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Summary of Contents for Instron DX Series
- Page 1 Industrial Products Group Model DX Static Hydraulic Universal Testing System System Concepts Manual M47-17028-EN Revision C www.instron.com The difference is measurable ®...
- Page 2 Illinois Tool Works Inc. (ITW). Other names, logos, icons and marks identifying Instron products and services referenced herein are trade- marks of ITW and may not be used without the prior written permission of ITW.
- Page 3 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.
- Page 4 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.
- Page 5 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. Product Support: www.instron.com...
- Page 6 Preliminary Pages Warnings 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.
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Page 7: Table Of Contents
Optional accessories ............Product Support: www.instron.com... - Page 8 Preliminary Pages Controls and electronics ............59 Series control unit .
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Page 9: Chapter 1 Introduction
Software test methods that are appropriate for your testing requirements are available. These instructions do not include the development of test methods within the materials testing software. This is covered in more advanced training that can be provided by Instron Service and Training departments. -
Page 10: System Overview
Purpose Warning If the equipment is used in a manner not specified by Instron, the protection provided by the equipment may be impaired. Injury to personnel or damage to the system may result. Be sure to read and understand the material presented in these instructions and in any other accompanying instructions. - Page 11 About these instructions Figure 1. DX testing systems - various configurations shown. Product Support: www.instron.com...
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Page 12: Frame Configuration Options
(i.e. the frame serial tag). The frame serial tag includes other important system information, including information on your frame’s configuration. Frame configuration information can also be found on your Instron quote. Refer to “Frame configuration options”... -
Page 13: Product Support
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... -
Page 14: Calibration And Verification
ASTM, ISO, and EN standards require the system be calibrated when it is installed or when it is moved or relocated. Instron calibrates the system at the factory, and provides a record of readings for the load cell. This frame may be verified on-site to ASTM E-4, BS 1610, DIN 51221, ISO 7500/1, EN 10002-2, JIS B7721, JIS B773 or AFNOR A03-501 standards. -
Page 15: Chapter 2 Installation Notes
If factory rationalization was purchased, these transducers will be requested 2-3 weeks prior to shipment of the system in order to integrate them. Some instruments can be rationalized separately from the shipment of the system, if necessary, to maintain your testing commitments. Contact your local Instron office for more information. -
Page 16: Interconnections
Chapter 2: Installation Notes Interconnections The following interconnection information is provided for reference. It is not intended to be a complete step-by-step installation procedure, but it does provide a general guideline of what and how system components should be interconnected. Depending on the components supplied with your system, all the interconnections listed may not be necessary for your system. -
Page 17: Electrical Interconnections
Expansion Channel Module box 68-Way mini-D cable 1. Encoder cable may have been disconnected from encoder for shipment. Cable remains hardwired to frame interface board. Connect cable end to encoder on bottom of hydraulic cylinder. Product Support: www.instron.com... -
Page 18: Software And Computer Setup
Chapter 2: Installation Notes Software and computer setup When a new computer system is purchased as part of the testing system and is supplied from the factory, or if a customer supplied computer was returned to the factory for integration with the system, then the computer system and controlling software were set up at the factory before shipment. - Page 19 Interconnections Windows XP operating system Windows 7 operating system Figure 2. Local area connection properties. Figure 3. Internet protocol properties. Product Support: www.instron.com...
- Page 20 Ethernet connection). The MAC address is case sensitive. The first six digits (00-90-C2) indicate that the EFI is an Instron device. The last six digits are unique to that EFI to ensure that Partner only communicates with that specific EFI (Figure viii.
- Page 21 Partner interface type selection. Figure 6. Partner MAC address entry. b. For systems with Bluehill software, perform the following: Start Bluehill. Select the Admin button. (Ensure no methods are open.) iii. On the Admin page, select Configuration. Product Support: www.instron.com...
- Page 22 59-Series control unit (usually below the ethernet connection). The first six digits (00-90-C2) indicate that the EFI is an Instron device. The last six digits are unique to that EFI to ensure that Bluehill only communicates with that specific EFI.
