before reading the cal-check number. 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. Travel Limits Damage to the load cell.12. Machine Protection 7.4. This protects the machine should the encoder be disconnected or faulty. the bottom line of the 602 display will return to the current rate display. This is also the decimal [. zero the Force. After showing the setting change.4.2. 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. The best way to use this function is to let the load cell warm up.The Cal Check number changes if the initial conditions change. This will also disable the motor drive. 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. 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. tooling etc.2. 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. remove any weight such as grips. If the collar cannot be moved anymore.11. then activate the Cal-Check and record this number 7.1. 7. 7.4.2. 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. Pressing [Test/Clear] will clear this condition. Pressing and holding this key will continue to decrease the selected speed in greater increments. This value should not change by more than 1% for any given Load Cell.4. 7. 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. This value is recorded at Calibration and noted on the Report and/or sticker. the 602 display will flash and the proper error message “UprLmt” or “LwrLmt” will be shown in the lower left hand corner. This only works with Strain Gauge Conditioner Modules. NOTE . To clear this alarm.] key when on one of the Menu Screens.5) © Tinius Olsen Ltd 820-7001_15 – Issue 3 Page 21 .3. Special Key Functions. 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. 7. Repeat the key sequence again to deactivate the cal-check. Force Calibration Check Number Pressing the [Menu] key.1. 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”. Should the loadcell be subjected to excessive load. If it not possible to remove the load.5) 7. Operation of Interlock Override To get to the Interlock Override press:• The [Menu] key • The [4] key for the Protected Mode • Type the Passcode (“602602”) • The [1] key for Interlock Override The following menu will display. Use Caution when moving Crosshead. It may be necessary to press [Test/Clear] to clear out the old fault status. Once the crosshead has moved enough to clear the fault position press the [Menu] key to exit back to the live screen. The Positive and Negative Limits must be set for their respective limits. DO NOT MOVE the Crosshead in the same direction as damage will be caused to the loadcell 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. the lower left hand corner of the remote will show “Ovrld”.4.3. 7. Overtravel may also damage the loadcell and tooling.4.4. If the load can be removed or reduced then pressing the [Test/Clear] button will re-set the display. Interlock Override Use up and down arrow Keys to move crosshead. DO NOT MOVE the Crosshead in the same direction as it will go through the limit switch and will damage the Limit Switch Arrangement. the lower left hand corner of the remote will show “Pos”. the crosshead can be backed off using the override feature. Press Menu key to exit. the channel displays will flash and the drive will be disabled.4.4.CAUTION: When using the Interlock Override be sure that the Crosshead is moved in the OPPOSITE direction AWAY from the activated Limit Switch Collar. Loadcell Overload The maximum force limit is 1. Should the limit be exceeded. the display will flash and the drive will be disabled. Should this occur please contact Tinius Olsen for advice before continuing to use the machine. The machine crosshead can be moved back into a valid position by simply re-zeroing the position or using the override feature (See 7.5.09 x FS capacity (N). The user may enter smaller limits if desired. (See 7. © Tinius Olsen Ltd 820-7001_15 – Issue 3 Page 22 . Position Limit The position limit is set using the Menu [1] [3]. this limit is normally set to +/-1199mm. 98 • . Settings highlighted should not be altered under normal circumstances and may be locked on the handset (see Error! Reference source not found.9mm • + DAC +99.Position -1199.4. the handset will typically display the following settings.5. Units [Menu # 2 1] • • • Force Position Speed N mm mm/min 7. Typical Settings When set at the factory.9mm • .25 0 7. Limits [Menu # 1 3] • + Force +150000N * • . 7.2.5 0. 7.DAC -99.01 – 500 mm/min 0.1. Position Control [Menu # 1 2] • • • • Home Threshold Hold P Gain Hold I Gain 0 2 0.3.5.5.5.Force -150000N * • + Position +1199.5.01 – 500 mm/min 0.01 – 750mm/min * 0.5.5.7. [Menu # 4 2]) 7. Speed [Menu # 1 1] • • • • • • Speed 1 Speed 2 Return Speed Gain 1 Gain 2 Gain Return 0.98 (*) Force limit will depend upon loadcell fitted.5 0. Hold / Sample Rate [Menu# 4 1 6] • • © Tinius Olsen Ltd Hold Rate Sample Rate 1000 100 820-7001_15 – Issue 3 Page 23 .25 (*) Max speed will depend upon supply voltage. 