6800 Series Dual Column Table Model

Operator’s Guide
M10-17415-EN Revision C
 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.

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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 listed are trademarks or trade names of their respective
companies.

Original Instructions

Copyright © 2020 Illinois Tool Works Inc. All rights reserved. All of the specifications shown in
this document are subject to change without notice.

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 Preliminary Pages

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 product
safety risk assessment.

Product Support: www.instron.com 3

Preliminary Pages

Warnings

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.

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 Preliminary Pages

Warnings

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.

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. When working in this area, ensure that other personnel cannot operate
any of the system controls. 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 - 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.

Product Support: www.instron.com 5

Preliminary Pages

Warnings

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.

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.

6 M10-17415-EN
 Preliminary Pages

Warnings

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.

Product Support: www.instron.com 7

Preliminary Pages

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 Preliminary Pages

Table of Contents

Chapter 1: Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
System Description and Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Principle of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Hardware Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
System Safety and Information Labeling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Conformity with EU directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Product Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Product Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Location of your Preinstallation manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Chapter 2: Risk reduction and safe use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Rapid crosshead motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Pinching fingers between grip jaw faces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Impact of debris from breaking specimens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Collision Mitigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Ingress Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Solid particle ingress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Liquid ingress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Operator Protection Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Chapter 3: Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Level the load frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Power supply compatibility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Set the input voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
System components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Dual column table model load frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Connect the system components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

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Preliminary Pages

Bluehill® Operator Dashboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

First time startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Chapter 4: Function of controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Power input connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Emergency Stop button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Handset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Indicator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Bluehill® software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Home Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Operator Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Move between modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Jog at High Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Operator Protection Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
®
Bluehill Operator Dashboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Basic touch functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Touchscreen gestures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Pneumatic Grips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
How Operator Protection works with grips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Operate grips using footswitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Operate grips using toggle switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Grips not in use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Chapter 5: Assemble the load string . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Select a load cell. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Before you begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Install the load cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Install a 2530 load cell (capacities 5 N through 100 N) . . . . . . . . . . . . . . . . . . . . . . . 83
Install a 2580 load cell (capacities 500 N through 5 kN) . . . . . . . . . . . . . . . . . . . . . . 87
Install a 2580 load cell (10kN capacity) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Install a 2580 load cell (capacities 30kN and 50kN) . . . . . . . . . . . . . . . . . . . . . . . . . 94
Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

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 Preliminary Pages

68TM-5 and 68TM-10 base adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

68TM-30 and 68TM-50 base adapters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Coupling adapters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Select Grips and Fixtures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Insert Jaw Faces into Grips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Install grips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Preload the load string . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Unload the load string . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Chapter 6: Testing specimens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Testing a sample. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Testing with no interlock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Testing with an interlock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Create a new sample . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Calibrate a transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Automatic calibration of a force or strain transducer. . . . . . . . . . . . . . . . . . . . . . . . . 119
Manual calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Set the zero displacement point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Crosshead limit stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Set the crosshead limit stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Move Off a Crosshead Limit Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Set the limits for a transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Balance a transducer configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Stop a test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Emergency Stop Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Crosshead Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Software Event . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Shut down the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Turn the system off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
A Software Transducer Limit Trips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
A Crosshead Travel Limit Trips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
You press the Emergency Stop button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Product Support: www.instron.com 11

Preliminary Pages

Chapter 7: Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

Preventive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Daily Maintenance Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Periodic Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Lubricate ballnuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
General Maintenance Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Test Limit Stops. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Replace a Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Troubleshooting for Load Cells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Ancillary parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

12 M10-17415-EN
 Chapter 1
Introduction

• System Description and Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

• System Safety and Information Labeling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
• Conformity with EU directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
• Product Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
• Product Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

These instructions are intended to get you started working with your testing system.
They 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, a load cell, a set of
manually-operated grips and Bluehill® test control software
• the system has been installed by an Instron® service engineer
• Bluehill® test methods that are appropriate for your testing requirements are
available

These instructions include the following information:

• installing and connecting all the system components together (carried out by an
Instron® service engineer for first-time installation)
• configuring the system before you start testing (carried out by an Instron® service
engineer for first-time installation)
• routine maintenance of the system
• spare parts

Using these instructions you will be able to:

• check the interconnections between all elements of the basic system

• install the grips and preload the load string
• prepare a set of specimens (sample) for testing

Product Support: www.instron.com 13

Chapter: Introduction

• test the sample

• view the test results and print a test report.
• perform routine maintenance of the system

These instructions do not include the development of Bluehill® test methods. This is
covered in more advanced training that can be provided by the Instron® Service and
Training departments.

14 M10-17415-EN
 System Description and Terminology

System Description and Terminology

2
5
1
3

6 10
4

11

Figure 1. 6800 Dual Column Table Model with Bluehill® Operator Dashboard - Front
View

Product Support: www.instron.com 15

Chapter: Introduction

Legend for Figure 1

Label Component

1 T-slots

2 Top plate

3 Column cover

4 Load cell

5 Upper limit switch

6 Limit switch actuator

7 Lower limit switch

8 Emergency stop button

9 Indicator panel

10 Bluehill® Operator Dashboard (optional)

11 Handset

16 M10-17415-EN
 System Description and Terminology

9
8

6
7
1

4 5
3

Figure 2. 6800 Dual Column Table Model - Rear View

Legend for Figure 2

Label Component

1 Power inlet connection and power switch

2 System ID label

Product Support: www.instron.com 17

Chapter: Introduction

Label Component

3 Rear panel

4 Controller panel

5 Frame base

6 Base beam

7 Base adapter

8 Crosshead

9 Ballscrew cover

Components

The major components of an Instron® electromechanical testing system include:

• Load frame with integral controller

• Load cell mounted to the crosshead
• Grips for tension testing or table-mounted anvils on a platen for compression
testing.
• Instron® approved computer system with Instron Bluehill® software.

Special fixtures are available for applications such as flexure and peel testing. For strain
measurement, an optional strain gauge extensometer attaches to the specimen. You
can use non-contacting extensometers with specimens that are unable to support a
contacting extensometer. Contact your regional Instron® office or check our web site at
www.instron.com for assistance with Instron’s grips and fixtures.

The following table defines the components of the testing system:

Table 1. Testing System Components

Component Description

Load Frame The load frame comprises a base, one or two columns, a moving crosshead,
and a top plate. It is a high stiffness support structure against which the test
forces react.
Each column comprises a guide column and a ballscrew. The crosshead is
mounted on both the guide column and the ballscrew. Rotation of the
ballscrew drives the crosshead up or down while the guide column provides
stability.

18 M10-17415-EN
 System Description and Terminology

Table 1. Testing System Components (Continued)

Component Description

Controller The hardware that controls the frame and any ancillary equipment connected
to the testing system. The controller panel contains all the connectors for load
cells, extensometers and any other sensors that are required for testing.

Indicator Panel Indicators showing the status of the testing system.

Handset Holds all of the controls for the testing system.

Load String Comprises all of the components that you install between the moving
crosshead and the load frame base (or fixed crosshead). Typically this involves
a load cell, a set of grips, any adapters that are required to connect the
components, and the specimen to be tested.
Typically, you mount a load cell on the crosshead, then a pair of grips or
fixtures on the load cell and frame base. The grips or fixtures secure the
specimen and when you start a test the crosshead moves up or down applying
a tensile or compressive load to the specimen. The load cell converts this load
into an electrical signal that the software measures and displays.

Bluehill® Software Instron® testing software that controls the testing system, running tests and
analyzing test data to produce test results.

Specimen A single piece of material to be tested.

Principle of Operation

The system communicates primarily through the controller. The controller contains
sensor conditioning cards for the system transducers and transfers data between the
transducers and the computer. The controller also communicates with the load frame
via a Safety Monitoring Board (SMB) via a Break Out Board (BOB) inside the load frame.
The Break Out Board links all the electrical components of the frame together.

Hardware Controls
The hardware controls consist of:

• Emergency stop button - to be used whenever you need to stop the crosshead
immediately because an unsafe condition exists.
• Limit stops - these must be set before each test session to protect the operator and
load string components against unexpected crosshead movement.
• Indicator panel - indicators showing the status of the testing system.
• Handset - holds all the controls for the testing system.

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Chapter: Introduction

Software

Control of the testing system is carried out via Instron Bluehill® software. Setting test
parameters, operating the system, and collecting test data is done through the software
program.

Table 2. Software Terminology

Term Description

Test Method In Bluehill® software, a test method is a file that contains a set of defined
parameters that the system uses to run tests, analyze the test data, and
produce calculated results.

Sample A group of material specimens, whose properties are studied and

compared to gain statistical or quality assurance information. For
example, you could take a specimen from different parts of a single
manufacturing run of a material to form a sample of the material. The
sample is then representative of the complete run and you can test it to
ensure that the material quality has remained stable over the complete
run. You perform the same test on each specimen in a sample.

System Safety and Information Labeling

Table 3 on page 20 explains the meanings of any safety and information labels that
may be attached to any part of the testing system.

Table 3. Safety and Information Labeling Descriptions

Label Meaning Purpose

Electrical Indicates that an electrical hazard exists

hazard from high voltage and/or electrical current.

Disconnect power Disconnect the power supply before

supply servicing machine.

20 M10-17415-EN
 System Safety and Information Labeling

Table 3. Safety and Information Labeling Descriptions (Continued)

Label Meaning Purpose

Electrical - fuse warning Indicates an electrical hazard exists.

Advises disconnecting power mains before
changing fuses and using only specified
fuses.

Belt Indicates that a hazard exists from the

entanglement hazard drive belt and pulley system.

High Indicates that a heat hazard exists. Stay

temperature hazard clear of area when operating the machine.

Rotating machinery Indicates that a rotating hazard exists.

hazard Keep clear of these areas (and tie back
long hair and loose clothing).

Ground stud Indicates a ground stud.

Read the manual Read and understand the operator’s

manual before using the machine.

Crosshead direction Indicates the direction to turn the pulley to

manually move the crosshead upward.
Pulleys can be turned by hand when power
is disabled.

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Chapter: Introduction

Table 3. Safety and Information Labeling Descriptions (Continued)

Label Meaning Purpose

Crush hazard Indicates the crush hazard of the moving

crosshead and instructs the user to read
! WARNING and understand the operator’s manual
before using the machine.

Crush hazard.
Keep clear of test
area when machine
is in motion.
Read and understand
operator's manual
before using this
machine.

Waste Electrical and In accordance with the European Union’s

Electronic Equipment WEEE directive, the crossed out wheeled
(WEEE) bin symbol indicates that the equipment
must be disposed of separately from other
waste at the end of its usable life. For
advice on the disposal of electrical and
electronic equipment in your country,
contact your local Instron representative.

Conformity with EU directives

Instron® declares under our sole responsibility that 68SC and 68TM testing systems are
in conformity with all relevant provisions of the following regulations:

• Machinery Directive 2006/42/EC

• EMC Directive 2014/30/EU
• ROHS Directive 2011/65/EU including substances added by amendment 2015/
863/EU

Instron® testing systems are CE marked. A signed CE declaration of conformity is

supplied with each system.

22 M10-17415-EN
 Product Support

Product Support
Instron® provides documentation, including manuals and online help, that can answer
many of the questions you may have. It is recommended that you review the
documentation sent with the system you purchased for possible solutions to your
questions.

If you cannot find answers in these sources, contact Instron® Service directly. A list of
Instron® offices is available on our website at www.instron.com. In the US and
Canada, you can call directly at 1-800-473-7838.

Product Documentation
Instron® offers a comprehensive range of documentation to help you get the most out of
your Instron products. Depending on what you have purchased, your documentation
may include some or all of the following:

Operator’s Guide How to use your system components and controls, procedures for
setting limits, calibration and other frequently performed operating
tasks.
Information about system installation, set up and configuration,
transducer connection and calibration.
Routine maintenance and spare parts.

Preinstallation Manual System requirements and specifications, instructions for lifting and
handling to transport the system to its final location before
installation.

Reference Help Software products come complete with context sensitive help,
which provides detailed information on how to use all software
features.

Equipment Reference How to set up and use any accessories you have purchased, for
example grips, fixtures, extensometers, transducers, and
environmental chambers.

We welcome your feedback on any aspect of the product documentation. Please email
[email protected] with your comments.

Location of your Preinstallation manual

A copy of the Preinstallation manual for your model was sent upon receipt of your order
to assist you to prepare for the arrival of your shipment.

Product Support: www.instron.com 23

Chapter: Introduction

You can find a copy of the Preinstallation manual on the USB drive provided with your
system. This drive contains your Bluehill® software.

The Preinstallation manuals are stored in a directory named:

Frame Manuals

The following table lists the manuals for dual column table model load frames:

Model number Manual number

68TM-5 (5 kN) M10-17416-EN

68TM-10 (10 kN) M10-17417-EN

68TM-30 (30 kN) M10-17418-EN

68TM-50 (50 kN) M10-17419-EN

The manual numbers listed are in English (EN). To find a different language, match the
two letter extension on this Operator’s Guide to the equivalent language Preinstallation
manual, e.g. M10-xxxxx-FR for French.

24 M10-17415-EN
 Chapter 2
Risk reduction and safe use

• Residual risks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
• Collision Mitigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
• Ingress Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
• Operator Protection Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Residual risks
The equipment described in this documentation is designed with features to reduce the
risk of injury to an operator. There are, however, always residual risks in the use of this
equipment, influenced by:

• the test application

• the design of the test method or procedure
• the jog, return and test speeds used
• the type of specimen being tested
• the size of the specimen being tested
• the design of grips and test fixtures
• the experience of the operator using the equipment

It is our strong recommendation, therefore, that you carry out your own risk assessment
for your particular equipment setup and testing application.

Each of the following sections describes a specific hazard zone of the testing system
and lists the most common risks for testing using this equipment. Use the information in
the following sections, together with the instructions in the remainder of this manual, to
conduct your own risk assessment.

Product Support: www.instron.com 25

Chapter: Risk reduction and safe use

Rapid crosshead motion

Warning
Crush hazard to fingers or hands.
This hazard relates to grips and fixtures coming together as a result of rapid crosshead
motion, crushing hands or fingers.

For example, an operator inadvertently commands the system to jog or return while their
hands are in test area. This may also happen if the operator, in an attempt to be more
efficient, reaches in to remove broken specimen pieces while simultaneously returning
the crosshead to zero displacement.

Recommendations

In all situations:

• Set up test methods so that operators do not need to have their hands in the space
between fixtures while the crosshead is moving.
• Use the Operator Protection feature in Bluehill® software. This uses a reduced jog
speed (default 600 mm/min) during set up and you can set a lower jog speed if your
risk assessment requires it.
• Set appropriate travel limits every time you change the grips and adjust the
crosshead.

In addition, if the gap between grips and fixtures is less than 50 mm:

26 M10-17415-EN
 Residual risks

• Use a specimen insertion tool and other appropriate equipment and practices to
keep fingers out of the space between the fixtures.

In addition, if the gap between grips and fixtures is less than 25 mm:

• Use a specimen insertion tool to keep fingers out of the space between the fixtures.
• Use an interlocked shield to limit or disallow motion when the shield door is open.
When the space is less than 25mm, the crush hazard is very significant, so this is
the best option.

Product Support: www.instron.com 27

Chapter: Risk reduction and safe use

Pinching fingers between grip jaw faces

Warning
Pinch hazard to fingers.
This hazard relates to grip jaws closing quickly, pinching fingers.

Recommendations

For 2712 Series pneumatic grips:

• In the documentation supplied with the grips, read and follow the safety
recommendations for installing a specimen.
• Use the Operator Protection feature in Bluehill® software. This uses a reduced initial
grip pressure (default 15 psi) during set up and you can set a lower initial grip
pressure if your risk assessment requires it.
Refer to “Pneumatic Grips” on page 72 for more details.
• Use jaw face shields.

• Use the thumb screw knobs on the sides of the grip (2712-04x grips only) to reduce
the jaw face gap to the smallest practical gap for your specimens.
Correct:

28 M10-17415-EN
 Residual risks

Incorrect:

Impact of debris from breaking specimens

Warning
Hazard from flying debris.
This hazard relates to brittle or composite specimens that can explode when they break.

Recommendations

For less dangerous debris (specimen dust or fibers, for example):

• Use personal protection equipment (for example safety glasses).

For more dangerous projectile debris (brittle composite specimens, for example):

• Use an interlocked shield.

