Instron 5940 Handbuch

5940 Series Single Column Table Frames

Operator’s guide M10-16245-EN Revision E

The difference is measurable

Electromagnetic Compatibility

Where applicable, this equipment is designed to comply with International Electromagnetic Com-

patibility (EMC) standards.

To ensure reproduction of this EMC performance, connect this equipment to a low impedance

ground connection. Typical suitable connections are a ground spike or the steel frame of a building.

Proprietary Rights Notice

This document and the information that it contains are the property of Illinois Tool Works Inc.

(ITW). Rights to duplicate or otherwise copy this document and rights to disclose the document and

the information that it contains to others and the right to use the information contained therein may

be acquired only by written permission signed by a duly authorized officer of ITW.

Trademarks

Instron® is a registered trademark of Illinois Tool Works Inc. (ITW). Other names, logos, icons and

marks identifying Instron products and services referenced herein are trademarks of ITW and may

not be used without the prior written permission of ITW.

Other product and company names used herein are trademarks or trade names of their respective

companies.

Original Instructions

shown in this document are subject to change without notice.

Worldwide Headquarters

Instron

825 University Avenue

Norwood, MA 02062-2643

United States of America

European Headquarters

Instron

Coronation Road

High Wycombe, Bucks HP12 3SY

United Kingdom

Industrial Products Group

Instron

900 Liberty Street

Grove City, PA 16127

United States of America

iii

Preliminary Pages

Product Support: www.instron.com

General Safety Precautions

Materials testing systems are potentially hazardous.

Materials testing involves inherent hazards from high forces, rapid motions, and stored

energy. You must be aware of all moving and operating components in the testing system

that are potentially hazardous, particularly force actuators or a moving crosshead.

Carefully read all relevant manuals and observe all Warnings and Cautions. The term

Warning is used where a hazard may lead to injury or death. The term Caution is used

where a hazard may lead to damage to equipment or to loss of data.

Instron products, to the best of its knowledge, comply with various national and

international safety standards, in as much as they apply to materials and structural

testing. We certify that our products comply with all relevant EU directives (CE mark).

Because of the wide range of applications with which our instruments are used, and over

which we have no control, additional protection devices and operating procedures may

be necessary due to specific accident prevention regulations, safety regulations, further

EEA directives or locally valid regulations. The extent of our delivery regarding

protective devices is defined in your initial sales quotation. We are thus free of liability

in this respect.

At your request, we will gladly provide advice and quotations for additional safety

devices such as protective shielding, warning signs or methods of restricting access to

the equipment.

The following pages detail various general warnings that you must heed at all times

while using materials testing equipment. You will find more specific Warnings and

Cautions in the text whenever a potential hazard exists.

Your best safety precautions are to gain a thorough understanding of the equipment by

reading your instruction manuals and to always use good judgement.

It is our strong recommendation that you should carry out your own safety risk

assessment on the use of the test system, test methods employed, specimen loading and

specimen behavior at failure.

Preliminary Pages

iv M10-16245-EN

Warnings

Crush Hazard - Allow only one person to handle or operate the system at all times.

Operator injury may result if more than one person operates the system. Before working

inside the hazard area between the grips or fixtures, ensure that no other personnel can

operate the computer or any of the system controls.

Crush Hazard - Take care when installing or removing a specimen, assembly,

structure, or load string component.

Installation or removal of a specimen, assembly, structure, or load string component

involves working inside the hazard area between the grips or fixtures. Keep clear of the

jaws of a grip or fixture at all times. Keep clear of the hazard area between the grips or

fixtures during actuator or crosshead movement. Ensure that all actuator or crosshead

movements necessary for installation or removal are slow and, where possible, at a low

force setting.

Hazard - Press the Emergency Stop button whenever you consider that an unsafe

condition exists.

The Emergency Stop button removes hydraulic power or electrical drive from the testing

system and brings the hazardous elements of the system to a stop as quickly as possible.

It does not isolate the system from electrical power, other means are provided to

disconnect the electrical supply. Whenever you consider that safety may be

compromised, stop the test using the Emergency Stop button. Investigate and resolve the

situation that caused the use of the Emergency Stop button before you reset it.