6. Setting Force Limits Note that for the Force Limits to apply. If optional software is being used. the [1] key on the Select Channel Menu for “Force”. the [3] key on the Main Menu for “Configuration”. 7. and then [1] on the Xducer Menu for “Select Transducer”.1) With each load cell there must a cable with a Strain Gauge Conditioner Module.3. Selecting Device Once the read in process is done. 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.1.09 x FS capacity (N). DO NOT PLUG ANY NEW MODULES DURING A TEST BECAUSE THE 602 WILL STOP THE DRIVE DURING THE READ IN PROCESS. Replacing Loadcells 7. The 602 will exit back to the live screen. 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. Too many connected devices reduces the bandwidth of the system. check that it is connected correctly. Mount the module onto the crosshead and plug the 8-pin RJ45 jack into the receptacle on the side. If the desired cell is not listed.5. That is because any device with the RJ45 connectors plugged in is considered active by the 602. When a lower capacity load is read into the 602. this can be done by the software settings and the operator doesn’t have to use the 602 menus. The 602 will show a list of any connected “Force” Modules by description.Only modules that are intended to be used should be plugged in to the RJ45 connectors.6. Press the number for the description of the new Load cell to be used. Press the [Zero Force] key to zero the load cell. © Tinius Olsen Ltd 820-7001_15 – Issue 3 Page 24 . then manually push up on the base of the loadcell and check that the Force Display shows an appropriate response. the load cell must be directed to the first (Force) line on the 602. particularly at higher sample rates. NOTE . Fitting To change Load Cells. the operator must direct the new Load cell to the Force Display (top line) by pressing [Menu].6. It is recommended that the total number of connected devices be limited to 3 or 4 7.7.6. the primary load cell must be removed and the new Load Cell mounted (See 4.2. the Force Limit Settings will be rewritten 1. Now rotate the fixing locking collar clockwise until it makes contact with load cell.7mm) 16mm 20mm 24mm The attachment fixing threads range from M6 to M42.1. this will require a M33 fixing thread tooling attachment.4.05mm) 30mm 40mm 50mm 60mm 5/16 inch (7. The parallel section includes a hole for a grip pin to be inserted to attaching to the tooling.1. Attaching to the Machine 8.300 5/8 inch (15. 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 0 . The tooling attachment for the fixed crosshead is M36 and standard loadcell is M33. depending on the capacity of load cell used. please contact Tinius Olsen or local authorised distributors to discuss your requirements.3. To install the tooling attachment to the load cell. Do not tighten the attachment locking collar at this stage. In general this comprises:Nose Piece Locking Collar (X 2) Grip pin The diagram below indicates attachment parts. Align the fixing thread to the load cell and rotate in a clockwise direction to engage.8.1. Once engaged rotate a further 6 to 8 times. 8.525mm) 1/2 inch (12.9375mm) 3/8 inch (9.20 20 – 50 50 – 100 100 150 200 . an adaptor is available to reduce this if required.875mm) 3/4 inch (19.1. Ensure the tooling attachment hole is facing forward. Repeat the above procedure for the fixed crosshead.2. 8.1. first ensure both locking collars are centralised on the tooling attachment. Tooling Tinius Olsen manufacture a wide range of sample tooling.1. A large proportion of tooling uses the same method of attachment to secure the tooling to the machine / load cell. This is to ensure the correct amount of thread has been inserted. 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 8. The diagrams below indicate tooling attachments for load cell and fixed crosshead. Nose pieces have a threaded section to screw into the loadcell / machine and a parallel section to fit inside the tooling. © Tinius Olsen Ltd 820-7001_15 – Issue 3 Page 25 . 8. 8. Ensure the distance between the load cell and the fixed crosshead is sufficient for installation of tooling.6. Repeat the above procedure for the fixed crosshead tooling.1.7. Insert the grip pin from the front. make small adjustments to the tooling position to enable the grip pin to slide in freely. 820-7001_15 – Issue 3 Page 26 .5.1.8. 8. Align tooling female nose piece with load cell attachment male nose piece. 