Product Support: www.instron.com 29

Chapter: Risk reduction and safe use

Collision Mitigation
The 3400 and 6800 Series systems are equipped with the Collision Mitigation feature to
help reduce accidental equipment and specimen damage. Collision Mitigation enables
the system to continually monitor force during jog and return operations, and will
automatically stop the crosshead movement if an unexpected force is detected.

• When paired with the system’s matching capacity load cell, Collision Mitigation can
protect the system from colliding with rigid surfaces at speeds up to 600 mm/min.
• Collision Mitigation is intended to mitigate damage to the equipment.
• Collision Mitigation is not safety rated, nor safety intended.

Ingress Protection
To comply with relevant safety and machinery design standards, all aspects of the
testing system have been designed to meet an ingress protection rating of at least IP 2X.
The testing system is designed for indoor use only, away from wet areas.

The first digit of the ingress protection rating (IP 2_) signifies protection against ingress
by solid objects. The number “2” indicates that the design prevents any solid object
larger than 12.0 mm from contacting any hazardous internal components (e.g. moving
parts, electrical hazards) when all covers and guards are in place.

30 M10-17415-EN
 Ingress Protection

The second digit of the ingress protection rating (IP _X) signifies protection against
ingress by liquids. The letter “X” indicates that ingress protection against liquid is not
required to be specified for this application. The testing system is protected only against
hazards caused by the incidental spillage of liquids.

Note that in many cases, pragmatic improvements against solid and liquid ingress have
been implemented in the design to improve durability and longevity of the testing
system.

Solid particle ingress

Solid particles and other debris, particularly conductive or abrasive dust (e.g. metal
scale, carbon-based composite fibers) may cause damage to the testing system if
allowed to accumulate. If your testing application generates debris, follow these special
precautions:

• Clean the testing system and adjacent areas frequently with a vacuum or soft brush
to prevent any accumulation of debris.
• As part of periodic maintenance, contact Instron® Service to inspect the inside of
the testing system for accumulation of debris, and clean it if necessary.
• Clean all outer surfaces thoroughly before performing any service. This prevents
debris from falling onto the internal components of the testing system.

Liquid ingress

Any liquid spill onto the testing system may cause equipment damage. Incidental liquid
spills will not pose a hazard to the operator if properly addressed.

Take particular care when using any accessory that could spill liquid onto the testing
system (e.g. condensation from an environmental chamber, BioBath, or hydraulic
accessories).

Instron® sells a variety of accessories, such as drip trays, that can be used to reduce the
impact of spilled liquids on your testing system.

If a liquid spill occurs:

1. Discontinue testing immediately and turn off the power to the equipment. Unplug the
power cord (if applicable).
2. Clean up as much spilled liquid as possible on the outside of the equipment. Be sure
to check underneath rubber mats (if present) and any installed accessories.

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Chapter: Risk reduction and safe use

3. If you have reason to believe that liquid entered the testing system, contact Instron®
Service.
a The service engineer will remove the covers of the equipment and clean up all
traces of spilled liquid.
b Any components damaged by liquid may need to be replaced.
c The service engineer will perform an operational check to verify proper function
of safety systems.

Warning
Continuing to operate a testing system after liquid has entered the testing system may
pose a hazard to the operator and lead to additional equipment damage.

4. Resume testing only after the liquid spill has been properly cleaned up. If the testing
system exhibits any faults or unexpected behavior, discontinue testing immediately
and contact Instron® Service.

Operator Protection Overview

The majority of hazards for operating materials testing systems are associated with:

• rapid movement of the crosshead causing crush injuries

• rapid closing of pneumatic grips causing pinch injuries

Operator Protection in Bluehill® provides a mechanism that lets you limit crosshead jog
speed and reduce grip closing pressure while you are setting up a test.

The default conditions during test set up are:

• crosshead jog speed reduced to a maximum of 600 mm/min, and can be set lower
if your risk assessment requires it
• grip closing pressure reduced to a default of 15 psi, and can be set lower if your risk
assessment requires it.
Refer to “How Operator Protection works with grips” on page 73 for more
details.

Operator Protection lets an Administrator configure the testing system to be consistent

with the risk assessment for that system.

32 M10-17415-EN
 Operator Protection Overview

Access to the controls for Operator Protection is password protected. If you have
Administrator rights you can modify Operator Protection in the Admin tab in Bluehill®.

Refer to “Operator Protection” on page 62 for more details.

Product Support: www.instron.com 33

Chapter: Risk reduction and safe use

34 M10-17415-EN
 Chapter 3
Installation

• Level the load frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

• Power supply compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
• System components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
• First time startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Level the load frame

Level the load frame immediately after you position it for installation. This prevents the
base from rocking and provides a level test surface for more accurate results.

Refer to Figure 3 on page 35 and follow the procedure.

Figure 3. Adjust the leveling feet

You need the following equipment (supplied in the ancillary parts kit unless specified
otherwise):

Product Support: www.instron.com 35

Chapter: Installation

• Spirit level (not supplied)

• 19mm combination wrench (part no. P632-484)
• 16mm thin open-ended wrench (part no. P632-482)

Caution
Make sure that the full weight of the frame is bearing down on the feet. If it is not, you
will not be able to adjust the feet.
1. Place a spirit level on the center of the base beam.
2. Use the 19mm wrench to loosen the lock nut (1) on each leveling foot.
3. Use the 16mm thin open-ended wrench to turn the level adjuster nut (2) on each foot
while you monitor the spirit level reading.

Warning
As you make adjustments, make sure that no more than 12 mm (0.5 in) of thread is
exposed.
If you expose more than 12 mm (0.5 in) of thread, there is a risk that the threaded
adapter can separate from the foot.

4. Rotate the spirit level 90 degrees to verify that the load frame is level side to side and
front to back.
5. When the machine is level, use the 16mm thin open-ended wrench to hold the level
adjuster nut (2) while using the 19mm wrench to tighten the lock nut (1) on each foot.

Power supply compatibility

The first step in the installation is to verify that the voltage and electrical plug are
compatible with the location’s power supply.

The power cord set and plug is based on the country to which the frame was shipped
and is compatible with the electrical requirements for that country.

Warning
Frames may overheat or suffer damage if connected to a power supply greater than
15% above the configured voltage.

36 M10-17415-EN
 Power supply compatibility

Caution
Frames may not be able to run at rated speeds if connected to a power supply more
than 10% below the configured voltage.

Before proceeding with installation, verify the following:

• The machine’s voltage is compatible with the main power supply of your facility.
Refer to “Determine the voltage setting” on page 38.
• The machine’s power cable can reach the electrical power supply with some slack in
the cable.
• The plug is compatible with the electrical power outlet.

If your power source is not the voltage originally specified on your purchase order, you
can follow the instructions in “Change the voltage setting” on page 38 to change the
voltage. Ensure that you use the appropriate electrical plug when changing voltages.

Warning
Hazard - Do not remove covers to any component of your system, unless it is
specified in a procedure.
There are dangerous voltages and rotating machinery inside the machine that may
cause bodily injury or damage to equipment.

Warning
Electrical hazard - to ensure safety and Electromagnetic Compatibility (EMC) the
facility’s receptacle must be a 3-wire grounded receptacle. The ground must be a
low impedance earth ground in accordance with national and/or local regulations.

The frame operates from a single-phase, two-wire grounded power source that applies
240 volts rms or less between the supply conductors or between the ungrounded supply
conductor and earth ground.

The connector on the power cable must be compatible with the power source. If the
power cable supplied with your system does not fit your power source outlet, add a male
plug to the cable that is compatible with the voltage. Observe the CEE wire color code as
follows:

• Brown - high (live)

• Light blue - low (neutral)

Product Support: www.instron.com 37

Chapter: Installation

• Green and yellow - earth (ground)

Set the input voltage

The load frame voltage is factory set according to the voltage that was specified at the
time of purchase.

Use the following procedures only if the facility power source does not match the frame
voltage setting. This situation may arise if the system is moved to another location with a
different voltage rating from the factory setting on the frame.

Determine the voltage setting

Figure 4. Power input connector with voltage setting

1. Locate the power input connector on the rear of the testing machine base.
2. Inspect the power input connector and refer to Figure 4 on page 38. The indicated
voltage in Figure 4 is 120V.

Change the voltage setting

Use the following procedure only if the facility power source does not match the frame
voltage setting. This situation may arise if the system is moved to another location with a
different voltage from the factory setting on the frame.

38 M10-17415-EN
 Power supply compatibility

You will need the following equipment (not supplied):

• Small flat-head screwdriver or probe

• Long-nose pliers

Warning
Electrical hazard - shut off the main power switch and disconnect the power to the frame
before changing the power setting. There are dangerous voltage levels inside the fuse
holder.

Warning
Hazard - Do not remove covers to any component of your system, unless it is
specified in a procedure.
There are dangerous voltages and rotating machinery inside the machine that may
cause bodily injury or damage to equipment.
1. Ensure that the power switch is in the Off (0 ) position and disconnect the power cable
from the power source. Verify that no LEDs are illuminated on the indicator panel.
2. Insert a small flat-head screwdriver into the slot indicated in Figure 5 on page 39
and pry out the fuse holder.

Figure 5. Prying out the fuse holder

3. Remove the fuse holder (1) from the power input connector.
4. Using long-nose pliers, remove the voltage selector unit (see Figure 6 on page 40).

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Chapter: Installation

Figure 6. Voltage selector unit

5. Re-insert the voltage selector unit into the connector so that the required voltage
faces front.
6. If necessary, change the fuse holder. Refer to“Replace a Fuse” on page 137 for
instructions on replacing a fuse.
7. Re-install the fuse holder into the connector. Ensure that the indicator pin now indi-
cates the correct input voltage. See Figure 4 on page 38 for reference.
8. Reconnect the power cable to mains power and turn on the system. Verify that the
white DISABLED indicator on the indicator panel illuminates.
9. Before you carry out any testing, perform the procedure described in “First time
startup” on page 51.

System components
Instron® Service installs your testing system. These diagrams and instructions are
provided as a reference if you need to move the system after the initial installation.

40 M10-17415-EN
 System components

Dual column table model load frame

5
11 7

1
4

2
3

9
8 6
10

Figure 7. Frame connections

Legend for Figure 7

Label Component More detail

1 Mains cable and plug

2 Ground connection (when required) “Ground connection detail”

on page 45

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Chapter: Installation

Label Component More detail

3 To Bluehill® Operator Dashboard or

separate computer (not shown in
Figure 7)

4 System ID label

5 and 6 Exhaust vents Leave at least 152 mm (6 in)

of space behind the frame to
allow for ventilation and
periodic access.

7 Cable clip Use T-nut, cable clips, cable

tie hooks and loops to secure
load cell cables and
pneumatic grip connections

8 Rear panel “Rear panel connections

detail” on page 43

9 Controller panel “Controller connections

detail” on page 44

10 Adjustable feet “Level the load frame” on

page 35

11 Power inlet connection, power switch, “Power supply

fuses and voltage selector compatibility” on page 36

Not shown Connector for handset On right hand side of frame

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Rear panel connections detail

6 4 5
1 2 3

Figure 8. Rear panel connections detail

Legend for Figure 8

Label Component More detail

1 Pneumatic grips - grip 1 connector

(typically upper grip)

2 Pneumatic grips - grip 2 connector

(typically lower grip)

3 Pneumatic grips - air inlet connector 120 psi (8.3 bar) maximum

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Chapter: Installation

Label Component More detail

4 Pneumatic grips - air exhaust connector Install air muffler or connect

to exhaust system

5 Pneumatic grips - air exhaust connector Install air muffler or connect

to exhaust system

6 Ethernet (to Bluehill® Operator Dashboard)

or separate computer

Warning
Do not connect the two exhaust ports together.
In some situations, unexpected grip motion can result. To prevent this, do not link the
exhaust ports (for example with a “T” or “Y” fitting). The two exhaust ports must remain
separate.

Controller connections detail

1 2 3 4

8 7
10 11 6

Figure 9. Controller connections detail

Legend for Figure 9

Label Component More detail

1 Encoder connector Connects to various

accessories, including AVE2
and AutoX extensometers

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 System components

Label Component More detail

2 Foot switch connector

3 Status indicators

4 PIP jack

5 Strain connectors Optional

6 Status indicators

7 Force connector Connects to load cell

8 Sync connector

9 Service connectors For use by Instron® Service

only

10 Expansion connector Optional

11 I/O (Input/Output) connector Optional

Ground connection detail

If the electrical supply is not grounded, you must use this functional ground connection
to connect the frame to a suitable ground in the building.

This connection can also be used in certain cases when auxiliary equipment, such as an
automatic extensometer or a monitoring device, requires grounding for functional
reasons or for EMC compliance. Any instructions for connection to this ground will be in
the documentation for the accessory.

Refer to Figure 10 on page 46 for connection details.

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Chapter: Installation

3
2

Figure 10. Ground connection detail

Legend for Figure 10

Label Description

1 Sheet metal

2 Connect ground cable for frame here

3 Connect ground cable for any accessories here

Connect the system components

Instron® Service installs your testing system. These instructions are provided as a
reference if you need to move the system after the initial installation.

This procedure describes the connections for the basic components of the system. If you
purchased additional accessories for your system, you need to refer to the
documentation for those accessories for proper installation.

Warnings
Electrical hazard - Do not connect power cables when the power is on. Turn the
power off to avoid hazardous voltages and component damage.

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Hazard - Do not remove covers to any component of your system, unless it is

specified in a procedure.
There are dangerous voltages and rotating machinery inside the machine that may
cause bodily injury or damage to equipment.
1. Ensure that the power switch is set to Off (O ) and the mains power cable to the
machine is disconnected.
2. Connect the load cell cable to the FORCE connection on the controller (see
“Controller connections detail” on page 44).
3. If using pneumatic grips, connect the grips and the air supply to the appropriate
connectors on the rear panel (see “Rear panel connections detail” on page 43).
4. If you are using pneumatic grips with a foot switch, connect the foot switch to the
FOOT SWITCH connector on the rear panel (see “Controller connections detail”
on page 44).
5. Connect the handset cable to the BNC connector on the right side of the load frame.
6. Use the cable clips on the column to secure the load cell cable and pneumatic grip
connections (see “Dual column table model load frame” on page 41).
7. Instron® systems provide an option to measure strain. If your system is equipped to
measure strain, connect the extensometer to the STRAIN 1 connection on the
controller (see “Controller connections detail” on page 44). Always use STRAIN 1
as the primary connection for strain. STRAIN 2 is an available option that you can use
to connect another extensometer or other strain device to the system.
Caution
The connectors labeled SERVICE are for the use of Instron® Service only. Never
connect any equipment to any of the SERVICE connectors.
8. If the frame or any accessories require a ground (earth) connection, make the
connections (refer to “Ground connection detail” on page 45).
9. Connect the Ethernet connection on the Bluehill® Operator Dashboard to the
Ethernet connection on the rear panel (see “Rear panel connections detail” on
page 43).
10. Verify the following:
a The machine’s voltage is compatible with the main power supply of your facility.
Refer to “Determine the voltage setting” on page 38. If it is not, refer to
“Change the voltage setting” on page 38.
b The plug is compatible with the electrical power outlet.

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Chapter: Installation

Warning
Frames may overheat or suffer damage if connected to a power supply greater than
15% above the configured voltage.

Caution
Frames may not be able to run at rated speeds if connected to a power supply more
than 10% below the configured voltage.

11. Connect the mains power cable to the IEC connector on the rear of the machine and
to the electrical power supply (see “Dual column table model load frame” on
page 41).
12. Connect the mains power cable on the Bluehill® Operator Dashboard to the electrical
power supply.

The system is now ready to be turned on. Refer to “First time startup” on page 51.

Bluehill® Operator Dashboard

The Bluehill® Operator Dashboard provides a touch-friendly interface for controlling your
testing machine using Bluehill® software.

Adjustment and connection

Instron® Service will install the Bluehill® Operator Dashboard on your system.

1. You can adjust the height of the Bluehill® Operator Dashboard for the comfort of
different operators. Loosen the lock (1 in Figure 11 on page 49) and slide the arm
mounting (2 in Figure 11 on page 49) to the desired height. Re-tighten the lock.

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Figure 11. Height adjustment

2. Connect the Ethernet connector on the rear of the Bluehill® Operator Dashboard to
the Ethernet connector on the rear panel of the testing machine.
3. Connect the mains power cable to the electrical power supply.

Disconnection and moving

If you need to move the testing system you must disconnect and remove the Bluehill®
Operator Dashboard as follows:

1. Ensure that the power switch is set to Off and the mains power cable is disconnected.
2. Disconnect all cables that connect to or from the Bluehill® Operator Dashboard.