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Page 23: Initial Startup
9. It is necessary to bleed air from the hydraulic cylinder. This requires a procedure that must be performed by the Instron service engineer. 10. The system is now ready for normal operation. Before the system is operated any further, be sure to read and understand the material provided in the System Operating Instructions (supplied separately). -
Page 24: Install Grip Assembly Components
Semi-permanently mounted accessories are typically not installed until the system is fully operational. Typically the Instron service engineer will assist with this during installation of the system. For more detailed information on these accessories, refer to the individual instructions that are included with each accessory. -
Page 25: Chapter 3 Additional System Details
Chapter 3 Additional System Details • Frame ..............25 •... -
Page 26: Adjustable Crosshead
Chapter 3: Additional System Details Loading Unit Components: Fixed Unit Components: • Tension Crosshead* • Adjustable Crosshead • Notched Columns* • Screw Columns • Compression Table • Base • Hydraulic Cylinder G8-Style G1-Style or G7-Style G8-Style G1-Style or G7-Style Crossheads Crossheads Crossheads Crossheads... -
Page 27: Grip Assemblies
Figure 9. DX frame components. Grip assemblies Grip assemblies are provided on frames with either G1-style or G7-style crossheads; they are not provided on frames with G8-style crossheads. Both the tension and adjustable crossheads are equipped with grip Product Support: www.instron.com... - Page 28 Chapter 3: Additional System Details assemblies that are designed to grip specimens for tensile testing. Frames can be purchased with either manual grip actuation (G1-style crossheads) or hydraulic grip actuation (G7-style crossheads). Manual grip actuation - G1-style crossheads For G1-style crossheads, the grip assemblies are actuated manually. Components of the grip assemblies are illustrated in Figure 10.
- Page 29 8. Button head cap screw* 9. Filler plate 10. Grip jaw 11. Bumper plate * See Operating Instructions for specifications. View B Adjustable Crosshead Exploded View Assembled View Figure 10. Components of the grip assemblies for G1-style crossheads. Product Support: www.instron.com...
- Page 30 Chapter 3: Additional System Details Hydraulic grip actuation - G7-style crossheads For G7-style crossheads, the grip assemblies are actuated hydraulically. Components of the grip assemblies are illustrated in Figure 11. The operator uses a grip control handset (Figure 12 page 32) to operate a hydraulic piston that is inside the crosshead. A push plate (17) is mounted to the piston.
- Page 31 14. Access hole for retainer setscrew (600DX only) 15. Grip pocket 16. Guide slot for guide pin 17. Push plate and piston View A View B View C Figure 11. Components of the grip assemblies for G7-style crossheads. Product Support: www.instron.com...
- Page 32 Chapter 3: Additional System Details Grip controls Warning These grip assemblies are designed to grip specimens for testing. Therefore, an unavoidable pinching hazard exists. Make sure to read and understand all installation, removal and operating instructions before using the grip assemblies! A hand-held grip control unit (Figure 12) is supplied to control operation of the hydraulic grips.
- Page 33 3. Tighten the locknut. 4. Check jaw operation before inserting a specimen or performing a test. Upper grip close Upper grip open Adjustment knob Locknut Lower grip open Lower grip close Figure 13. Clamping speed adjustment - flow control valves Product Support: www.instron.com...
