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Summary of Contents for Instron DX Series
- Page 1 Industrial Products Group Model DX Static Hydraulic Universal Testing System Operating Instructions M47-17027-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
Adjust the position of the adjustable crosshead ........Product Support: www.instron.com... - Page 8 Preliminary Pages Operate grip assemblies - G1-style and G7-style crossheads ......Grip jaw selection ............Specimen guidelines.
- Page 9 Appendix B Grip Jaws ............93 Product Support: www.instron.com...
- Page 10 Preliminary Pages M47-17027-EN...
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Page 11: 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 12: 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 13 System overview Figure 1. DX testing systems - various configurations shown. Product Support: www.instron.com...
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Page 14: 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 15: Frame Components
View A Loading Unit View B Fixed Unit Frame with Frame with G8-style G1-style or crossheads G7-style crossheads Figure 2. DX frame components - for legend see Table Product Support: www.instron.com... - Page 16 Chapter 1: Introduction Table 1. Frame component descriptions, see Figure Component Description View A: Loading unit Applies load to the specimen during the test. Consists of: a tension crosshead two notched columns , a compression table, and the hydraulic cylinder. View B: Fixed unit Remains fixed during the test.
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Page 17: System Control Components
Grip controls Allows the operator to open and close the grip jaws. Operated either manually (G1-style crossheads) or hydraulically (G7-style crossheads). Refer to “Operate grip assemblies - G1-style and G7-style crossheads” on page for more information. Product Support: www.instron.com... -
Page 18: System Safety And Information Labeling
High pressure hazard - Indicates that a hazard exists from high pressure. Do not adjust or reset any pressure settings until you have read and understood the operator’s manual. Personal injury or damage to equipment may result. Most pressure settings should only be adjusted by an Instron service engineer. - Page 19 System overview Table 3. Descriptions of safety and information labeling. (Continued) Label Meaning and Purpose Grease location - Indicates the location of grease fitting to apply appropriate lubricant. Product Support: www.instron.com...
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Page 20: 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 21: Chapter 2 Specifications
The system can operate in servo control mode only through an Instron Materials Testing Software package. The system must never be left unattended while in operation. -
Page 22: Frame
Chapter 2: Specifications Frame The technical specifications for the various standard DX frames can be found in Table 5. If unsure of the options included with your frame, check the model number listed on the frame’s serial number tag; it includes option designations. - Page 23 G1, G7 356 mm (14 in) 279 mm (11 in) 356 mm (14 in) 559 mm (22 in) Stroke 152 mm (6 in) 152 mm (6 in) Adjustable Crosshead Travel 356 mm (14 in) 381 mm (15 in) Product Support: www.instron.com...
- Page 24 Chapter 2: Specifications Table 5. DX frame technical specifications. (Continued) Specification 300DX 600DX (D) Crosshead Thickness 98 mm (3.875 in) 178 mm (7 in) Tension crosshead: 356 mm (14 in) 267 mm (10.5 in) Adjustable crosshead: 381 mm (15 in) 98 mm (3.875 in) 178 mm (7 in) (E) Column Diameter...
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Page 25: 59 Series Control Unit
(position) readout should not be used as the primary strain measuring device where an extensometer on the specimen is clearly warranted. Frame compliance can be accounted for to some extent by Instron software. 11.At speeds below approximately 0.1 mm/min (0.004 in/min) the hydraulic cylinder moves in increments approximately equal to these values and can be seen as load steps depending on the specimen stiffness and load range. -
Page 26: Environmental Conditions
Real-time closed-loop control Real-time data acquisition Data Transfer to Computer 1000 Hz Transducer Inputs Standard Instron rationalized transducers Any 0-10 V analog DC input Transducer Resolution 1 part in 500,000 of +/- full scale (19 bits) Load Measurement Accuracy +/- 0.5% of reading down to 1/500 of load cell capacity Linearity +/- 0.25% of reading over a range of 0.2% to 100% of capacity... -
Page 27: Noise Level
The noise level readings were taken at a location in front of the system as shown in Figure 4. This is the typical location for an operator to stand when operating the system. Frame Approximately 500 mm (18 in) Operator Figure 4. Location of noise level reading. Product Support: www.instron.com... - Page 28 Chapter 2: Specifications M47-17027-EN...
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Page 29: Chapter 3 Operation
Chapter 3 Operation • Operation of controls ............29 •... - Page 30 Chapter 3: Operation Table 9. Control functions. (Continued) Control Location Description Adjustable crosshead HPS control Adjust the position of the adjustable crosshead either before or after a control switch test. This changes the height of both the tension test opening and the compression test opening.
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Page 31: Operation Of Controls
Provides an indication of self-tests that are performed by the controls control unit when the system is powered up and is also an indicator of system status. System status is normal when the indicator is green and the indicator is blinking red. Product Support: www.instron.com... - Page 32 Chapter 3: Operation Figure 5. User control panel. M47-17027-EN...