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Chapter: Installation

Figure 12. Mounting arm

3. If necessary, loosen the set screw on the side of the “elbow” on the mounting arm (1
in Figure 12 on page 50).
4. Operate the release mechanism on top of the “elbow” (2 in Figure 12 on page 50)
and lift the Bluehill® Operator Dashboard clear of the mounting arm (Figure 13 on
page 51).

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 First time startup

Figure 13. Lift to remove

5. Place the Bluehill® Operator Dashboard face down on a soft material to avoid
scratching the screen.

First time startup

When the testing system is installed, you need to configure Bluehill® to communicate
with the testing hardware.

1. Ensure that all cables are properly installed and securely connected.

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Chapter: Installation

2. Turn the power switch on the machine to the On (1 ) position.

The white LED above the DISABLED indicator flashes.
3. Turn on the power to the Bluehill® Operator Dashboard and any other accessories
that make up the testing system.
4. Start the Bluehill® software.
The first time the software is started, the configuration wizard runs.
5. Follow the instructions in the configuration wizard. The keycode for the software is
printed on the media supplied. Steps include:
• select the controller type and frame model
• enter the system ID (located on a label on the rear of the frame)
• enter the Ethernet address (located on a label on the controller panel)
• enter any additional information, e.g. service contract number
• select any additional accessories that are installed
If you need to change any of these settings, when you purchase an additional accessory
for example, go to the Admin tab in the software.

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Function of controls

• Power input connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

• Emergency Stop button. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
• Handset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
• Indicator Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
• Bluehill® software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
• Operator Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
• Bluehill® Operator Dashboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
• Pneumatic Grips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Before you start the system, make sure you familiarize yourself with the following
controls:

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Chapter: Function of controls

Power input connector

1 2 3 4

Figure 14. Power input connector

Legend for Figure 14

Label Component

1 IEC inlet connector

2 Power switch

3 Selected voltage

4 Fuse carrier and voltage selector access

The power input connector, shown in Figure 14 on page 54, performs the following
functions:

• connects the load frame to the electrical power supply

• contains the ON/OFF switch
• holds the power fuse
• controls the voltage setting. The voltage setting can be changed if necessary, refer
to “Power supply compatibility” on page 36.

Refer to Figure 2 on page 17 to see the location of the power input connector on your
load frame.

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Emergency Stop button

Figure 15. Emergency Stop button

The Emergency Stop button is a large, round, red button on the testing system. Press
this button to stop the test as soon as possible when a condition develops that:

• could affect the safety of anyone operating the system

• could damage the specimen, load frame, or test fixtures

Warning
If you are using an integrated air kit with a foot switch to control a set of pneumatic
grips, be aware that pressing the Emergency Stop button to disable the frame will
also deactivate the grips, causing them to open.

With an integrated air kit, any action that disables the frame will also open the grips.

Handset
All the controls for the testing system are on the handset. When you operate a control on
the handset, any change to the testing mode is displayed on the indicator panel (refer to
“Indicator Panel” on page 58).

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Chapter: Function of controls

Figure 16. Handset

Legend for Figure 16

Label Description

1 Softkeys 1 and 2
These softkeys duplicate the functions assigned to Softkey 1 and 2 in
Bluehill® software.
Buttons illuminate white when available.

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Label Description

2 UNLOCK button - switches the frame between the following modes:

• DISABLED to SET UP, i.e. enable the frame
• SET UP to CAUTION, e.g. prepare to start a test
Button illuminates white when available.

3 RETURN button - returns the crosshead to zero displacement.

Return speed is set in Bluehill® software and can be any value up to the
maximum speed for the frame.
The button is only available after the frame has transitioned to CAUTION
mode.
When you press this button, the frame runs in TESTING mode until the
return is completed.
Button illuminates white when available.

4 START TEST button - press the button to start a test. Bluehill® software
must be in the Test screen before you can start a test.
• The button is only available after the frame has transitioned to CAUTION
mode.
• When you press this button, the frame runs in TESTING mode until the test
is completed or you initiate another action.
Button illuminates white when available.

5 JOG buttons
When in SET UP mode, the jog speed is restricted to 600 mm/min or less.
When in CAUTION or TESTING mode, the jog speed is unrestricted, i.e. any
speed up to the maximum speed for the frame.
Buttons illuminate white when available.

6 FINE JOG wheel

Turn this thumbwheel to slowly position the crosshead. This control lets you
set an accurate zero displacement point, or set a precise grip position for
loading specimens.

7 SPECIMEN PROTECT button

Press this button to toggle on or off the SPECIMEN PROTECT function. This
function protects the test specimen and load string components from
overloads.
Button illuminates white when available and changes to green when you
activate it.

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Chapter: Function of controls

Label Description

8 ZERO DISPLACEMENT button

Press this button to set the current position of the crosshead as the zero
displacement point (or gauge length) position. After setting the zero
displacement point, the crosshead returns to this position when:
• You press the RETURN button
• The crosshead encounters a pre-set limit or event that instructs the cross-
head to return to the zero displacement point
Button illuminates white when available and changes to green when you
activate it.

9 STOP button
Stops crosshead motion, e.g. during jogging, testing, or returning to zero.
If you need to disable the frame, press and hold the STOP button for
2 seconds.
Button illuminates white when available

The UNLOCK , TEST and RETURN buttons illuminate to indicate availability.

Indicator Panel
This panel shows the status of the testing system. When you operate a control on the
handset (refer to “Handset” on page 55), the testing mode is displayed on this panel.

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Mode indicators - different color LEDs indicate the current mode of the frame.

• DISABLED (white)

• SET UP (blue)

• CAUTION (yellow)

• TESTING (red)

Bluehill® software
The software controls:

• setting test parameters

• collecting and analyzing test data

Refer to the Bluehill® online help and reference for more details.

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Chapter: Function of controls

Home Screen

Bluehill® software opens at the Home screen, with the following components:

• Console area at the top and bottom of the screen. Provides important information
about the system. Always visible and available from any screen.
• Buttons to access other parts of the software - creating test methods, running tests,
analyzing data, producing reports.

Buttons

Table 4. Buttons on the Home screen

Button Function

Test Perform tests on specimens. The software displays a sequence of screens

where you:
1 choose a test method from which to load test parameters.
2 perform tests.
3 name the sample and select a location to store the test data.

Method Create, edit and save test method files.

Analysis Modify an existing sample or replay a sample with parameters from a

(optional) different test method.

Admin Change the configuration of the testing system.

Logout Log out the current user and let a new user log in to the software. When
you log out you do not exit the program.
This button is hidden if Security is not enabled.

Instron® Connect Uses an Internet connection to check the status of the system, including
verification status of transducers. Checks for software updates.
You can also use this connection to contact Instron® Service for
assistance and upload files to Instron® Service for diagnosis.

Help Open the online help.

Exit Exit the program.

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Console area

The console area provides important information during testing and is also where you
can edit system wide settings.

At the top of the screen:

• Live displays track values of parameters that you choose

• System button opens the System details dialog where you can view system
information, view the event logs, and change settings including:

• set up the load frame and any connected transducers

• set up live displays
• set up soft keys
• set up the test area, specimen protect, jog rate, return rate and collision
mitigation
• enable features on pneumatic grips

At the bottom of the screen:

• soft keys that you have set up in the soft keys screen appear here

Status Bar

The status bar appears at the bottom of every screen and provides status information
for:

• Security - the name of the currently logged in user or a statement that security is off.
• Machine - is the software connected to a testing machine or running in No machine
mode.
• Test type - e.g. tension, compression, metals.
• Sample - the name of the current sample file that is open, if any.
• Method - the name of the current method file that is open, if any.
• Report - the name of the current report template that is open, if any.
• Progress messages - various messages indicating progress, for example “Opening”,
“Closing” and “Generating”.

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Chapter: Function of controls

Operator Protection
Operator Protection in Bluehill® provides a mechanism that lets you limit crosshead jog
speed and reduce grip closing pressure while you are setting up a test.

Operator Protection lets an Administrator configure the testing system to be consistent

with the risk assessment for that system.

Access to the controls for Operator Protection is password protected. If you have
Administrator rights you can modify Operator Protection in the Admin tab in Bluehill®.

Operating Modes
Bluehill® displays the current system mode corresponding to the four LEDs on the
indicator panel:

DISABLED SET UP CAUTION TESTING

(white) (blue) (yellow) (red)

Disabled

Bluehill® displays gray border with white text, Frame is disabled.

DISABLED (white) LED illuminates on the indicator panel.

This is the default state of the frame upon start up after the software is opened. If the
frame is not connected to the software, the LED flashes.

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When the frame is disabled:

• crosshead cannot move

• pneumatic grips cannot operate

The frame disables when:

• Emergency stop button is pressed

• A frame fault occurs
• You press and hold the STOP button for 2 seconds.

When the frame transitions from any other mode to disabled, any pneumatic grips
connected to the integrated air kit will open automatically.

To proceed to SET UP mode, you press the UNLOCK button.

Set Up

Bluehill® displays blue border with white text, Ready to set up.

SET UP (blue) LED illuminates on the indicator panel.

This is a restricted state of the frame.

The indicator LED flashes blue whenever the crosshead is moving, e.g. jogging.

When the frame is in set up mode:

• crosshead can jog at the operator protect jog speed (no greater than 600 mm/min)
• pneumatic grips can close at the initial grip pressure (default value of 15 psi)

The frame returns to set up mode when:

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Chapter: Function of controls

• the test is paused (e.g. during extensometer removal)

• after a test is complete
• after a return is complete
• when an interlocked shield is opened

To proceed to CAUTION mode, you press the UNLOCK button.

Caution

Bluehill® displays yellow border with white text, Ready to test.

Yellow warning message, Keep clear of test area, disappears after a few seconds.

CAUTION (yellow) LED illuminates on the indicator panel.

This is an unrestricted state of the frame.

The indicator LED flashes yellow whenever the crosshead is moving, e.g. responding to
the software specimen protect setting.

When the frame is in caution mode:

• pneumatic grips, previously closed at initial grip pressure in the set up state, clamp
at full test pressure
• the frame returns to set up mode if a test is not started within 2 seconds (unless a
debris shield with interlocks is present and closed)

To start the test, you press the START TEST button.

To return the crosshead after completing a test, you press the RETURN button.

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Testing

Bluehill® displays a red border with white text, Test in progress. The border flashes while
the crosshead is moving.

Red warning message, Keep clear of test area, disappears after a few seconds.

TESTING (red) LED illuminates on the indicator panel and flashes while the crosshead is
moving.

This is an unrestricted state of the frame.

When the frame is in testing mode:

• frame is currently running a test

• frame is currently returning to zero displacement after a test

The frame also enters this mode during high-speed jogging, which can be initiated by
pressing and holding the UNLOCK button while simultaneously pressing one of the
JOG buttons. Once the jog has started, you can release the UNLOCK button so long as
you maintain pressure on the JOG button. Crosshead speed ramps up gradually to the
maximum speed of the frame.

Move between modes

The following table shows how the controls on the handset move the system between
modes to set up and run a test.

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Chapter: Function of controls

Table 5. Move between modes

Initial condition Action Result

1 DISABLED Press SET UP

(white) (blue)

2 System remains in set up mode until you make a change. During this time you can:
• move the crosshead at the restricted speed set up in the Admin tab, up to a maximum of
600 mm/min
• operate pneumatic grips at the initial pressure set up in the Admin tab, up to a maximum of
15 psi
When the specimen is installed and Bluehill® is displaying the Test screen, you can move on.

3 SET UP Press CAUTION

(blue) (yellow)

Pneumatic grips clamp to full

pressure.

4 CAUTION Press (within 2 secs) TESTING

(yellow) (red)

5 TESTING Test runs to completion. SET UP

(red) (blue)

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Table 5. Move between modes (Continued)

Initial condition Action Result

6 SET UP Press CAUTION

(blue) (yellow)

7 CAUTION Press (within 2 secs) TESTING

(yellow) (red)

Crosshead returns to zero

position at speed set in the
software.

8 TESTING Crosshead returns to zero SET UP

(red) position. (blue)

Additional notes:

• Once the frame is enabled, the default mode when it is idle is SET UP mode with the
light above the UNLOCK button illuminated. If you want to disable the frame, press
and hold the STOP button for 2 seconds.
• When you enter CAUTION mode, and if you are using a footswitch to control the
grips, pneumatic grips clamp to full pressure. If you do not press the START button
within 2 seconds, the frame returns to SET UP mode. The grips, however, remain at
full pressure until you run a test. If you are using toggle switches on the grips to
control them, the grips are at full pressure only during TESTING mode.

Typical test flow

“Move between modes” on page 65 describes each of the test controls and how they
are used to move between testing modes.

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Chapter: Function of controls

For a step-by-step description of a typical test flow using these controls, refer to
“Testing a sample” on page 111. This section contains two procedures, one for
systems using an interlock and one for systems without an interlock.

Jog at High Speed

Under normal conditions, in SET UP mode, jog speed is limited to 600 mm/min or less.
There may be situations, such as moving the crosshead into position at the start of a
testing session, where this low speed in inconvenient.

Jogging at high speed involves more risk so the process involves pressing both the
UNLOCK and JOG buttons at the same time, as follows:

Table 6. High speed jog

Initial condition Action Result

SET UP Press TESTING

(blue) (red)

and
Crosshead moves up, ramping
up to the maximum speed set in
together the software.

SET UP Press TESTING

(blue) (red)

and
Crosshead moves down,
ramping up to the maximum
together speed set in the software.

Additional notes:

• Although you must press the UNLOCK and JOG buttons together to start the jog at
full speed, you can release the UNLOCK button once the crosshead starts to move.
The crosshead ramps up to full speed and continues to move while you are pressing
the JOG button.

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 Operator Protection

• You would typically use this functionality when initially setting up test fixtures and
bringing the crosshead to the correct position to install specimens. Thereafter, you
can use the RETURN button to bring the crosshead back to the zero displacement
position.

Operator Protection Controls

If you have Administrator rights, you can make changes to the Operator Protection
settings, via Admin > Frame > Operator Protection.

For more details on the operation of these software controls, refer to the Bluehill®
online help and reference.

Operator Protection options define the restrictions on the system when it is in SET UP
mode.

Control Description

Jog rate Sets the restricted speed of the crosshead when the
system is in SET UP mode. Default setting is 600 mm/min,
which is also the maximum permitted.
If the maximum speed of the crosshead is less than
600 mm/min, then the restricted speed is limited to the
maximum speed of the frame.

Initial grip air pressure Sets the maximum grip pressure allowed when the system
is in SET UP mode.
Allows the operator to close the grips on the specimen with
sufficient pressure to hold the specimen in place but
reduces the risk of injury from pinching.

Override point of control Default is disabled, which means that the primary point of
control for the system is at the load frame. The operator
must use the buttons on the frame to start a test or
position the crosshead.
When this option is enabled, the system can be configured
to use the software to initiate these actions.

Override point of control - Default is Frame Controls, i.e. start test and return using
Start test and return the buttons on the frame.
Only choose Remote if you are using an interlock
accessory. The interlock automatically transitions the
system to CAUTION mode when the interlock is closed. If
there is no interlock, you must press the UNLOCK button
to transition to CAUTION mode.

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Chapter: Function of controls

Control Description

Pneumatic grips Enables and disables pneumatic grips connected to the

testing system with the integrated air kit.

Grip control (when pneumatic Default is Footswitch. You close both grips using the
grips are enabled) integrated air kit and foot switch.
Toggle switch lets you use the toggle switches on the
grips with the integrated air kit. The footswitch is disabled
when you choose this.
Remote lets you control the grips via a software program
operating through the API.
Upper footswitch/lower remote applies only if your test
method includes pretension. Upper grip closes with the
foot switch and the lower grip closes automatically after
the specified load threshold is achieved.

Behavior when the interlock If the testing system includes an accessory with an
is tripped interlock, then Operator Protection defines the behavior
of the frame when the interlock is tripped. For example,
when an interlocked door is opened and the operator has
access to the test area.
Disable frame - the frame is disabled when the interlock
is tripped. This is the recommended setting as it is the
safest.1
Allow limited motion - the frame remains enabled when
the interlock is tripped. This allows an operator access to
the test area while allowing limited crosshead movement
as specified in Operator Protection.
Although this option can facilitate installing a specimen or
removing an extensometer during a test, it also increases
the risk of injury. You should perform a risk assessment
before selecting this option.
1. If you choose this option, be aware that the operation of pneumatic grips is also disabled. If
you want no crosshead motion when the interlock is tripped but need pneumatic grips to
function, select Allow limited motion and set Jog rate to 0 mm/min.