Flying Debris Hazard - Make sure that test specimens are installed correctly in

grips or fixtures in order to eliminate stresses that can cause breakage of grip

jaws or fixture components.

Incorrect installation of test specimens creates stresses in grip jaws or fixture components

that can result in breakage of these components. The high energies involved can cause

the broken parts to be projected forcefully some distance from the test area. Install

specimens in the center of the grip jaws in line with the load path. Insert specimens into

the jaws by at least the amount recommended in your grip documentation. This amount

can vary between 66% to 100% insertion depth; refer to supplied instructions for your

specific grips. Use any centering and alignment devices provided.

Hazard - Protect electrical cables from damage and inadvertent disconnection.

The loss of controlling and feedback signals that can result from a disconnected or

damaged cable causes an open loop condition that may drive the actuator or crosshead

rapidly to its extremes of motion. Protect all electrical cables, particularly transducer

cables, from damage. Never route cables across the floor without protection, nor suspend

cables overhead under excessive strain. Use padding to avoid chafing where cables are

routed around corners or through wall openings.

Preliminary Pages

Product Support: www.instron.com

High/Low Temperature Hazard - Wear protective clothing when handling

equipment at extremes of temperature.

Materials testing is often carried out at non-ambient temperatures using ovens, furnaces

or cryogenic chambers. Extreme temperature means an operating temperature exceeding

60 °C (140 °F) or below 0 °C (32 °F). You must use protective clothing, such as gloves,

when handling equipment at these temperatures. Display a warning notice concerning

low or high temperature operation whenever temperature control equipment is in use.

You should note that the hazard from extreme temperature can extend beyond the

immediate area of the test.

Hazard - Do not place a testing system off-line from computer control without first

ensuring that no actuator or crosshead movement will occur upon transfer to

manual control.

The actuator or crosshead will immediately respond to manual control settings when the

system is placed off-line from computer control. Before transferring to manual control,

make sure that the control settings are such that unexpected actuator or crosshead

movement cannot occur.

Robotic Motion Hazard - Keep clear of the operating envelope of a robotic device

unless the device is de-activated.

The robot in an automated testing system presents a hazard because its movements are

hard to predict. The robot can go instantly from a waiting state to high speed operation in

several axes of motion. During system operation, keep away from the operating envelope

of the robot. De-activate the robot before entering the envelope for any purpose, such as

reloading the specimen magazine.

Hazard - Set the appropriate limits before performing loop tuning or running

waveforms or tests.

Operational limits are included within your testing system to suspend motion or shut off

the system when upper and/or lower bounds of actuator or crosshead travel, or force or

strain, are reached during testing. Correct setting of operational limits by the operator,

prior to testing, will reduce the risk of damage to test article and system and associated

hazard to the operator.

Electrical Hazard - Disconnect the electrical power supply before removing the

covers to electrical equipment.

Disconnect equipment from the electrical power supply before removing any electrical

safety covers or replacing fuses. Do not reconnect the power source while the covers are

removed. Refit covers as soon as possible.

Warnings

Preliminary Pages

vi M10-16245-EN

Rotating Machinery Hazard - Disconnect power supplies before removing the

covers to rotating machinery.

Disconnect equipment from all power supplies before removing any cover which gives

access to rotating machinery. Do not reconnect any power supply while the covers are

removed unless you are specifically instructed to do so in the manual. If the equipment

needs to be operated to perform maintenance tasks with the covers removed, ensure that

all loose clothing, long hair, etc. is tied back. Refit covers as soon as possible.

Hazard - Shut down the hydraulic power supply and discharge hydraulic pressure

before disconnection of any hydraulic fluid coupling.

Do not disconnect any hydraulic coupling without first shutting down the hydraulic

power supply and discharging stored pressure to zero. Tie down or otherwise secure all

pressurized hoses to prevent movement during system operation and to prevent the hose

from whipping about in the event of a rupture.

Hazard - Shut off the supply of compressed gas and discharge residual gas

pressure before you disconnect any compressed gas coupling.