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Page 34: Limit Switch Assembly
Chapter 3: Additional System Details Limit switch assembly A limit switch (2, Figure 14) is mounted to the underside of the base plate (1). The purpose of the limit switch is to protect the hydraulic cylinder from overtravel. The limit switch is actuated by a guide rod (3) that is mounted to the piston (8a). -
Page 35: Position Measurement
The electrical signal is transmitted to the 59 Series control unit. The 59 Series control unit converts the signal into the relative position of the loading unit in relation to a stationary frame member. Figure 15. Location of position encoder on 600 DX Product Support: www.instron.com... -
Page 36: Optional Accessories
Chapter 3: Additional System Details Optional accessories Instron offers a wide variety of testing accessories that can be used with the DX frame. Some are designed to be mounted temporarily in the frame, while others are designed to be mounted semi- permanently to the frame. -
Page 37: Controls And Electronics
“P” indicates the all self- tests have passed. If the LEDs should flash the letter “F” at any time during the sequence, this indicates that a self-test has failed. If this occurs, you should contact your local Instron Services department as directed on page for assistance in troubleshooting the failure. -
Page 38: Electrical Panel
On-line Help system or to the manual provided. Computer systems are typically purchased from Instron with the testing system, however they may be customer supplied. If this is the case, refer to any information provided by the computer vendor in regards to its operation, warranty, etc. -
Page 39: Hydraulic System
The reservoir is equipped with an oil level and temperature sight gauge. The sight gauge (4, Figure 17) is visible through the opening provided on the right side of the frame base. The reservoir should be filled so Product Support: www.instron.com... - Page 40 Chapter 3: Additional System Details Rear and side covers removed. 1. Motor 2. Air breather filter 3. Fill hole 4. Sight gauge 5. Oil filter 6. Heat exchanger and fan System pressure gauge 8. Relief valve RV1 9. Servo manifold 10.
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Page 41: Manifold Assemblies
This flow control adjustment is set at the factory and should not require further adjustment. Any adjustments should only be made by an Instron service engineer. For pump and motor maintenance, refer to the separately supplied manufacturer’s information. - Page 42 This pressure gauge is visible through a cut out in the left side cover of the base. System pressure is set at the factory and should not require further adjustment. Any adjustments should only be made by an Instron service engineer. Dump valve: When unloading the frame, the servo valve changes position to allow oil to return through the system to the reservoir.
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Page 43: Pressure Settings
All relief valves, reducing valves, pressure switches, etc. are set at the factory to their proper operating pressure. They should not need further adjustment. If you feel adjustment is necessary, contact your local Instron Services department as directed on page 13. Any adjustments should only be made by an Instron service engineer. -
Page 44: Troubleshooting
If the problem cannot be determined through the chart, contact your local Instron Services department as directed on page 13. Another option would be to check the listing of Frequently Asked Questions (FAQs), available on the Instron website (www.instron.com), for a description/solution to your problem. - Page 45 Check the user control panel cable for stating “Control Panel Watchdog with the user control panel damage. If damage is found contact your Timeout” local Instron Services department as directed on page 13. • After opening a procedure the HPS The frame is not enabled...
- Page 46 20.7 bar (300 psi). If it does not, or if this seems insufficient for your testing needs, contact your local Instron Services department as directed on page 13. • During a tensile test when an The specimen is slipping in the Problem No.
- Page 47 Select position or strain control and restart test, or contact your local Instron Services department as directed on page 13. Load cell cable could be Check load cell cable for damage and...
- Page 48 It is possible to overload the crosshead motor. If it is overloaded, oil is load is more than 1% of frame capacity, relieved back to the reservoir. Damage to load cell, fixtures, etc. could contact your local Instron Services result. department as directed on page 13.
- Page 49 8.2a or above for Partner, or 2.15 or above for Bluehill • If none of the above correct the problem, then contact your local Instron Services department as directed on page Partner Software Bluehill Software Figure 18. Controlling software error messages.
- Page 50 Chapter 3: Additional System Details Figure 19. Internet protocol properties. M47-17028-EN...
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Page 51: Chapter 4 Parts Replacement
• Fuses All other parts replacement should be done by an Instron service engineer. For assistance with replacement of any part, contact your local Instron Services department as directed on page 13. -
Page 52: Replacement Of Fuses
Chapter 4: Parts Replacement Replacement of fuses The system is equipped with fuses as outlined in Table Table 6. Fuse information. Instron Fuse Description Specifications Part Number Quantity Fuses 1FU and 2FU 7 amp, For 115 VAC main power supply... -
Page 53: Replacement Or Repair Of Load Cells
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. If you suspect that a cell may be damaged, contact your local Instron Services department as directed on page to arrange returning the load cell for analysis and possible repair. - Page 54 Chapter 4: Parts Replacement This page is intentionally blank. M47-17028-EN...
- Page 56 Product Support: www.instron.com...
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