Bluehill® Operator Dashboard

The Bluehill® Operator Dashboard provides a touch-friendly interface for controlling your
testing machine using Bluehill® software.

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Basic touch functions

Basic touch screen functions in Bluehill®:

• tap a control to select it (equivalent to clicking in non-touch interfaces)

• to enter text in a field, tap the field and, if the keyboard is not already displayed, tap
the keyboard icon to display it
• to enter numbers in a field, tap the keypad button to the right of the field
• if there is a task menu associated with part of a screen (accessed via right-click in
non-touch interfaces), there will be a Menu button on the screen. Tap it to open the
menu.

• if there is a Properties dialog associated with part of a screen, there will be a

Properties button on the screen. Tap it to open the dialog.

• enable/disable controls (check boxes in non-touch interfaces) are toggle controls.

Tap the control to enable or disable it. Enabled is colored, disabled is gray.

Touchscreen gestures

Gestures supported in Bluehill®:

• graph - pinch to zoom (must also be enabled in the Admin screen)

• test workspace component - if the component is maximized, you can move between
components by selecting the appropriate icon in the tool bar below the maximized
component
• test workspace setup - when editing test workspace layout, swipe left or right to
move between available components
• test workspace specimen selector - swipe up (portrait orientation) or swipe left
(landscape orientation) to display a panel that lets you quickly include or exclude a
specimen from the sample
• any scrollable screen component - flick up or down, left or right to quickly scroll
through the list

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Chapter: Function of controls

Pneumatic Grips
Table 7 on page 72 lists the pneumatic grips recommended for use with these testing
systems, combined with the optional integrated air kit and footswitch. They utilize the
grip control features of Operator Protection including reduced initial grip pressure, which
reduces the speed and force of closing while setting up a test, thus reducing the risk of
injury.

Warning
The Cat. no. 2701-004 air kit and footswitch combination should never be used with
any of the grips listed in Table 7 on page 72 nor should it be used with any grips for
which it was not originally supplied.

For pneumatic grips which were originally supplied with the pneumatic-only, single
pedal footswitch (Cat. no. 2701-004), be aware that these grips and associated air
kit and footswitch do NOT utilize any of the features of Operator Protection.

Warning
Always disable the frame before installing or changing pneumatic grips.
When the frame is enabled, the integrated air kit is pressurized. If you attach a grip to
the system in this state, the grip could close.

Table 7. Recommended pneumatic grips

Grip model number Grip capacity

2712-041 1 kN

2712-042 2 kN

2712-045 5 kN

2712-046 10 kN

2712-052 250 N

2712-051 50 N1
1. These low capacity grips do not include the toggle switch.

Other pneumatic grips can be used with the system, including operation with the
integrated air kit and footswitch, but they may not be designed to utilize the full range of
features of Operator Protection. Contact Instron® Service for advice.

72 M10-17415-EN
 Pneumatic Grips

How Operator Protection works with grips

When in SET UP mode, pneumatic grips close at a reduced initial grip pressure. The
lower the pressure, the lower the force and speed at which the grips close. You should
therefore set this speed to the minimum required to close the grips and grip the
specimen within a reasonable time, but taking into account that even low pressures can
cause injury.

The default value is 15 psi. The following table lists recommended initial grip pressures
for the pneumatic grips listed in Table 7 on page 72:

Recommended initial grip

Grip model number Grip capacity pressure - psi (bar)

2712-051 50 N 15 (1.03)

2712-052 250 N 12 (0.83)

2712-041 1 kN 9 (0.62)

2712-042 2 kN 5 (0.34)

2712-045 5 kN 8 (0.55)

2712-046 10 kN 7 (0.48)

Minimum pressure may be slightly higher or lower for any given grip due to age,
environmental conditions and use.

Warning
Be aware that even at these recommended initial grip pressures, the force exerted
by the closing grips can cause injury.
For example, a 10 kN grip closing at the default initial pressure of 15 psi exerts a
minimum force of 4kN (900 lbf). The same grip closing at 7 psi exerts a minimum force
of 1.9kN (420 lbf), still a significant force that can cause injury.

Warning
Be aware also that setting initial grip pressure too low may result in the grip not
closing completely at the initial grip pressure. This may cause a hazard when the
grips transition to full pressure.
If the grips do not close completely at the initial pressure, they will close at full force
when the grips transition to full pressure.

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Chapter: Function of controls

Warning
If the grips feature an air inlet flow adjustment control (see below), make sure that
the flow adjustment is set to fully open (screw fully counterclockwise).

Do not use the air inlet flow adjustment control to reduce air flow as you risk
transitioning from initial pressure to full pressure before the grips have closed. If the
grips do not close completely at the initial pressure, they will close at full force when
the grips transition to full pressure.

In addition to the hazard caused by reducing the air flow, operation of the air inlet flow
adjustment control can result in an inaccurate grip pressure reading which may disable
the frame.

You can remove the air inlet flow adjustment control and connect the 1/8” NPT quick
disconnect directly to the grip or via a 1/8” NPT right angle male to female adapter, as
shown below.

74 M10-17415-EN
 Pneumatic Grips

Operate grips using footswitch

The recommended pneumatic grip configuration is one of the grips listed in Table 7 on
page 72 combined with the integrated air kit and footswitch.

If for any reason you have to disconnect the footswitch from the frame controller, you
must cycle power on the frame to re-establish communication between the footswitch
and the frame.

The operation of this configuration with Operator Protection is described in “Operator

Protection using the footswitch” on page 75.

Operator Protection using the footswitch

The point of control for grips in the Operator Protection control dialog must be set to
Footswitch.

The footswitch operates as follows:

• tap right pedal once, closes grip connected to port 1 (typically the top grip)
• tap right pedal again, closes grip connected to port 2 (typically the bottom grip)
• tap left pedal once, opens both grips

The footswitch integrates with Operator Protection as follows:

• in SET UP mode, you can open and close the grips

• in CAUTION mode, you can open the grips
• in DISABLED or TESTING mode, the footswitch does not operate

Warning
If your grips have toggle switches installed, do not use them when the point of
control for grips is set to Footswitch.
If you intend to always use the footswitch, you should replace the toggle switches on the
grips with the blanking plugs provided with the grips in the ancillary parts kit.
1. Starting with the system in DISABLED mode, press the UNLOCK button.
The system moves to SET UP mode.
2. Operate the system in SET UP mode and install the specimen using the footswitch to
open and close the grips at the initial pressure set in the software.
3. Press the UNLOCK button to transition to CAUTION mode.
The grips pressurize to full pressure.

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Chapter: Function of controls

4. Within 2 seconds, press the START TEST button to start the test.
If you do not start the test immediately and the system returns to SET UP mode, the
grips continue at full pressure until you run a test or release the grips.
The system transitions to TESTING mode.
5. Stop the test, or the test ends.
The system reverts to SET UP mode but the grips are maintained at full pressure
until you open them using the footswitch.

Warning
Do not operate the toggle switches when the testing system is in TESTING mode and
the grips are pressurized to full pressure.The system may detect an error and disable
the frame.
You must not operate the toggle switches when the grips are at full pressure. The grips
will open but when you use the toggle switch again to close the grips, the grips will close
at full pressure and the system may detect an error and disable the frame.
You may start a test with one grip closed if desired. If you move to CAUTION mode after
closing one grip, you cannot close the second grip, even if you transition back to SET UP
mode. You must use the footswitch to open the first grip in order to proceed.

Operate grips using toggle switches

The recommended pneumatic grip configuration is one of the grips listed in Table 7 on
page 72 combined with the integrated air kit and footswitch.

If you are using the integrated air kit but prefer to use toggle switches on the grips
instead of a footswitch there are some differences in the operation of the grips that you
should be aware of:

• Grips maintain full pressure during TESTING mode only. At the end of a test, when
the system reverts to SET UP mode, the grip pressure reduces to the initial grip
pressure. This may cause problems if the specimen has stored energy which could
cause the specimen to slip out of the grips. If that is a concern, you should use a
footswitch to run your tests.
• You must not operate the toggle switches when the grips are at full pressure. The
grips will open but when you use the toggle switch again to close the grips, the grips
will close at full pressure and the system may detect an error and disable the frame.

The operation of this configuration with Operator Protection is described in “Operator

Protection using the toggle switches” on page 77.

76 M10-17415-EN
 Pneumatic Grips

Operator Protection using the toggle switches

The point of control for grips in the Operator Protection control dialog must be set to
Toggle switch.

If you have a footswitch connected to the system, it will not operate.

Warning
Make sure that the toggle switches are in the open position.

If the toggle switches are in the closed position, the grips will close immediately
when the system transitions to SET UP mode.

1. Starting with the system in DISABLED mode, press the UNLOCK button.
The software displays a message, warning you to make sure that the toggle
switches are in the open position.
2. Press the UNLOCK button again to transition to SET UP mode.
3. Operate the system in SET UP mode and install the specimen using the toggle
switches to open and close the grips at the initial pressure set in the software.
4. Press the UNLOCK button to transition to CAUTION mode. The grips are maintained
at the initial grip pressure.
5. Within 2 seconds, press the START TEST button to start the test.
The system transitions to TESTING mode and the grips pressurize to full pressure.
6. Stop the test, or the test ends.
The system reverts to SET UP mode and the grip pressure returns to the initial grip
pressure.

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Chapter: Function of controls

Caution
If your test ends and the specimen has stored energy, e.g. the specimen did not break,
the specimen may slip out of the grips when the grip pressure reduces at the end of the
test.
If this could be an issue, it is recommended that you set the point of control for grips to
Footswitch and use a footswitch for your tests. When using a footswitch, pneumatic
grips remain at full pressure after the test ends until you release them using the
footswitch.

Warning
Do not operate the toggle switches when the testing system is in TESTING mode and
the grips are pressurized to full pressure.The system may detect an error and disable
the frame.
You must not operate the toggle switches when the grips are at full pressure. The grips
will open but when you use the toggle switch again to close the grips, the grips will close
at full pressure and the system may detect an error and disable the frame.

Grips not in use

There may be situations where you want to remove the grips from the load string,
placing them on a bench alongside the system perhaps while you perform different
types of tests. Be aware that if the point of control for grips is set to Toggle, the grips
could present a hazard.

Warning
If you remove the pneumatic grips from the load string but do not disconnect them
from the integrated air kit, you should disablethe grips in the Operator Protection
controls in the software.
If the point of control for grips in the software is set to Toggle, and you remove them
from the load string without disconnecting them from the integrated air kit, the grips will
close at initial pressure and cycle between full pressure and initial pressure as you
continue your testing.

78 M10-17415-EN
 Chapter 5
Assemble the load string

• Select a load cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

• Before you begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
• Install the load cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
• Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
• Coupling adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
• Select Grips and Fixtures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
• Preload the load string . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
• Unload the load string . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

The load string consists of all the hardware components between the crosshead and the
base of the testing machine. It includes the load cell, grips, the specimen and any
adapters that let you connect any of these components together.

Instron® Service sets up the testing machine during installation, but you may need to
change one or more of these components for different types of testing.

When creating a load string, keep in mind the maximum capacity for all the components
making up the load string. The expected test load should not exceedthe maximum
capacity of any load string components including, but not limited to:
• load frame
• load cell
• adapters
• grips or fixtures

Select a load cell

If you know the approximate tensile or compressive strength of the material that you are
testing, use these guidelines to choose a load cell:

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Chapter: Assemble the load string

• Make sure that the load cell is verified for the range of force that you anticipate for
your testing
• If there is a choice between two different load cells because of overlapping ranges:
• select a higher capacity load cell when you require minimum deflection of the
load cell
• select a lower capacity load cell when you require maximum long term balance
or stability

If you don’t know the tensile strength of the material, refer to a Properties of Materials
handbook to obtain an approximate strength. To calculate the tensile strength in force
units for a specimen, use the following equation:

tensile strength x cross-sectional area

For example, for a standard ASTM tensile specimen (0.502 in wide, 0.125 in thick)
made with a material of tensile strength 5200 psi (from Materials Handbook) perform
the following calculation:

5200 x 0.502 x 0.125 = 328 lbf

This produces a recommendation of the 5 kN (1000 lb, 500kg) capacity load cell.

If you cannot determine an approximate value of tensile strength, use the highest
capacity load cell rated for the frame. Perform a preliminary test at a very slow speed to
obtain the load range required. You can then determine if a lower capacity load cell can
provide improved resolution.

Table 8 on page 80 and Table 9 on page 81 list the load cells that are recommended
for use with these frames.

If you have a load cell that is not listed, contact Instron® for advice on compatibility and
adapters that may be available for your load cell.

Table 8. 2530 Series

Capacity Effective length

Catalog no. N (lbf) mm (in) Mechanical fitting Interface size

2530-5N 5 N (1) 48 (1.89) 2.5 mm clevis pin OOf

and 6 mm clevis pin Of

2530-10N 10 N (2.25) 48 (1.89) 2.5 mm clevis pin OOf

and 6 mm clevis pin Of

2530-50N 50 N (11) 48 (1.89) 2.5 mm clevis pin OOf

and 6 mm clevis pin Of

80 M10-17415-EN
 Before you begin

Table 8. 2530 Series (Continued)

Capacity Effective length

Catalog no. N (lbf) mm (in) Mechanical fitting Interface size

2530-100N 100 N (22) 48 (1.89) 2.5 mm clevis pin OOf

and 6 mm clevis pin Of

Table 9. 2580 Series

Capacity Effective length

Catalog no. N (lbf) mm (in) Mechanical fitting Interface size

2580-500N 500 N (112) 100 (3.9) 6 mm clevis pin Of

2580-1KN 1 kN (225) 100 (3.9) 6 mm clevis pin Of

2580-2KN 2 kN (450) 100 (3.9) 6 mm clevis pin Of

2580-5KN 5 kN (1125) 127 (5.0) 12.5 mm clevis pin Df

2580-10KN 10 kN (2250) 148 (5.8) 12.5 mm clevis pin Df

2580-30KN 30 kN (6750) 148 (5.8) 12.5 mm clevis pin Df

2580-50KN 50 kN (11250) 148 (5.8) 12.5 mm clevis pin Df

Before you begin

Check the following before installing a load cell:

• You have all the parts required for installation. Refer to the appropriate figure for
your load cell in “Install the load cell” on page 82.
• Mounting screws are lubricated.
• A torque wrench is available.
• All threads, bores and mating surfaces are clean and free of damage.
• The crosshead is positioned below its travel midpoint so that you can easily and
safely access the crosshead.
• The frame is in the disabled state, i.e. the white LED above the DISABLED indicator
on the indicator panel is illuminated.

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Chapter: Assemble the load string

Install the load cell

These instructions cover the installation of load cells from 5 N up to 50 kN.

The hardware required to install a load cell depends on the following:

• the model number and capacity of the load frame

• the model number and capacity of the load cell
• the configuration of the hole in the center of the crosshead

The hole in the center of the crosshead can have one of two configurations.

• a shallow counter-bore to accommodate a locating ring only

• a double counter-bore to accommodate a locating ring and a spacer

Each installation procedure starts with a diagram of the load cell and crosshead
followed by two separate sections listing the hardware required for each of the
crosshead configurations. The last section details the installation procedure.

• “Install a 2530 load cell (capacities 5 N through 100 N)” on page 83

• “Install a 2580 load cell (capacities 500 N through 5 kN)” on page 87
• “Install a 2580 load cell (10kN capacity)” on page 91
• “Install a 2580 load cell (capacities 30kN and 50kN)” on page 94

82 M10-17415-EN
 Install the load cell

Install a 2530 load cell (capacities 5 N through 100 N)

2
3

4 5
6

Figure 17. Install a 2530 series load cell - capacities 5 N through 100 N

Determine the type of counter-bore configuration on the crosshead on your system and
refer to the appropriate section, either “Crosshead configuration with single
shallow counter-bore” on page 84 or “Crosshead configuration with single
shallow counter-bore” on page 84 to select the hardware required for installation.

Refer to “Procedure” on page 85 for installation instructions.

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Chapter: Assemble the load string

Crosshead configuration with single shallow counter-bore

The following tables list the hardware required to install the load cell on each load frame
model. SW is a standard width frame, EW is an extra wide frame.