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. this procedure may require additional help (tooling may be heavy). the distance may require to be increased using the direction control keys. NOTE . Installing Tooling Depending on the type of tooling to be installed. © Tinius Olsen Ltd Tooling Alignment Tooling alignment is extremely important to obtain realistic measurements.The HW20 Wedge Grip is shown as an example. the same principals apply to all tooling using this type of attachment. slide the two together until daylight can be seen through both grip pin hole in tooling and attachment.1. The diagram below indicates the HW20 Wedge Grip fitted to the load cell. 9. Whilst held in this position lightly tighten both attachment and tooling locking collars. Load cells from 200N to 2kN should be lightly tightened with breaker bar. © Tinius Olsen Ltd 820-7001_15 – Issue 3 Page 27 . When installing low capacity load cells. 8. The same care must be taken when removing tooling from the load cells. extreme care must be taken. Care must be taken when tightening locking collars attached to a load cell as lower capacity load cells can be damaged from excess torque.1. Repeat this procedure for the tooling attached to the load cell. As a general rule load cell capacities from 25 to 100N only require locking collars finger tight. Ensure the fixed crosshead tooling is parallel to the crosshead. To minimise risk of damage ensure the sensitive area of the load cell is supported when tightening these locking collars.8. Note Load cells below 25N can be damaged by handling alone. Repeat this procedure until the tooling is aligned.1. Load cells from 5kN to 10kN can be fully tightened with breaker bar.8. Fully tighten the fixed crosshead locking collars with the breaker bar supplied. and above 10kN the breaker bar limits torque that can be applied. reposition tooling and retighten collars. Check alignment in all three axis. If alignment is out . loosen the tooling locking collars. 1. etc.1. IF INSUFFICIENT.1. when testing in tension or centred between the compression platens when testing in compression. that the Load Cell and any attached tooling or specimens do not contact any part of the machine or any tooling. but if the load exceeds 150% of the rated capacity this can result in zero shift. Testing Using The Handset The following assumes that the machine is set up..9. 9. The force-measuring element (Load Cell) will only deflect approximately 0.1mm at the full rated capacity. the overload protection is only effective when the machine is being operated within the response capabilities of the load indicator. 9. Conducting a test 9. span changes and possible damage or breakage. ALWAYS CHECK THE CLEARANCES IN THE AREA AROUND THE CROSSHEAD. Off centre loading can result in an erroneous load reading and possible damage to the load cell or tooling. STOP THE TEST BEFORE THE TRAVEL OF THE CROSSHEAD CAN CAUSE DAMAGE. This "HARD" weighing system permits extremely sensitive and accurate load indication. See this manual for further details. 9. specimens.3.1. 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. CAUTION: DURING A TEST. The following information is included to caution the operator as to unintentional misuse and resulting damage to the load cell. Obviously. Basic Operation These are some typical precautions to be observed when operating a Tinius Olsen H150KU Testing Machine.1. all grips are fitted and all handset settings have been made. 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.2.4. etc… 9. 9.2. run the crosshead to the desired starting position and press the [Zero Pos] key to zero the Position Channel at this position.1. Use of Low Capacity Loadcells The load cells are designed for some overloading. Preparing the Machine With the proper grips or holders installed.2. the extent and responsibility is to be determined solely by the manufacturer. The Force Channel can also be zeroed now by pressing the [Zero Force] key. As load cell damage can be difficult to see visually and where load cells may be damaged. 9. The Load Cell Weighing System of the H150KU is considered a very "HARD" type of weighing system. Mounting of Specimens Care must be taken to insure that the specimen is always cantered in the grips.1. Overloading a load cell will usually result in the inability to zero the load cell or an offscale reading. © Tinius Olsen Ltd 820-7001_15 – Issue 3 Page 28 . Clearance Care must be taken whenever running the crosshead up or down. the overload protection cannot prevent overloading and the resulting damage if a rigid specimen is impacted at a high rate of speed. However. EXTREME CARE should be taken when using low capacity load cells that they are not dropped or overloaded when mounting tooling. 9. post-yield speed or jog speed). The operator can see the actual crosshead rate in the bottom right corner of the 602 display. Press the number for the description of the new instrument to be used.4. DO NOT USE THE FORCE CHANNEL ZERO TO ELIMINATE PRELOAD ON A SPECIMEN. the [3] key on the Select Channel Menu for “Aux”. It is recommended that the total number of connected devices be limited to 3 or 4 9. in some cases. If needed. or they can run the crosshead slowly in the proper direction until zero force is displayed. install protective devices around the test specimen or test machine to prevent injury to the operator or personnel in the area.g. 