Do not release gas connections without first disconnecting the gas supply and

discharging any residual pressure to zero.

Explosion Hazard - Wear eye protection and use protective shields or screens

whenever any possibility exists of a hazard from the failure of a specimen,

assembly or structure under test.

Wear eye protection and use protective shields or screens whenever a risk of injury to

operators and observers exists from the failure of a test specimen, assembly or structure,

particularly where explosive disintegration may occur. Due to the wide range of

specimen materials, assemblies or structures that may be tested, any hazard resulting

from the failure of a test specimen, assembly or structure is entirely the responsibility of

the owner and the user of the equipment.

Hazard - Ensure components of the load string are correctly pre-loaded to

minimize the risk of fatigue failure.

Dynamic systems, especially where load reversals through zero are occurring, are at risk

of fatigue cracks developing if components of the load string are not correctly pre-loaded

to one another. Apply the specified torque to all load string fasteners and the correct

setting to wedge washers or spiral washers. Visually inspect highly stressed components

such as grips and threaded adapters prior to every fatigue test for signs of wear or fatigue

damage.

Warnings

vii

Preliminary Pages

Product Support: www.instron.com

Table of Contents

Chapter 1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

System Description and Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Principle of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Hardware Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

System Components and Interconnections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

System Safety and Information Labeling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Product Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Product Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Chapter 2 Preparing the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Before you Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Power Input Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Emergency Stop Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Start the System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Bluehill Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Home Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Console. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Status Bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Assemble the Load String . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Select a Load Cell. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Install the Load Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Select Grips and Fixtures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Insert Jaw Faces into Grips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Install Grips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Preload the Load String . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

To preload the load string: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

To unload the load string: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Preliminary Pages

viii M10-16245-EN

Chapter 3 Testing Specimens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Testing a Sample . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Create a sample in Bluehill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Create a new sample . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Name the new sample . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Calibrate a transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Automatic calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Manual calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Set the zero extension point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

From Bluehill software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

From the Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Set the crosshead limit stops. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Set the crosshead limit stops:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Move Off a Crosshead Limit Stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Set the limits for a transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Balance a transducer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Stop a test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Control Panel Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Emergency Stop Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Crosshead Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Software Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Shut down the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

A Software Transducer Limit Trips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

A Crosshead Travel Limit Trips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

You press the Emergency Stop button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

The System Shuts down Unexpectedly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Appendix A Conformance Documents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Certificate of Conformance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

1-1

Chapter 1

Introduction

•System Description and Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

•System Components and Interconnections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

•System Safety and Information Labeling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

•Product Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

•Product Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

These instructions describe the following table model single column load frames, Model

5942 500 N capacity, Model 5943 1 kN capacity, Model 5944 2kN capacity. They are

intended to get you started working with your testing system.

These instructions assume the following:

•You are an operator familiar with the operation of materials testing systems in general.

•Your system consists of a load frame with integral controller and a control panel fitted to

the column, a load cell, a set of manually-operated grips and Instron Bluehill®test

control software.

•The system has been installed in its final location by an Instron service engineer.

•Bluehill software test methods that are appropriate for your testing requirements are

available.

Using these instructions you will be able to:

•Check the interconnections between all the individual elements of the basic system.

•Select and install a load cell, if the one that you want to use is not already installed.

•Install the grips and preload the loadstring.

•Prepare a set of specimens (sample) for testing.

•Test the sample.

•View the test results and print a test report.

These instructions do not include the development of Bluehill test methods. This is covered

in more advanced training that can be provided by Instron Service and Training

departments.

Chapter: Introduction

1-2 M10-16245-EN

System Description and Terminology

Components

The major components of an Instron electromechanical testing system include:

•Load frame with integral controller

•Load cell mounted to the crosshead

Figure 1-1. 5940 Single Column Table Frame

Frame base Base

Base adapter

Controller

Motor cover

Ground stud

Not shown: Computer

T-slots

Crosshead

Lifting eye

Emergency stop

button

Power input

connector

Control

panel

beam

System ID label

Options

panel

Upper limit stop

Lower limit stop

Ballscrew cover

Column

cover

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