Table 10. Component and Part numbers for individual frame models

Label in Figure 17
on page 83 Component and Part Number

68TM-5 68TM-30 (SW)

68TM-10 68TM-50 68TM-30 (EW)

1 Screw, M10 x 90 Screw, M10 x 130 Screw, M10 x 140

(201V62) (201V633) (71-63-1169)

2 M10 load washer Not required M10 load washer

(610J9) (610J9)

Table 11. Remaining components for all frame models

Label in Figure 17 on
page 83 Component Part number

3 M10 spacer T604-90

4 Load cell anti-rotation pin 705K84

5 Locating ring T1335-1048

6 2530 load cell - 5 N through 100 N

7 Crosshead

84 M10-17415-EN
 Install the load cell

Crosshead configuration with double counter-bore

The following tables list the hardware required to install the load cell on each load frame
model. SW is a standard width frame, EW is an extra wide frame.

Table 12. Component and Part numbers for individual frame models

Label in Figure 17
on page 83 Component and Part Number

68TM-5 68TM-30 (SW)

68TM-10 68TM-50 68TM-30 (EW)

1 Screw, M10 x 70 Screw, M10 x 120 Screw, M10 x 120

(201V60) (201V632) (201V632)

2 M10 load washer M10 load washer M10 load washer

(610J9) (610J9) x 2 (610J9) x 2

Table 13. Remaining components for all frame models

Label in Figure 17 on
page 83 Component Part number

3 M10 spacer T604-90

4 Load cell anti-rotation pin 705K84

5 Locating ring T1335-1048

6 2530 load cell - 5 N through 100 N

7 Crosshead

Procedure

1. Refer to Figure 17 on page 83 and its associated legend.

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Chapter: Assemble the load string

Caution
Check items 1, 2 and 3 in the legend carefully. The screw, washer and spacer
required depends on the frame model.

2. Collect together the correct mounting screw, washer, spacer, anti-rotation pin and
locating ring for your combination of load frame and load cell.
3. Assemble the mounting screw, washer and spacer, as shown in the figure.
4. Place the mounting screw, washer and spacer assembly into the top of the central
bore of the crosshead.
5. Insert the anti-rotation pin into one of the holes on the bottom of the crosshead.
There are four pin holes on the bottom of the crosshead that let you position the load
cell either straight on or at an angle.
6. Place the locating ring into the top surface of the load cell that connects to the cross-
head.
7. Place the load cell against the bottom of the crosshead, ensuring that the anti-rota-
tion pin and locating ring fit securely in place against both the crosshead and load
cell. Place the cable to the left side of the column.
8. Tighten the mounting screw by hand so that it secures to the load cell underneath the
crosshead.
9. Lower the crosshead to a position below the center of the travel range to prevent
tipping.
Caution
When applying torque to the mounting screw, prevent the load frame from sliding by
holding the crosshead with one hand while applying torque with the other.

10. Use the torque wrench to tighten the mounting screw to 40 N-m (29.5 ft-lb).
11. Connect the load cell cable to the FORCE connector on the controller. Ensure that the
connector is fully engaged in the socket.
12. Press the load cell cable into the clips on the column cover to prevent it from inter-
fering with your test.
13. Calibrate the load cell (refer to “Calibrate a transducer” on page 119).
14. Leave the system on for at least 15 minutes to allow the load cell circuitry to stabilize.
After this warm-up period, calibrate the load cell again.

86 M10-17415-EN
 Install the load cell

Install a 2580 load cell (capacities 500 N through 5 kN)

2
3

7
5 4

Figure 18. Install a 2580 series load cell - capacities 500 N through 5 kN

Determine the type of counter-bore configuration on the crosshead on your system and
refer to the appropriate section, either “Crosshead configuration with single
shallow counter-bore” on page 88 or “Crosshead configuration with double
counter-bore” on page 89 to select the hardware required for installation.

Refer to “Procedure” on page 89 for installation instructions.

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Chapter: Assemble the load string

Crosshead configuration with single shallow counter-bore

The following tables list the hardware required to install the load cell on each load frame
model. SW is a standard width frame, EW is an extra wide frame.

Table 14. Component and Part numbers for individual frame models

Label in Figure 18
on page 87 Component and Part Number

68TM-5 68TM-30 (SW)

68TM-10 68TM-50 68TM-30 (EW)

1 Screw, M10 x 90 Screw, M10 x 140 Screw, M10 x 140

(201V62) (71-63-1169) (71-63-1169)

2 Not required M10 load washer Not required

(610J9) x 2

Table 15. Remaining components for all frame models

Label in Figure 18 on
page 87 Component Part number

3 M10 spacer T604-90

4 Load cell anti-rotation pin 705K84

5 Locating ring T1335-1048

6 2580 load cell - 500 N through 5 kN

7 Crosshead

88 M10-17415-EN
 Install the load cell

Crosshead configuration with double counter-bore

The following tables list the hardware required to install the load cell on each load frame
model. SW is a standard width frame, EW is an extra wide frame.

Table 16. Component and Part numbers for individual frame models

Label in Figure 18
on page 87 Component and Part Number

68TM-5 68TM-30 (SW)

68TM-10 68TM-50 68TM-30 (EW)

1 Screw, M10 x 70 Screw, M10 x 120 Screw, M10 x 120

(201V60) (201V632) (201V632)

2 Not required Not required Not required

Table 17. Remaining components for all frame models

Label in Figure 18 on
page 87 Component Part number

3 M10 spacer T604-90

4 Load cell anti-rotation pin 705K84

5 Locating ring T1335-1048

6 2580 load cell - 500 N through 5 kN

7 Crosshead

Procedure

1. Refer to Figure 18 on page 87 and its associated legend.

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Chapter: Assemble the load string

Caution
Check items 1 and 2 in the legend carefully. The screw and spacer required
depends on the frame model.

2. Collect together the correct mounting screw, spacer, anti-rotation pin and locating
ring for your combination of load frame and load cell.
3. Assemble the mounting screw and spacer, as shown in the figure.
4. Place the mounting screw and spacer assembly into the top of the central bore of the
crosshead.
5. Insert the anti-rotation pin into one of the holes on the bottom of the crosshead.
There are four pin holes on the bottom of the crosshead that let you position the load
cell either straight on or at an angle.
6. Place the locating ring into the top surface of the load cell that connects to the cross-
head.
7. Place the load cell against the bottom of the crosshead, ensuring that the anti-rota-
tion pin and locating ring fit securely in place against both the crosshead and load
cell. Place the cable to the left side of the column.
8. Tighten the mounting screw by hand so that it secures to the load cell underneath the
crosshead.
9. Lower the crosshead to a position below the center of the travel range to prevent
tipping.
Caution
When applying torque to the mounting screw, prevent the load frame from sliding by
holding the crosshead with one hand while applying torque with the other.

10. Use the torque wrench to tighten the mounting screw to 40 N-m (29.5 ft-lb).
11. Connect the load cell cable to the FORCE connector on the controller. Ensure that the
connector is fully engaged in the socket.
12. Press the load cell cable into the clips on the column cover to prevent it from inter-
fering with your test.
13. Calibrate the load cell (refer to “Calibrate a transducer” on page 119).
14. Leave the system on for at least 15 minutes to allow the load cell circuitry to stabilize.
After this warm-up period, calibrate the load cell again.

90 M10-17415-EN
 Install the load cell

Install a 2580 load cell (10kN capacity)

6
4 3

Figure 19. Install a 2580-10kN load cell

Determine the type of counter-bore configuration on the crosshead on your system and
refer to the appropriate section, either “Crosshead configuration with single
shallow counter-bore” on page 92 or “Crosshead configuration with double
counter-bore” on page 92 to select the hardware required for installation.

Refer to “Procedure” on page 93 for installation instructions.

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Chapter: Assemble the load string

Crosshead configuration with single shallow counter-bore

The following table lists the hardware required to install the load cell on the 68TM-10
frame model.

For the 68TM-30 and 68TM-50 models Instron recommends that you use the
mechanical tensioner supplied with the system, which is also used to install 30 kN and
50 kN capacity load cells. (refer to “Install a 2580 load cell (capacities 30kN and
50kN)” on page 94).

Table 18. Components for 68TM-10 frame models

Label in Figure 19 on
page 91 Component Part number

1 Screw M16 x 100 201V85

2 M16 load washer x 2 610J12

3 Load cell anti-rotation pin 705K85

4 Locating ring adapter 40/20 mm diameter T604-101

5 2580 load cell - 10 kN

6 Crosshead

Crosshead configuration with double counter-bore

The following table lists the hardware required to install the load cell on the 68TM-10
frame model.

92 M10-17415-EN
 Install the load cell

For the 68TM-30 and 68TM-50 models Instron recommends that you use the
mechanical tensioner supplied with the system, which is also used to install 30 kN and
50 kN capacity load cells. (refer to “Install a 2580 load cell (capacities 30kN and
50kN)” on page 94).

Table 19. Components for 68TM-10 frame models

Label in Figure 19 on
page 91 Component Part number

1 Screw M16 x 80 201V83

2 M16 load washer x 2 610J12

3 Load cell anti-rotation pin 705K85

4 Locating ring adapter 40/20 mm diameter T604-101

5 2580 load cell - 10 kN

6 Crosshead

Procedure

1. Refer to Figure 19 on page 91 and its associated legend.

2. Collect together the correct mounting screw, washer, anti-rotation pin and locating
ring for your combination of load frame and load cell.
3. Assemble the mounting screw and washer, as shown in the figure.
4. Place the mounting screw and washer assembly into the top of the central bore of the
crosshead.
5. Insert the anti-rotation pin into one of the holes on the bottom of the crosshead.
There are four pin holes on the bottom of the crosshead that let you position the load
cell either straight on or at an angle.
6. Place the locating ring into the top surface of the load cell that connects to the cross-
head.
7. Place the load cell against the bottom of the crosshead, ensuring that the anti-rota-
tion pin and locating ring fit securely in place against both the crosshead and load
cell. Place the cable to the left side of the column.
8. Tighten the mounting screw by hand so that it secures to the load cell underneath the
crosshead.
9. Lower the crosshead to a position below the center of the travel range to prevent
tipping.

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Caution
When applying torque to the mounting screw, prevent the load frame from sliding by
holding the crosshead with one hand while applying torque with the other.

10. Use the torque wrench to tighten the mounting screw to 60 N-m (44.3 ft-lb).
11. Connect the load cell cable to the FORCE connector on the controller. Ensure that the
connector is fully engaged in the socket.
12. Press the load cell cable into the clips on the column cover to prevent it from inter-
fering with your test.
13. Calibrate the load cell (refer to “Calibrate a transducer” on page 119).
14. Leave the system on for at least 15 minutes to allow the load cell circuitry to stabilize.
After this warm-up period, calibrate the load cell again.

Install a 2580 load cell (capacities 30kN and 50kN)

Determine the type of counter-bore configuration on the crosshead on your system and
refer to the appropriate section, either “Crosshead configuration with single
shallow counter-bore” on page 94 or “Crosshead configuration with double
counter-bore” on page 96 to select the hardware required for installation.

Refer to “Procedure” on page 98 for installation instructions.

Crosshead configuration with single shallow counter-bore

The following figure and associated table lists the hardware required to install 30 kN
and 50 kN capacity load cells.

For the 68TM-30 and 68TM-50 models Instron recommends that you use the same
hardware to install 10 kN capacity load cells and not the hardware listed in “Install a
2580 load cell (10kN capacity)” on page 91.

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 Install the load cell

1
2

3
30kN - 50kN 4

Figure 20. Install a 2580 series load cell - capacities 30kN and 50kN

Legend for Figure 20

Label Component Part number

1 Mechanical tensioner, M16 x 2 thread with matching 52-2-82

washer

2 Threaded rod, M16 x 170 mm long T620-978

3 Locating ring adapter 40/20 mm diameter T604-101

4 Load cell anti-rotation pin 705K84

5 Crosshead

6 2580 load cell - 30 kN through 50 kN

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Chapter: Assemble the load string

Crosshead configuration with double counter-bore

The following figure and associated table lists the hardware required to install 30 kN
and 50 kN capacity load cells.

For the 68TM-30 and 68TM-50 models Instron recommends that you use the same
hardware to install 10 kN capacity load cells and not the hardware listed in “Install a
2580 load cell (10kN capacity)” on page 91.

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 Install the load cell

1
2

4
30kN - 50kN 5

Figure 21. Install a 2580 series load cell - capacities 30kN and 50kN

Legend for Figure 21

Label Component Part number

1 Mechanical tensioner, M16 x 2 thread with matching 52-2-82

washer

2 Spacer 30 mm diameter T620-979

(refer to Caution note below)

3 Threaded rod, M16 x 170 mm long T620-978

4 Locating ring adapter 40/20 mm diameter T604-101

5 Load cell anti-rotation pin 705K84

6 Crosshead

7 2580 load cell - 30 kN through 50 kN

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Chapter: Assemble the load string

Caution
Be sure to use the 30 mm diameter spacer (T620-979, item 2 in the table above) for
this crosshead configuration.
Failure to include this spacer will cause permanent and irreparable damage to the
crosshead and tensioner.

Procedure

1. Refer to “Crosshead configuration with single shallow counter-bore” on

page 94 or “Crosshead configuration with double counter-bore” on page 96,
depending on your crosshead configuration.
2. Prepare the mechanical tensioner and its matching washer by backing off the four
set screws so that they are flush with the bottom of the tensioner body. Do NOT
remove them.
3. Screw one end of the threaded rod into the top of the load cell, ensuring that it is fully
engaged. Use a flat-head screwdriver if necessary.
4. Insert the anti-rotation pin into one of the holes on the bottom of the crosshead.
There are four pin holes on the bottom of the crosshead that let you position the load
cell either straight on or at an angle.
5. From underneath the crosshead, insert the threaded rod and loadcell assembly into
the hole in the center of the crosshead.
6. Place the load cell against the bottom of the crosshead, ensuring that the anti-rota-
tion pin and locating ring fit securely in place against both the crosshead and load
cell. Place the cable to the left side of the column.
7. FOR CROSSHEAD WITH DOUBLE COUNTER-BORE ONLY - install the 30 mm diameter
spacer into the matching recess in the top of the crosshead.
Caution
Failure to include this spacer will cause permanent and irreparable damage to the
crosshead and tensioner.

8. Thread the mechanical tensioner and its matching washer onto the top of the
threaded rod.
9. Tighten the mounting assembly by hand so that it secures the load cell underneath
the crosshead.

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 Install the load cell

Caution
Make sure that the tensioner assembly is in contact with the crosshead before
tightening any of the set screws on the assembly.

10. Lower the crosshead to a position below the center of the travel range to prevent
tipping.
11. Use the torque wrench (80-9-11) with the matching 5 mm hex drive socket (67-4-29)
supplied in the mechanical tensioner kit to tighten the four set screws (shown in
Figure 22 on page 99) on the mechanical tensioner to 14 N-m (10.3 ft-lb) according
to the following procedure:

Figure 22. Mechanical tensioner assembly

a Tighten 2 bolts on opposite sides to 7 N-m (5.1 ft-lb) (50% of the recommended
torque).
b Tighten the remaining 2 bolts to 14 N-m (10.3 ft-lb) (100% of the recommended
torque).
c Moving in a circular pattern, re-tighten all bolts to 14 N-m (10.3 ft-lb) (100% of the
recommended torque).
12. Connect the load cell cable to the FORCE connector on the controller. Ensure that the
connector is fully engaged in the socket.
13. Press the load cell cable into the clips on the column cover to prevent it from inter-
fering with your test.
14. Calibrate the load cell (refer to “Calibrate a transducer” on page 119).
15. Leave the system on for at least 15 minutes to allow the load cell circuitry to stabilize.
After this warm-up period, calibrate the load cell again.

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Chapter: Assemble the load string

Adapters
Adapters let you connect grips or fixtures to the frame when the interfaces have
different connection sizes. There are two types of adapters: base adapters and coupling
adapters.

68TM-5 and 68TM-10 base adapters

Base adapters let you connect grips and fixtures to the base of the load frame. The load
frame is supplied with a Type D base adapter installed.

If you need to remove and re-install the base adapter, for example to change the
orientation, use the following procedures.

Remove the base adapter

1. Remove the compression spring located inside the adapter.

2. Use the 8 mm bit (part no. 80-3-13) to loosen and remove the M10 screw inside the
adapter.
3. Lift the adapter away from the base beam.

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 Adapters

Reinstall the base adapter

7
8 5

Figure 23. Type D base adapter - 68TM-5 and 68TM-10

Legend for Figure 23

Label Component Part number

1 Grip

2 Compression spring 66-5-6

3 M10 x 40 mm screw

4 Clevis pin T29-515

5 Clevis pin clip T1223-1053

6 Type D base adapter

7 Anti-rotation pin

8 Load frame base beam

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Chapter: Assemble the load string

1. Insert the adapter into the base beam, noting the orientation of the locating pin on
the bottom of the adapter. There are a number of locating pin holes on the base beam
to allow for different orientations of the base adapter.
2. Use the 8 mm bit (part no. 80-3-13) and the M10 screw to secure the base adapter
to the base beam.
3. Use the torque wrench to tighten the mounting screw to 40 N-m (29.5 ft-lb).
4. Insert the compression spring into the center of the base adapter.