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. Set a crosshead speed or rate that meets the applicable test specification. pre-yield speed) and Speed 2 is set for a faster speed (e.3. If the desired cell is not listed.2) 9. and then [1] on the Xducer Menu for “Select Transducer”. Too many connected devices reduces the bandwidth of the system.2. The 602 will exit back to the live screen.g.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. (See 10. Mount Specimen Secure the specimen properly in the grips or holders.2. the Strain System and/or Computer being used.typically Speed 1 is set for a slow speed (e. Start Test • • • • © Tinius Olsen Ltd Ensure that the drive is enabled by pressing [Hi] or [Low] Press [STOP] to keep the 602 in “Hold” mode Before starting the test. NOTE .9. • • • Mount the module into the rack at the rear of the machine and plug the adjacent 8-pin RJ45 jack. 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. Install Protective Devices (if applicable) If necessary. 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. The operator can start the test with a small preload on the specimen. 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. and the Sample Break Detector is not active. 820-7001_15 – Issue 3 Page 29 . placing the 602 into a "READY" Mode. the Peak Hold and Maximum Values will not be retained. In the absence of a testing specification.6. the [3] key on the Main Menu for “Configuration”. NOTE . If the 602 remote is not in the “READY” Mode before starting a test. the [Test/Clear] key must be pressed.Only modules that are intended to be used should be plugged in to the RJ45 connectors. The 602 will show a list of any connected “Aux” Modules by description. When securing a specimen there might be some amount of ±preload applied to the specimen. the operator must direct the new instrument to the Aux Display (third line) by pressing [Menu]. 9.5. mount the Strain Instrument following the instructions provided for the instrument.2. particularly at higher sample rates.2. That is because any device with the RJ45 connectors plugged in is considered active by the 602. Mount Aux Instruments (if applicable) If Strain data is to be recorded. it may be necessary to calculate the loading speed from known or given data. check that it is connected correctly. press the directional key a second time to go to Speed #2.2. and the results are saved. When using a computer.3.2.] key. Once the test has started.A small Start Load % of Full Scale (typically 1-10 % FS) is required to prevent false triggering of the Sample Break Detect 9.2. 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. NOTE . After the test is over. the operator must end the test manually using the [Stop  ] key. For tensile testing.. If the 602 display in the “READY” mode simply press the directional key to start the next test. Setup the test the same as described in section 9. for the next test. The user must press [Test/Clear] to clear the old results and re-arm the 602 for the next Test 9. because once the [Test/Clear] key is pressed the prior results are cleared. WARNING .the user must take care if using the handheld in conjunction with the computer because of possibility of conflict.9. If there is no drop-off or failure during a test.9.8.Do not press the [Test/Clear] key until the results from the prior test are recorded. 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. the computer will send all the needed information to the 602 Display to run the test remotely. but start the test in the software instead using the directional key. if enabled. 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. reset the 602 Display and Sample Break Detector. Next Test The machine should always be left in its Start Test (Home) Position until the next test is ready to be started. The 602 display will then go to HOLD Mode and hold that crosshead position. Testing Using Optional Software For machines provided with optional Tinius Olsen Test Software. In addition. NOTE .2. then press the [Test/Clear] key on the 602 remote to clear the maximum values being held. the program monitors the test and advances the segments according to the program and the Machine Control Settings being used for that test. Remove the tested specimen. 9. When you are ready to return the crosshead to it’s starting position press the [Return