68TM-30 and 68TM-50 base adapters

Base adapters let you connect grips and fixtures to the base of the load frame. The load
frame is supplied with a Type D base adapter installed.

If you need to remove and re-install the base adapter, for example to change the
orientation, use the following procedures.

Remove the base adapter

1. Remove the compression spring located inside the adapter.

2. Use the 8 mm bit (part no. 80-3-13) to loosen and remove the three M10 screws that
secure the adapter to the base beam.
3. Lift the adapter away from the base beam.

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 Adapters

Reinstall the base adapter

2
3

4
6

8 7
5

Figure 24. Type D base adapter - 68TM-30 and 68TM-50

Legend for Figure 24

Label Component Part number

1 Grip

2 Compression spring 66-4-5

3 M10 x 40 mm screw (x3)

4 Clevis pin T29-515

5 Clevis pin clip T1223-1053

6 Type D base adapter

7 Alignment ring

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Chapter: Assemble the load string

Label Component Part number

8 Load frame base beam

1. Place the adapter on the base beam, positioning it over the alignment ring.
2. Use the 8 mm bit (part no. 80-3-13) and the three M10 screws to secure the base
adapter to the base beam.
3. Use the torque wrench to tighten the mounting screws to 40 N-m (29.5 ft-lb).
4. Insert the compression spring into the center of the base adapter.

Coupling adapters
Coupling adapters let you attach grips and fixtures of different sizes to the load cell and
base adapter, providing more options for testing. There are two primary types:

• For tension testing only:

Tension coupling adapters, also known as self-aligning coupling adapters, which
provide a swivel connection and connect between clevis pin type interfaces. The
swivel action allows the grip or fixture to self-align in the direction of the test load,
thus minimizing any bending load on the specimen.
• For tension or compression testing:
Rigid coupling adapters which also connect between clevis pin type interfaces but
use check nuts to provide fixed connections. This type can also have a threaded
interface. These couplings are not self-aligning and the load string alignment is
dependent on the accuracy of load cell alignment during installation.

When assembling the load string, you may need to use adapters if the load cell
interface, or base adapter interface, differs from your grip interface. A coupling adapter
creates a secure connection between these two different interfaces.

If your grip or fixture interface is the same size as your load cell interface, then you can
connect these directly and you do not need an adapter. If, however, you need the self-
aligning feature that the adapter offers, you should use the appropriate self-aligning
coupling adapter.

Coupling types are listed from the load cell towards the accessory or from the frame
base towards the accessory. For example, if you need to connect a load cell with a Type
D (female) connector to a grip with a Type O (male) connector you require a Type Dm to
Of adapter.

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 Select Grips and Fixtures

Select Grips and Fixtures

A set of grips are installed on the system during installation by a service engineer. If your
testing requires it, you may need to install a different set to obtain optimum test results.

The selection of grips depends on the material, geometry and strength of the test
specimen.

In compression testing, the diameter or area of the anvil is important, in addition to the
maximum loading capacity.

For tensile testing:

• Make sure the tensile strength of the specimen does not exceed the maximum
loading capacity of the grips.
• Minimize the risk of slippage by:
• selecting jaw faces with a surface area large enough to cover the tab (for
dumbbell-shaped specimens) or as much surface area as possible for parallel-
sided specimens.
• ensuring that the specimen is gripped by at least 75% of the available jaw face
length.
• using serrated jaw faces
• Breaks at the jaw face may be caused by:
• Screw action grips - you may be using too much force when tightening the grips.
Use a torque wrench or switch to pneumatic grips for a consistent force.
• Pneumatic grips - the pressure may be too high. Drop the pressure, but not to
the point where you get slippage.
• Serrated faces - the serrations are damaging the specimen. Change to faces
that have more serrations per inch (less bite) or cover with masking tape or
similar material to soften the bite and prevent damage to the specimen.

Insert Jaw Faces into Grips

Different grips use different mechanisms for attaching jaw faces. Refer to the
documentation supplied with the grips for more information.

Install grips

Before you begin, check the following:

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Chapter: Assemble the load string

• There is sufficient space between the load cell and the load frame base to install the
grips.
• The crosshead is stationary.
• The frame is in the disabled state, i.e. the white LED above the DISABLED indicator
on the indicator panel is illuminated.
• The crosshead limit stops on the load frame are set to prevent the upper and lower
grips from colliding with each other (refer to “Set the crosshead limit stops” on
page 124).
• The mating surfaces of the grips, load cell and the base adapter are free of dirt or
debris.

Refer to Figure 25 on page 107 when following this procedure.

1. For the upper grip, insert the adapter on the grip into the female clevis socket (1 in
Figure 25) on the load cell adapter.
2. Align the clevis holes (2 in Figure 25)and insert the clevis pin (3 in Figure 25)
through the holes.
3. Secure the clevis pin in position with the clevis pin clip (4 in Figure 25).
4. Repeat steps 1 through 3 to install the lower grip onto the load frame base adapter.
5. When both grips are installed, follow the procedure to preload the load string (refer
to “Preload the load string” on page 107).

106 M10-17415-EN
 Preload the load string

4
2

Figure 25. Typical grip installation

Preload the load string

This procedure eliminates backlash and deflections within the load string which can
degrade the integrity of test results, especially when testing at high loads. The
procedure involves preloading the entire load string and then hand-tightening all the
lock nuts on all the grips and couplings. Even when using self-aligning couplings on the
upper grip, it is good practice to preload the lower grip.

You will need a rigid specimen that is strong enough to sustain the preload value without
breaking. This means a specimen that can sustain a load that is:

• 10% above the expected test load, or

• the maximum load rating of the weakest component of the load string (grips or load
cell)

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Chapter: Assemble the load string

whichever is less. For example, if your grips are rated at 1kN, the load cell at 2kN and
your expected test load is 500N then you should preload to at least 550N but not more
than 1kN.

Before inserting the specimen ensure that:

• The grips and couplings are installed but the lock nuts are not tightened.
• Crosshead travel limits are set (refer to “Set the crosshead limit stops” on
page 124).
• The value of load in the live display is near zero. If it is not, balance the load (refer to
“Balance a transducer configuration” on page 125).
• The load limits are set in the software to a value that matches the maximum load
capacity of the weakest component in the load string.
1. Install the strong specimen.
2. Increase the load on the load string to the chosen preload value.
Caution
Do not attempt to increase the load by jogging the crosshead. The collision
mitigation feature will stop the crosshead before the system reaches the desired
load value.

a Start Bluehill® and prepare to run a test using the specifically-designed test
method, named Preload Grips. This method is located in the Templates directory
within Bluehill®.
b Enter values for Rate and Force and start the test.
The crosshead drives at the designated rate until it reaches the chosen preload
value and the test stops.
3. Hand tighten all the locknuts on the grips and any intermediate couplings.
4. Reduce the load to zero.
5. Remove the specimen.

The load string is now preloaded and all the locknuts are tight and should not move
during subsequent testing. The system is now ready to test.

When you next need to change grips or any other part of the load string, the locknuts will
be too tight to loosen by hand. You will need to follow the procedure “Unload the load
string” on page 109

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 Unload the load string

Unload the load string

If you have followed the procedure to preload the load string (“Preload the load
string” on page 107) you will need to follow this procedure before you can change grips
or any or any other part of the load string. The locknuts will be too tight to loosen by
hand.

1. Install the strong specimen.

2. Increase the load on the load string to the chosen preload value.
Caution
Do not attempt to increase the load by jogging the crosshead. The collision
mitigation feature will stop the crosshead before the system reaches the desired
load value.

a Start Bluehill® and prepare to run a test using the specifically-designed test
method, named Preload Grips. This method is located in the Templates directory
within Bluehill®.
b Enter values for Rate and Force and start the test.
The crosshead drives at the designated rate until it reaches the chosen preload
value and the test stops.
3. Loosen all the locknuts on the grips and any intermediate couplings.
4. Reduce the load to zero.
5. Remove the specimen.

The loadstring is now unloaded and all the locknuts are loose so that you can change
any component.

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Chapter: Assemble the load string

110 M10-17415-EN
 Chapter 6
Testing specimens

• Testing a sample . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

• Create a new sample. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
• Calibrate a transducer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
• Set the zero displacement point. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
• Crosshead limit stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
• Set the limits for a transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
• Balance a transducer configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
• Stop a test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
• Shut down the system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
• Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Materials testing systems are inherently hazardous. Read the chapter “Risk reduction
and safe use” on page 25 before using the testing system.

Testing a sample
The following two procedures are guidelines for steps that you would typically go through
when testing a group of specimens. Some steps include references to more detail in
separate sections.

These scenarios assume that a test method has already been created that satisfies your
testing requirements and provides required test parameters (e.g. specimen dimensions,
testing notes) on the test workspace.

The two scenarios describe testing with and without an interlock.

An interlock is an optional accessory that changes the behavior of the system

depending on whether the interlock circuit is open or closed. For example, the door on a
protective shield may include an interlock. When the interlock circuit is open (e.g. the

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Chapter: Testing specimens

shield door is open), the circuit is interrupted and the system is either disabled or
restricted as defined by the Operator Protection settings.

Testing with no interlock

This test scenario assumes the system has no accessories with an interlock and that the
start test method in Operator Protection settings is set to Frame control (the default).

Warnings
Set the load frame limit stops to limit crosshead travel, and set adequate transducer
limits to ensure the safe operation of the testing system.
Set all available limits before using the system to avoid crosshead overtravel, contact
between grips and fixtures, overloading any component of the load string, or overtravel
of a contacting extensometer.

Hazard - do not allow more than one person to operate a testing machine.
Operator injury may result if more than one person operates the testing machine. For
example, injury can occur if one person moves the crosshead or actuator while the other
is working inside the hazard area between the grips or fixtures.

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. When working in
this area, ensure that other personnel cannot operate any of the system controls. 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.

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.

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 Testing a sample

Flying Debris Hazard - Brittle specimens may shatter upon failure.

The high energies involved in testing can cause broken parts of a specimen to be
projected forcefully some distance from the test area. 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.

Select the correct test area for the test. An incorrectly set test area can cause
unanticipated crosshead behavior. Press the Emergency Stop button if the frame
moves in an unexpected direction.
An incorrectly set test area can cause unanticipated crosshead behavior and create a
safety hazard that may damage the specimen or load cell. Verify the test area and test
direction before starting a test.
1. Collect all specimens together that will make up the testing sample.
2. Identify each specimen, e.g. by marking. Identifying each specimen helps match it to
the appropriate specimen number in the completed sample test report.
3. Start the frame and open the software.
The system is in DISABLED mode.
4. Ensure that the crosshead travel limits are set. Refer to “Set the crosshead limit
stops” on page 124.
5. Ensure that limits are set for each transducer (displacement, force, strain, and user-
defined). Refer to “Set the limits for a transducer” on page 125.
6. Press the UNLOCK button on the handset to transition the system to SET UP mode.
The system is now restricted to the Operator Protection settings specified on the
Configuration > Frame screen on the Admin tab.
7. In the software, create a new sample file. Refer to “Create a new sample” on
page 118
8. Verify that the test area is correct in System Details. Select Frame under Method
settings.
9. If necessary, calibrate the transducer configurations required by the test method.
Refer to “Calibrate a transducer” on page 119.
If the frame was previously off, allow the load cell to warm up for at least 20 minutes
to ensure stable readings.
10. Measure the required specimen dimensions for each specimen and enter the values
into the appropriate fields in the operator inputs component of the test workspace.
11. Use the jog controls to move the crosshead to its starting position and set zero
displacement. Refer to “Set the zero displacement point” on page 123.
12. Balance the Force transducer configuration. Refer to “Balance a transducer
configuration” on page 125

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Chapter: Testing specimens

13. Install the specimen into the grips. Refer to the documentation provided with the
grips for details.
If the system includes pneumatic grips, refer to “Pneumatic Grips” on page 72.
14. Verify that the specimen is aligned properly in the grips.
15. Balance each of the remaining transducer configurations, e.g. strain. Refer to
“Balance a transducer configuration” on page 125
16. Press the UNLOCK button to transition the system to CAUTION mode and then
press the START button on the handset to start the test.
CAUTION mode remains active for approximately two seconds after the unlock
button is released. You must start the test before the system reverts back to SET UP
mode.
The test will only start if the software displays the test workspace.
17. Upon starting the test, the various components on the test workspace update as the
test proceeds. Some components will not update until the test is complete.
18. To stop the test before it completes, press the STOP button on the handset.

Warning
In an emergency situation, press the large, round, red button on the frame to stop
the test immediately and disable the frame.
Refer to “Emergency Stop Button” on page 126.
19. After the test is complete, the system transitions to SET UP mode.
20. Remove the specimen/specimen pieces from each grip.
If the specimen did not break, use the jog controls to relieve the applied force from
the specimen before releasing the grips.
21. Complete any post-test inputs that the test method requires, e.g. final specimen
dimensions, specimen notes.
22. If necessary, press the UNLOCK button to transition the system to CAUTION mode
and then press the RETURN button on the handset to return the crosshead to its
starting position.
When the crosshead returns to its starting point, the system transitions to SET UP
mode for the next specimen.
23. After all specimens are tested, select Finish sample on the Test tab.

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 Testing a sample

Testing with an interlock

This test scenario assumes the system has an accessory with an interlock and that the
start test method in Operator Protection settings is set to Frame control (the default).

Warnings
Set the load frame limit stops to limit crosshead travel, and set adequate transducer
limits to ensure the safe operation of the testing system.
Set all available limits before using the system to avoid crosshead overtravel, contact
between grips and fixtures, overloading any component of the load string, or overtravel
of a contacting extensometer.

Hazard - do not allow more than one person to operate a testing machine.
Operator injury may result if more than one person operates the testing machine. For
example, injury can occur if one person moves the crosshead or actuator while the other
is working inside the hazard area between the grips or fixtures.

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. When working in
this area, ensure that other personnel cannot operate any of the system controls. 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.

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.

Flying Debris Hazard - Brittle specimens may shatter upon failure.

The high energies involved in testing can cause broken parts of a specimen to be
projected forcefully some distance from the test area. 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.

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Chapter: Testing specimens

Select the correct test area for the test. An incorrectly set test area can cause
unanticipated crosshead behavior. Press the Emergency Stop button if the frame
moves in an unexpected direction.
An incorrectly set test area can cause unanticipated crosshead behavior and create a
safety hazard that may damage the specimen or load cell. Verify the test area and test
direction before starting a test.
1. Collect all specimens together that will make up the testing sample.
2. Identify each specimen, e.g. by marking. Identifying each specimen helps match it to
the appropriate specimen number in the completed sample test report.
3. Start the frame and open the software.
The system is in DISABLED mode.
4. Ensure that the crosshead travel limits are set. Refer to “Set the crosshead limit
stops” on page 124.
5. Ensure that limits are set for each transducer (displacement, force, strain, and user-
defined). Refer to “Set the limits for a transducer” on page 125.
6. Press the UNLOCK button on the handset to transition the system to one of the
following:
• SET UP mode. System transitions to this mode if the interlock is open and an
operator has access to the test area. The system is now restricted to the Oper-
ator Protection settings specified on the Configuration > Frame screen on the
Admin tab.
If the interlock behavior is set to Disable frame then pressing the UNLOCK
button with the interlock open has no effect. You must close the interlock to
enable the frame.
• CAUTION mode. System transitions to this mode if the interlock is closed
and there is no access to the test area. The system can operate up to its full
capacity.

7. In the software, create a new sample file. Refer to “Create a new sample” on
page 118
8. Verify that the test area is correct in System Details. Select Frame under Method
settings.
9. If necessary, calibrate the transducer configurations required by the test method.
Refer to “Calibrate a transducer” on page 119.
If the frame was previously off, allow the load cell to warm up for at least 20 minutes
to ensure stable readings.
10. Measure the required specimen dimensions for each specimen and enter the values
into the appropriate fields in the operator inputs component of the test workspace.
11. Use the jog controls to move the crosshead to its starting position and set zero
displacement. Refer to “Set the zero displacement point” on page 123.

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12. Balance the Force transducer configuration. Refer to “Balance a transducer

configuration” on page 125
13. Open the interlock. The system behavior depends upon how the interlock behavior is
configured under Operator Protection:
• Disable frame option: the system transitions to DISABLED mode when the
interlock is open. You must close the interlock to enable the frame and move
the crosshead, if necessary.
• Allow limited motion option: the system transitions to SET UP mode when the
interlock is open. You can use the jog keys to move the crosshead when the
interlock is open. The crosshead is limited to the jog rate specified under
Operator Protection.

14. Install the specimen into the grips. Refer to the documentation provided with the
grips for details.
If the system includes pneumatic grips, refer to “Pneumatic Grips” on page 72.
15. Verify that the specimen is aligned properly in the grips.
16. Balance each of the remaining transducer configurations, e.g. strain. Refer to
“Balance a transducer configuration” on page 125
17. Close the interlock.
The system transitions to CAUTION mode.
18. Press the START button on the handset to start the test
The test will only start if the software displays the test workspace.
19. Upon starting the test, the various components on the test workspace update as the
test proceeds. Some components will not update until the test is complete.
20. To stop the test before it completes, press the STOP button on the handset.

Warning
In an emergency situation, press the large, round, red button on the frame to stop
the test immediately and disable the frame.
Refer to “Emergency Stop Button” on page 126.
21. After the test is complete, the system transitions to CAUTION mode.
If the specimen did not break, use the jog controls to relieve the applied force from
the specimen before opening the interlock to remove the specimen.

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Chapter: Testing specimens

22. Open the interlock to remove the specimen pieces from each grip. The system
behavior depends upon how the interlock behavior is configured under Operator
Protection:
• Disable frame option: the system transitions to DISABLED mode when the
interlock is open. You must close the interlock to enable the frame and move
the crosshead, if necessary.
• Allow limited motion option: the system transitions to SET UP mode when the
interlock is open. You can use the jog keys to move the crosshead when the
interlock is open. The crosshead is limited to the jog rate specified under
Operator Protection.

23. Close the interlock.

The system transitions to CAUTION mode.
24. Complete any post-test inputs that the test method requires, e.g. final specimen
dimensions, specimen notes.
25. If necessary, press the RETURN button on the handset to return the crosshead to its
starting position.
26. After all specimens are tested, select Finish sample on the Test tab.

Create a new sample

To create a sample, you can either select an existing test method that contains the
settings and parameters for the test (see below) or create a new method for the sample
(refer to the Bluehill® online help and reference).

To select an existing method file:

1. Select Test on the Home screen.

2. Under New Sample, select a test method. You can either:
• select a method shown under Methods. These are the most recently used
method files.
• select Browse methods to find a specific method file.

The system creates a sample based on the test parameters specified in the method file
and advances to the Test tab.

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The sample is initiated when the system advances to the Test tab. It is not yet saved as a
file. The sample will be saved as file upon finishing the sample or when you select the
Save button on the Test tab.

Calibrate a transducer

Automatic calibration of a force or strain transducer

Warning
Do not adjust the current calibration point value for an automatic calibration without
first contacting Instron® Service. Adjusting the calibration point can negatively affect
the validity of the data from the transducer.
A strain transducer can be an LVDT transducer. If the system identifies the strain
transducer as an LVDT transducer, the Calibration point field becomes available for
automatic calibration. The calibration point field is intended primarily for Instron®
Service and should only be used by the service personnel. Contact Instron® Service for
assistance.
1. Select in the console area to open System Details.
2. In the System Settings area, select the icon for the transducer to open the Transducer
Settings dialog.
3. Under Settings, select the transducer configuration in the Transducer configuration
field.
4. Ensure that Calibration type is set to Automatic.
Automatic calibration uses the following basis for the calibration point value:

Force 50% of the full-scale load transducer

Strain 100% of the full-scale strain transducer

5. Set the transducer to its zero point.

For force, zero point means no load on the system.
For strain, zero point means the starting point of the strain transducer (e.g. exten-
someter)
6. Select Calibrate.
7. Follow the instructions provided in the Transducer Settings dialog and then select OK
to proceed with the calibration.
Calibrating... displays in the transducer live display area during calibration.

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Chapter: Testing specimens

8. The calibration was successful if a value displays in the transducer live display area
and the transducer icon in System Details is no longer grayed.
9. Close the Transducer Settings dialog.
10. Close System Details.

The calibration is saved with the transducer configuration and is restored whenever the
transducer configuration is selected.

The transducer is now calibrated and ready for testing. The transducer must be
associated with a measurement in a method. Verify that the method used for testing
includes a measurement that is linked to the transducer configuration for this
transducer.

Manual calibration

During a manual calibration, you apply a measured physical force to the transducer and
the system calibrates on the signal that is output as a result of that force. For force
calibration, you can hang a measured weight from the load cell. For strain calibration,
you can install the extensometer on a specially designed calibration jig to apply a
precise deflection to the extensometer.

The system only saves the values entered for a manual calibration after there is a
successful calibration. If you select a different transducer configuration or close the
dialog before calibrating a transducer configuration, the calibration fields revert to the
default values for that configuration.

Manual calibration of a rationalized force or strain transducer

1. Select in the console area to open System Details.

2. In the System Settings area, select the icon for the transducer to open the Transducer
Settings dialog.
3. Under Settings, select the transducer configuration in the Transducer configuration
field.
4. Set Calibration type to Manual.
5. Enter a value for the calibration point. This value is the force (for a load cell) or deflec-
tion (for an extensometer) that you apply to the transducer during calibration.
For example, to calibrate a 100 kN load cell using a 50 kN weight, the full scale value
is 100 kN and the calibration point is 50 kN.
The range for a valid calibration point value is between:

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 Calibrate a transducer

Force Strain
(% full scale) (% full scale)

Minimum 2 2

Maximum 105 110

If you change the units for a field, the software converts the corresponding value to its
equivalent value in the new units. Verify that the value is correct for the specified units.

6. Select Calibrate.
7. Follow the instructions provided in the Transducer Settings dialog and select OK to
proceed with the calibration:
a Set the transducer to its zero point or gauge length point.
b Deflect the transducer to its calibration point using a weight (load cell) or a cali-
bration jig (extensometer).
For force, if you have a load cell with an associated electrical calibration circuit,
you can use this to apply an electrical signal instead of applying a physical force
to the load cell.
c Return the transducer to its zero point or gauge length point.
Calibrating... displays in the transducer live display area during calibration.
8. The calibration was successful if a value displays in the transducer live display area
and the transducer icon in System Details is no longer grayed.
9. Close the Transducer Settings dialog.
10. Close System Details.

The calibration is saved with the transducer configuration and is restored whenever the
transducer configuration is selected.

The transducer is now calibrated and ready for testing. The transducer must be
associated with a measurement in a method. Verify that the method used for testing
includes a measurement that is linked to the transducer configuration for this
transducer.

Manual calibration of a non-rationalized force or strain transducer

1. Select in the console area to open System Details.

2. In the System Settings area, select the icon for the transducer to open the Transducer
Settings dialog.
3. Under Settings, select the transducer configuration in the Transducer configuration
field.
4. Set Calibration type to Manual.

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Chapter: Testing specimens

5. Enter the full scale value of the transducer.

6. For strain transducers, enter the gauge length of the extensometer.
The system must know the gauge length of the installed extensometer in order to
calculate strain values for display and for further calculations.
7. Enter a value for the calibration point. This value is the force (for a load cell) or deflec-
tion (for an extensometer) that you apply to the transducer during calibration.
For example, to calibrate a 100 kN load cell using a 50 kN weight, enter 100 kN as
the full scale value and 50 kN as the calibration point.
The range for a valid calibration point value is between:

Force Strain
(% full scale) (% full scale)

Minimum 2 2

Maximum 105 110

If you change the units for a field, the software converts the corresponding value to its
equivalent value in the new units. Verify that the value is correct for the specified units.

8. Select Calibrate.
9. Follow the instructions provided in the Transducer Settings dialog and select OK to
proceed with the calibration:
a Set the transducer to its zero point or gauge length point.
b Deflect the transducer to its calibration point using a weight (load cell) or a cali-
bration jig (extensometer).
For force, if you have a load cell with an associated electrical calibration circuit,
you can use this to apply an electrical signal instead of applying a physical force
to the load cell.
c Return the transducer to its zero point or gauge length point.
Calibrating... displays in the transducer live display area during calibration.
10. The calibration was successful if a value displays in the transducer live display area
and the transducer icon in System Details is no longer grayed.
11. Close the Transducer Settings dialog.
12. Close System Details.

The calibration is saved with the transducer configuration and is restored whenever the
transducer configuration is selected.

The transducer is now calibrated and ready for testing. The transducer must be
associated with a measurement in a method. Verify that the method used for testing
includes a measurement that is linked to the transducer configuration for this
transducer.

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 Set the zero displacement point

Set the zero displacement point

Setting the zero displacement point sets the transducer value to zero. This identifies the
current position as the starting point from which total crosshead displacement is
measured during a test. This effectively balances the displacement transducer.

“Zero displacement” is also known as “Reset the gauge length” or “Balance displace-
ment”.
1. Use the jog controls to move the crosshead to its starting position for the test.
2. Press the ZERO DISPLACEMENT button on the handset. The button illumination
changes from white to green.

Crosshead limit stops

Warning
Crush hazard - you must set the crosshead travel limits as protection against
unexpected crosshead movement.

Although Bluehill lets you set limits of travel in the software, you must set the
crosshead travel limits as well. These hardware limits provide an absolute limit of
travel that operates independently of the software.
Set the crosshead limits stops after you have established the crosshead starting
position, but before you start a test.

The crosshead limit stops are two adjustable blocks mounted on the limit switch rod,
which is located inside the column of the machine, as shown in Figure 26 on
page 124. Limit stops (1 and 2) have thumbscrews that you tighten and release by
hand, and you can move them to any position on the limit rod. Position these stops just
beyond the test parameters to prevent crosshead over-travel. When the crosshead
reaches the maximum pre-set travel, the limit switch actuator (3) contacts one of these
stops. Contact between the limit actuator and the limit stop moves the limit switch rod
(4) and activates the limit switches. This stops crosshead motion.

There is an additional, second level of crosshead limit stop that is activated if the first
level switch malfunctions. Activating a second-level limit switch disables the drive
system so you cannot move the crosshead. The second level limits are internal to the
machine. They are calculated relative to the first level limits and cannot be
independently set.

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Chapter: Testing specimens

Set the crosshead limit stops

1. Ensure that the crosshead is stationary and that the test parameters are set.
When setting limit stops, allow for an additional 3 mm of crosshead travel after the
actuator activates a limit stop. There is a small delay time from the point when the
actuator hits the limit stop and when the message relays to the limit switches located
in the frame base.
2. Set the upper limit stop at a position just above the expected maximum crosshead
travel in the upward direction when tension testing, or just above the test starting
point when compression testing. Tighten the stop securely on the limit rod.
3. Set the lower limit stop at a position just below the starting position when tension
testing or just below the expected maximum crosshead travel in the down direction
when compression testing. Tighten the stop securely on the limit rod.

Figure 26. Setting Limit Stops

124 M10-17415-EN
 Set the limits for a transducer

Caution
Do not use limit stops to end a test.
The limit stops are not intended to be an end of test condition to end every test.
Repeated use of the limit stops in this way may cause excessive wear, which can result
in the limit stop failing to stop the crosshead. Proper end of test conditions can be set
from the software. Refer to the online help system for further assistance.

Move Off a Crosshead Limit Stop

The test stops if the crosshead contacts the upper or lower limit stops. If this happens,
use the jog controls to move the crosshead away from the limit.

Set the limits for a transducer

1. Select in the console area to open System Details.
2. In the System Settings area, select the icon for the transducer to open the Transducer
Settings dialog.
3. Select Limits.
4. Select Enabled to activate the Maximum and Minimum limits.
The system activates the related fields. If Enabled is not selected, the system does
not monitor the transducer for that limit value.
5. Enter a value for the Maximum limit.
If you change the units for a field, the software converts the corresponding value to
its equivalent value in the new units.
6. Enter a value for the Minimum limit.
7. Close the Transducer Settings dialog.
8. Close System Details.

These settings are saved with the transducer configuration and are restored whenever
the transducer configuration is selected.

Balance a transducer configuration

Calibrate the transducer before you balance it.

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Chapter: Testing specimens

1. Make sure that no specimen is installed.

2. Select in the console area to open System Details.
3. In the System Settings area, select the icon for the transducer to open the Transducer
Settings dialog.
4. Under Settings, select the transducer configuration in the Transducer configuration
field.
5. Select Balance.
The system removes any offsets caused by minor electrical or mechanical changes
and resets the current transducer value to zero.
6. Close the Transducer Settings dialog.
7. Close System Details.

You can also:

• Select the live display that represents the transducer in the console area of the
main screen and use the Balance button in the dialog.
• set a soft key to Balance a specific source transducer.
• set a soft key to Balance all.

Stop a test
You can stop a test by using hardware controls on the machine or settings in the
software.

Emergency Stop Button

Figure 27. Emergency Stop Button

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 Stop a test

The Emergency Stop button on the testing system is a large, round, red button with a
yellow background. Press this button to stop the test as soon as possible when a
condition develops that:

• Could affect the safety of persons operating the system.

• Could damage the specimen, load frame, or test fixtures.

Investigate and resolve the situation that caused the use of the Emergency Stop button
before you reset the system.

When operated, the Emergency Stop button locks into the closed position and the
system is disabled until you reset the button and re-enable the load frame.

Warning
If you are using an integrated air kit with a foot switch to control a set of pneumatic
grips, be aware that pressing the Emergency Stop button to disable the frame will
also deactivate the grips, causing them to open.

With an integrated air kit, any action that disables the frame will also open the grips.

Re-enable the load frame

To reset the Emergency Stop button, rotate the button a quarter-turn clockwise until it
resets.

The steps to re-enable the frame are different between a system with and without an
interlock.

• In a system without interlocks:

a. Press the UNLOCK button on the handset.
The frame proceeds to SET UP mode.
• In a system with interlocks:
a. Open the interlock.
b. Close the interlock.
• In addition, in a system with interlocks where the interlock behavior is configured
under Operator Protection to Allow limited motion:
a. Press the UNLOCK button on the handset.

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Chapter: Testing specimens

Crosshead Limit Switches

The test stops if the crosshead contacts the upper or lower limit stops. If this happens,
use the jog controls to move the crosshead away from the limit.

Software Event

When the system encounters a pre-set limit or event set from the software, the test
stops. The crosshead stops moving.

Shut down the system

Wait until the system completes all active tasks before shutting it off or disconnecting
the electrical power.

Shut off the power to the system before you:

• Perform any maintenance procedure on the load frame.

• Disconnect the main power cable.
• Move the load frame.
• Connect or install optional components or accessories.

Turn the system off

1. Complete the test.

2. Remove the specimen.
3. Save any samples and test methods that may be open.
4. Exit the software and turn off the computer.
The DISABLED indicator flashes.
5. Shut off all any other components or accessories to the test system.
6. Switch the power for the load frame to the Off (O ) position. The DISABLED indicator
light no longer illuminates.

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 Troubleshooting

Troubleshooting

A Software Transducer Limit Trips

If the system trips a transducer limit, you must remove the condition that caused it to
trip and the limit resets.

For example, if you set a load of 10 kN and the crosshead moves to or beyond a point
that imposes a load of 10 kN on the specimen, you cannot proceed until you remove the
limit condition.

Use the jog buttons to drive the crosshead in the direction necessary to remove the limit
condition.

A Crosshead Travel Limit Trips

The test stops if the crosshead contacts the upper or lower limit stops. If this happens,
use the jog controls to move the crosshead away from the limit.

Second Level Limit Stops

The second level limit switch acts as a backup if the first level switch (the limit stops)
malfunctions. Activating a second-level limit switch disables the drive system so you
cannot move the crosshead. The second level limits are internal to the machine. They
are calculated relative to the first level limits and cannot be independently set.

Warning
Hazard - Identify and resolve the condition that caused the operation of the
secondary overtravel limit before you use the testing system.
Operation of a secondary overtravel limit indicates a serious problem with your testing
system, not least that the primary overtravel limit may have failed. Identify and resolve
the condition that caused the secondary overtravel limit to trip before you use the
testing system again. Contact Instron® Service for assistance.

You press the Emergency Stop button

Refer to “Emergency Stop Button” on page 126.

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Chapter: Testing specimens

130 M10-17415-EN
 Chapter 7
Maintenance

• Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

• General Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
• Troubleshooting for Load Cells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
• Ancillary parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

Warnings
Hazard - Only qualified personnel, trained to service Instron® machines, should
perform all internal maintenance procedures.
Instron® machines must operate within stringent specifications. In order to keep the
system working within the stated safety specifications, a professionally trained and
qualified technician must perform most maintenance procedures. If unqualified
personnel perform any maintenance procedures not described in this manual, the
machine may not perform to its stated specifications.