] key. etc. it is best to configure the system and run the machine entirely from the computer to avoid potential conflicts © Tinius Olsen Ltd 820-7001_15 – Issue 3 Page 30 .7. 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.2. all the controls on the 602 are available on the Top Tool Bar in the Software. When left unattended always disable the drive by pressing the E-Stop or taking it out of “Hi/Low” clutch mode. Only trained operators should use the machine. Operator must not place any part of their body within the test area when the machine is moving. Warnings • • • • • • • • • • • • © Tinius Olsen Ltd Under NO circumstances must the machine/tooling be used if damaged. Machine Emergency Stop switch must not be obstructed. Under NO circumstances should the machine/tooling be modified without consent from Tinius Olsen.10. The machine should never be left unattended in a loaded condition. Safety 10. Mains Supply isolator must not be obstructed and be within easy reach. 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. (No loose clothing) Eye protection must be worn at all times when operating the machine.1. Service/Repair of the machine must be carried out by trained personal 820-7001_15 – Issue 3 Page 31 . (Including operation of software) Operator must wear appropriate clothing. Where high loads and large extensions are required to break a sample failure often becomes more violent. Protective Screens 10.2.2. Illustration shows a fully enclosed guarding solution.2. if there is any possibility of fragments being ejected from the machine when a sample fails then a protective screen should be fitted. Standard machines are not supplied with protective screens. in this case interlocked screens should be fitted.10. Please contact Tinius Olsen if you require screens for your application. the operator must assess the type of sample failure likely to occur. 10.2. In case of doubt or for more advice on protective screens please contact Tinius Olsen or your local authorised distributor to discuss your requirements. Depending on the type of material being tested a protective screen may be required. This assessment will enable the correct protective screen to be selected. As a general rule. Prior to conducting any testing. © Tinius Olsen Ltd 820-7001_15 – Issue 3 Page 32 .1. Training covers both machine hardware and computer software. Training can be further extended to give a more in-depth knowledge of system on request.com. Training Tinius Olsen or local authorised distributors with qualified factory trained engineers can give operator training at the time of machine installation. Tinius Olsen Ltd 6 Perrywood Business Park Honeycrock Lane Salfords Redhill Surrey RH1 5DZ England © Tinius Olsen Ltd 820-7001_15 – Issue 3 Page 33 . For details of your nearest distributor. Contact Tinius Olsen or local authorised distributors to discuss your requirements. please check our website at www.tiniusolsen.11. 2.1. Calibration 12. © Tinius Olsen Ltd 820-7001_15 – Issue 3 Page 34 .1.com. Tinius Olsen maintains a Calibration and Service Department within the UK or through local authorised distributors with qualified factory trained technicians.2. please check our website at www. 12. Supply The H150KU machine operates from a 3ph phase 415V +/.3.000-15. 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. 12. 12. 12.3. The internal force and extension range calibration adjustments on this machine are set to factory specifications and should not be changed in the field.2.3.1.1.2.tiniusolsen. Electrical 12. 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. 12. Bearings Bearings are pre-packed with grease on assembly and should not require additional lubrication. Ballscrews The ballscrew nuts require a lithium soap based grease Number 2. 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.1. All the load cells supplied will already be calibrated and a calibration certificate provided. 12. 12.10% 50/60 Hz 15Amp Continuous. 12. Each load cell has its own calibrated conditioner module.2.3.3. In the event of either circuit breaker repeatedly tripping please contact Tinius Olsen or one of our authorised distributors.1.000m of travel. For details of your nearest distributor.1.12. 12.2.3. Maintenance The mechanics within the machine are designed for a minimum amount of maintenance.2. Lubrication 12. Re-calibration of the machine and auxiliary equipment should be performed regularly at yearly intervals or as required. Guide columns The columns (adjacent to the ballscrews) use DU dry self lubricating bearings. They will require approximately 2cc of grease per 12.3. Electronics All the electronics in the machine are solid state and do not require any maintenance. Circuit Breakers To protect the machine two circuit breakers have been incorporated at the rear of the machine. 30A peak. 13. Under certain conditions condensation can form within the packing and cause parts within the machine to rust. 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. © Tinius Olsen Ltd 820-7001_15 – Issue 3 Page 35 . If the machine is to be stored outside its normal working environment repack into its original packing case as supplied. To reduce this problem place at least one desiccator within the packing case. 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. 14.1. Appendix 14. © Tinius Olsen Ltd Dimensions 820-7001_15 – Issue 3 Page 36 .