Hazard - Do not remove covers to any component of your system, unless it is

specified in a procedure.
There are dangerous voltages and rotating machinery inside the machine that may
cause bodily injury or damage to equipment.

Preventive Maintenance
Preventive maintenance is the periodic inspection, cleaning, and lubrication of the test
system. The following sections provide guidelines for preventive maintenance.

To ensure that the frame continues working at its optimal performance, it is

recommended that the machine receive an annual service check. Instron® Service can
perform this annual service, and replace any damaged or worn parts to ensure that your
machine operates to its stated specifications.

Instron® offers many service agreements that provide a variety of services, including
annual service visits. Contact Instron® Service for details on a service agreement or
contract that best matches your needs.

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Chapter: Maintenance

If your testing application generates debris, particularly conductive or abrasive dust,

refer to “Ingress Protection” on page 30 for additional maintenance advice.

Daily Maintenance Checks

Before operating the system each day, ensure:

• All cable connections are tight and secure.

• All grips, fixtures and accessories are free of dirt, damage and deformation.
• The load frame is level. If an adjustment is necessary, refer to “Level the load
frame” on page 35.
• Signal and power cables have adequate slack to prevent excessive strain on
connectors.
• All cables and pneumatic hoses are free of wear and chafing. Re-route them if
necessary, and replace any that are damaged.
• After turning on the system, make sure that power is adequately supplied to the
electronics.

Correct any problems before you operate the testing system. If you require assistance,
contact Instron® Service.

Periodic Inspections

Every six to twelve months, perform the following inspections:

• Visually inspect the machine for any loose fittings. Check the limit stops, cable
connections, and connections for any accessories that are attached to the machine.
Tighten any loose connections that you may find.
• Operate the crosshead through the full range of motion. It should move smoothly
with no unusual noise, or erratic motion. If it does not, refer to Table 20 on
page 134 for lubrication recommendations.
• Test the limit stops to ensure they are in working order. Refer to “Test Limit Stops”
on page 136.
• If you have any additional safety equipment added to the machine, test the
equipment to ensure it is in working order.

If you notice any problems resulting from these inspections, contact Instron® Service for
immediate assistance.

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 Preventive Maintenance

Cleaning

Caution
Do not clean with solvents or abrasive cleaners. Some household or commercial
cleaners can react with painted surfaces or panel markings.
Do not apply excessive amounts of detergent cleaner. It may seep into electrical circuits
within the base and cause equipment failure.
Do not use too much oil. It attracts abrasive particles that may accelerate wear.
Use low pressure air to blow dust. Do not direct the air stream directly at sensitive
components.

It is recommended that the machine be cleaned weekly, or more often if it is operating

in a dusty or dirty environment.

To clean the load frame, wipe exterior surfaces of the load frame with a moist cloth.

If your machine has a maximum capacity of 50 kN or greater (all floor models and some
table models) and if the central mounting area on the base beam is exposed (no base
adapter is in place) then you must regularly lubricate the mounting area with oil to
prevent corrosion. If you regularly use a base adapter, then you do not need to lubricate
this area (refer to “Lubrication” on page 133).

Lubrication

The following areas of the machine will require periodic lubrication:

• Ballscrews - The ballscrews are lubricated via a ballnut that is located on the
crosshead where the ballscrew intersects the crosshead. As the crosshead moves
up and down, the ballnut disperses a thin layer of lubricant over each ballscrew as
the ballscrew passes through the ballnut. Periodically, the ballnut must be filled with
lubricant to ensure that the ballscrews remain well lubricated. The ballnut must be
maintained and filled in accordance with Table 20 on page 134.
Inspect the ballscrew and lubricate more frequently if any of the following conditions
exist:
• There is high-load or high-speed testing.
• There is long-term, continuous movement of the crosshead.
• The system operates in a dirty environment.
• There are high-load cycling tests.

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Chapter: Maintenance

• Guide columns - The guide columns require only a thin film of lubrication. It is
recommended that the machine be re-lubricated every two years.
The guide column is located behind the ballscrew. If you suspect that the guide
column needs lubrication, contact Instron® Service for assistance.

The top and bottom ballscrew bearings are sealed and should never need lubrication.

Table 20. Lubrication Requirements for Ballnuts

Recommended Lubricant Interval Instron® Part Number

Lithium based water resisting grease - 10001hours or 36 105-1-1057

NLGI Class 2 months of (small can of lubricant)
(DIN51825 class K2k LS2) operating time2

Equivalents:
Lubriplate: Lubriplate 1200-2
Mobil: Mobilux® 2
BP: Energrease® LS2
Shell: Alvania® R2
1. If the system is used more than 100 hours per month, inspect the lubricated area periodically and
increase lubrication frequency as required.
2. Operating time is defined as time of crosshead movement, not the length of time the system has been
powered on.

Lubricate ballnuts

Refer to Figure 28 on page 135.

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 Preventive Maintenance

Figure 28. Ballnut lubrication

Legend for Figure 28

Label Description

1 Ballscrew cover

2 Ballnut nipple

1. Ensure that the power switch is in the Off (0 ) position and disconnect the power cable
from the power source. Verify that no LEDs are illuminated on the indicator panel.
2. Detach the bottom ballscrew cover from the crosshead and slide it to the frame base.
3. Use a grease gun to apply the grease through the ballnut nipples on both columns. It
is not necessary to remove the guide column covers.
4. Fill the ballnuts until grease begins to ooze from the top of the nut. Wipe away the
excess grease.
5. Re-attach the bottom ballscrew cover to the crosshead.
6. Reconnect the power cable to mains power and turn on the system. Verify that the
white DISABLED indicator on the indicator panel illuminates.

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Chapter: Maintenance

7. Use the jog controls to move the crosshead over the full stroke of the frame to
distribute the grease in the ballnut and coat the ballscrew shaft.
8. Before you carry out any testing, perform the procedure described in “First time
startup” on page 51.

General Maintenance Procedures

General maintenance procedures are the procedures that you can perform should it
become necessary. These procedures do not require an Instron® service technician,
although assistance is available. Contact Instron® Service for assistance.

Test Limit Stops

It is recommended that you periodically test both the first and second level limit stops
on the load frame.

1. Ensure that the system is on and the crosshead is stationary.

2. Secure one of the limit stops (either the upper or lower limit stop) to the limit switch
rod.
3. Firmly hold the yellow part of the limit stop to gently move the stop either downward
(in compression) or upward (in tension) about 3 mm (1/8 in).
A first level limit warning displays on the computer.
4. Repeat Step 3 moving the limit stop another 3 mm (1/8 in) in the same direction.
A second level limit warning and frame disabled warning displays on the computer.
The white LED above the DISABLED indicator on the indicator panel illuminates.
The frame disabled warning indicates that the limit stops are working correctly. If
the frame disabled warning does not display, contact your local Instron® Service
office for assistance.
5. Re-enable the frame (refer to “Re-enable the load frame” on page 127).

The frame is now ready to resume testing.

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 General Maintenance Procedures

Replace a Fuse

Warnings
Electrical Hazard - Shut down the system and disconnect the power cable from the
main power source before replacing a fuse. Dangerous voltages can cause
personal injury.

Hazard - Do not remove covers to any component of your system, unless it is

specified in a procedure.
There are dangerous voltages and rotating machinery inside the machine that may
cause bodily injury or damage to equipment.

Caution
Replace a fuse with the same type and size as the original. Installing the wrong fuse
could damage the electrical circuits inside the machine.
1. Ensure that the power switch is in the Off (0 ) position and disconnect the power cable
from the power source. Verify that no LEDs are illuminated on the indicator panel.
2. Insert a small flat-head screwdriver into the middle of the connector and pry out the
fuse holder, as shown below.

3. Remove the fuse holder from the power input connector and remove the fuses.
4. Install new fuses in the holder. Spare fuses are supplied with the system (refer to
“Ancillary parts” on page 138).
5. Re-install the fuse holder into the connector.
6. Reconnect the power cable to mains power and turn on the system. Verify that the
white LED above the DISABLED indicator on the indicator panel illuminates.

Product Support: www.instron.com 137

Chapter: Maintenance

Troubleshooting for Load Cells

Instron® load cells, in general, are electrically calibrated, self-identifying and
rationalized. Approximate resistances are given that can verify a possible broken gauge,
or a faulty connector or cable.

If a strain gauge in a cell has been badly overstressed, but still maintains its electrical
continuity, the cell may show a higher than normal amount of creep. If a gauge has
become improperly bonded due to degradation in use, the cell may exhibit a
combination of general instability in its balance point, together with a large amount of
creep. Difficulties of this sort rarely appear as an instability in the calibration of the cell.

If a load cell has been overloaded, the load-sensitive member may be permanently
deformed to the extent that the proper dimensional alignments inside the cell are no
longer maintained. For example, if the position of the central spindle is changed, this
can result in the balance point shifting abruptly as the cell is loaded or unloaded.

To check the load cell, substitute another cell to re-check the test results carefully. If
your results differ significantly from the original test results, then the original load cell
may be damaged. However, many of the symptoms described above can also arise from
a faulty load sensor conditioner, or possibly a mechanical adjustment.

If you suspect that a cell may be damaged, contact Instron® Service to arrange return of
the load cell for analysis and possible repair.

Ancillary parts
This section lists the ancillary parts that are included with the system upon delivery.
These components are either required to complete the installation, or facilitate setting
up load cells and accessories on the load frame. Keep these components in a safe
place.

Parts list

Table 21. Ancillary parts

Part
Description Number Quantity Purpose

Cable tie hook and loop 11-10-1027 5 Cable management

Cable clip, 6-12 mm 11-6-60 3 Secures cables to the frame

138 M10-17415-EN
 Ancillary parts

Table 21. Ancillary parts (Continued)

Part
Description Number Quantity Purpose

Mechanical tensioner kit A636-167 1 Installation kit for 30 kN and

50 kN load cells.
Refer to “Install the load cell” on
page 82

M16 x 100 screw 201V85 1 Load cell installation screw and

washer combinations.
M16 x 80 screw 201V83 1
Refer to “Install the load cell” on
M10 x 140 screw 71-63-1169 1 page 82

M10 x 120 screw 201V632 1

M10 x 130 screw 201V633 1

M10 x 90 screw 201V62 1

M10 x 70 screw 201V60 1

M10 x 40 screw 201V57 3

M10 washer 610J9 3

M16 oversized washer 610K12 1

M16 washer 610J12 3

Pin 3mm diameter, 10mm long 705K84 3 Load cell anti-rotation pin

Pin 3mm diameter, 12mm long 705K85 3 Load cell anti-rotation pin

Locating ring T1335-1048 1 Locating ring for base - 40mm

diameter for M30 thread

Locating ring adapter T604-101 1 Adapter for load cell locating ring -
40mm/20mm - used for 2530
Series load cells (10kN, 30kN,
50kN)

M10 spacer T604-90 1 Use with M10 screws for load cell
attachment

Fuse, 10A Time lag, 5 x 20mm 27-2-233 2 Protection from electrical surges
glass high surge

Compression spring 66-4-23 1 Compression springs for different

base adapters.
Compression spring 66-4-5 1

Compression spring 66-5-6 1

Product Support: www.instron.com 139

Chapter: Maintenance

Table 21. Ancillary parts (Continued)

Part
Description Number Quantity Purpose

Hex wrench key set, 80-1-1011 1 Tools for maintaining the frame
1.5 to 10 mm and installation of accessories

Thin open-ended wrench, P632-482 1 Tool for adjustment of feet on load

16mm/17mm frame

Wrench, open end, thin, 18 x P636-681 2 Used to adjust the feet to level the
19mm load frame

Tool socket driver 14 mm key 80-3-50 1 Used for installation of 2580-10kN

load cell

8 mm bit - 1/2 in drive 80-3-13 1 Tool for tightening M10 screws

Torque wrench 80-9-9 1 Provides correct installation torque

for load cell and base adapter
attachment screws

Retainer clip for 0.5 in diameter T1223-1053 2 Prevents the grip coupling pin from
pin sliding out during testing

Accessories slot T-nut T1697-1307 3 Installing accessories onto the

column cover

Retaining pin, grip coupling T29-515 1 Secures the grip coupling

3 MTS Ground cable A712-213 1 Used to connect the frame to a

suitable ground where the mains
power supply is not grounded

Converter Type D to Type O 2501-346 1 Allows use of accessories with

Type O interface.

CAT5E patch cable, 3m black P636-647 1 For communication between the

load frame and the Bluehill®
Operator Dashboard.

140 M10-17415-EN
 Index

B I
balance transducer . . . . . . . . . . . . . . . . . . 125 installation
changing a fuse . . . . . . . . . . . . . . . . . . . 137
C Instron
calibrate transducer . . . . . . . . . . . . . . . . . . 119 contact information . . . . . . . . . . . . . . . . . 23
changing a fuse . . . . . . . . . . . . . . . . . . . . . 137 product support . . . . . . . . . . . . . . . . . . . . 23
checks
daily maintenance. . . . . . . . . . . . . . . . . . 132 L
cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 labeling
contact information . . . . . . . . . . . . . . . . . . . 23 safety and information. . . . . . . . . . . . . . . 20
controls limit stops
fine jog . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 moving off a limit . . . . . . . . . . . . . . 125, 129
reset GL . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 second level limits . . . . . . . . . . . . . . . . . 129
set zero extension point . . . . . . . . . . . . . . 58 testing . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
specimen protect. . . . . . . . . . . . . . . . . . . . 57 load cells
create troubleshooting . . . . . . . . . . . . . . . . . . . 138
sample lubricating
with existing method . . . . . . . . . . . . . . 118 ballscrew ballnuts . . . . . . . . . . . . . . . . . 133
crosshead lubrication . . . . . . . . . . . . . . . . . . . . . . . . . 133
travel limits, moving off a limit . . . 125, 129
travel limits, second level limits . . . . . . . 129 M
travel limits, testing . . . . . . . . . . . . . . . . . 136 maintenance
cleaning . . . . . . . . . . . . . . . . . . . 132 to 133
D daily checks . . . . . . . . . . . . . . . . . . . . . . 132
daily maintenance checks . . . . . . . . . . . . . 132 fuse replacement . . . . . . . . . . . . . . . . . . 137
inspection . . . . . . . . . . . . . . . . . . . . . . . . 132
E lubricating the ballscrew ballnuts . . . . . 133
extension lubrication. . . . . . . . . . . . . . . . . . . . . . . . 133
set to zero point. . . . . . . . . . . . . . . . . . . . 123 testing limit stops. . . . . . . . . . . . . . . . . . 136
maintenance schedule . . . . . . . . . . . . . . . 132
F
fine jog. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
P
fuse replacement . . . . . . . . . . . . . . . . . . . . 137 preventive maintenance
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 133
G daily checks . . . . . . . . . . . . . . . . . . . . . . 132
inspection . . . . . . . . . . . . . . . . . . . . . . . . 132
gauge length
lubrication. . . . . . . . . . . . . . . . . . . . . . . . 133
reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
product support. . . . . . . . . . . . . . . . . . . . . . 23
general maintenance
fuse replacement . . . . . . . . . . . . . . . . . . 137
R
replacing a fuse. . . . . . . . . . . . . . . . . . . . . 137

Product Support: www.instron.com 141

reset gauge length (GL) . . . . . . . . . . . . . . . . 58

S
safety and information labeling . . . . . . . . . . 20
safety limits
second level limits. . . . . . . . . . . . . . . . . . 129
testing . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
sample
create
with existing method . . . . . . . . . . . . . . 118
sample file
create
with existing method . . . . . . . . . . . . . . 118
set zero extension point . . . . . . . . . . . . . . . . 58
specimen protect button . . . . . . . . . . . . . . . 57
start
new sample
with existing method . . . . . . . . . . . . . . 118
support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

T
technical support . . . . . . . . . . . . . . . . . . . . . 23
test
create new sample
with existing method . . . . . . . . . . . . . . 118
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
testing safety limits. . . . . . . . . . . . . . . . . . . 136
Testing with an interlock accessory. . . . . . 115
transducer
balance . . . . . . . . . . . . . . . . . . . . . . . . . . 125
calibrate . . . . . . . . . . . . . . . . . . . . . . . . . . 119
limits
set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
travel limits
second level limits. . . . . . . . . . . . . . . . . . 129
testing . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
troubleshooting load cells . . . . . . . . . . . . . 138

142 M10-17415-EN
www.instron.com