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Page 33: Operation Of Hps
HPS is supported on the leveling feet. Check clearances all around the base of the HPS. If any part of it is in contact with the frame base, use the set screws and leveling feet to make adjustments to avoid contact. Product Support: www.instron.com... -
Page 34: Procedure For 600Dx Frames
Chapter 3: Operation 8. Remove the 4 set screws and lock nuts (No. 2 in Figure 9. Reinstall the rear and side panels. Reconnect the power supply and power on the machine. Check for leaks and proper machine operation. Procedure for 600DX frames Figure 7. -
Page 35: Mount Tension Fixtures
Some bolt patterns are designed for the mounting of specific standard Instron accessories or fixtures, while others are more general for the mounting of a wide range of standard Instron accessories or fixtures. Any bolt pattern can be used for the mounting of customer fixtures; appropriate adaptation may be necessary. - Page 36 Chapter 3: Operation 1. Bumper plate (typical) 2. Setscrew, M8 3. Button hole, 25 mm (1 in) diameter 4. Mounting button 5. Compression fixture Figure 8. Example of bumper plate. M47-17027-EN...
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Page 37: Start The System
Mount fixtures Start the system This document presumes that customer training (by Instron service personnel) has been completed and that at least one procedure has been created in the controlling software. Before operating the system: • Familiarize yourself with the operating features and controls described in these instructions and in all other accompanying documentation for the controlling software. -
Page 38: Change Height Of Tension Test Opening
Chapter 3: Operation Change height of tension test opening Warning Always wear appropriate personal protective equipment when preparing, operating and maintaining this equipment. Personal protective equipment should include, but is not limited to, eye protection and head protection. Other types of personal protective equipment may also be needed. - Page 39 Retaining ring use, style and fastener information. Frame Model Upper Retaining Ring Spacer Lower Retaining Ring Hinged clam style, one M8 SHCS Hinged clam style, one M8 SHCS 300DX-G1 (use 6 mm hex key) (use 6 mm hex key) Product Support: www.instron.com...
- Page 40 Chapter 3: Operation Table 10. Retaining ring use, style and fastener information. (Continued) Frame Model Upper Retaining Ring Spacer Lower Retaining Ring Split bolt-on style, four M10 x 35 mm SHCS 300DX-G7 (use 8 mm hex key) Two-piece style, two 3/8-24 SHCS Two-piece style, two 3/8-24 SHCS 600DX-G1 (use 5/16 in hex key)
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Page 41: Change Height Of Compression Test Opening
Adjustment can only be done between tests, never during a test. Adjust the position of the adjustable crosshead For procedure on moving the adjustable crosshead, see “Adjustable crosshead control switch” Table 9 on page 29. Product Support: www.instron.com... -
Page 42: Operate Grip Assemblies - G1-Style And G7-Style Crossheads
Use of Molykote type GN metal paste (high pressure lubricant) is necessary for proper operation of the grips. Instron recommends only this brand and type of high pressure lubricant. Use of any other lubricant risks damage to the grip components. This damage would not be covered under warranty. A small amount of Molykote type GN metal paste is supplied with the frame, additional quantities can be purchased from Instron, contact your local Instron Services department as directed on page 20. -
Page 43: Grip Jaw Selection
If the grip jaws do extend more than 7 mm (0.25 in) at the end of the test, this would indicate the wrong size jaws are being used. Instron offers a wide selection of grip jaws. For further information about the sizes and types of jaws available, see Appendix B. -
Page 44: General Use Guidelines
Use of Molykote type GN metal paste (high pressure lubricant) is necessary for proper operation of the grips. Instron recommends only this brand and type of high pressure lubricant. Use of any other lubricant risks damage to the grip components. This damage would not be covered under warranty. -
Page 45: Filler Plate Guidelines (G1-Style Crossheads Only)
Use as many filler plates as required so that the narrow end of the grip jaws does not protrude beyond the crosshead when the specimen is gripped. Product Support: www.instron.com... -
Page 46: Install Grip Jaws - G1-Style Crossheads
Chapter 3: Operation Install grip jaws - G1-style crossheads Equipment and supplies required All equipment must be supplied by the customer unless noted as “supplied”. For a list of equipment that was supplied with the system, refer to “Ancillary parts” on page 87. - Page 47 Use of Molykote type GN metal paste (high pressure lubricant) is necessary for proper operation of the grips. Instron recommends only this brand and type of high pressure lubricant. Use of any other lubricant risks damage to the grip components. This damage would not be covered under warranty.
- Page 48 Chapter 3: Operation View A Tension Crosshead Exploded View Assembled View 1. Tension crosshead 2. Crank handle and pinion 3. Adjustable crosshead 4. Grip pocket 5. Grip stop plate 6. Socket head cap screw (see Table 11 for size and quantity) Jaw retainer 8.
- Page 49 Size of Hex Key Frame Model Size Quantity Needed Size Quantity Needed 300DX-G1 M10 x 30 mm 8 mm 3/8-16 x 0.75 in 7/32 in 600DX-G1 M16 x 35 mm 14 mm 3/8-16 x 0.75 in 7/32 in Product Support: www.instron.com...
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Page 50: Remove Grip Jaws - G1-Style Crossheads
Chapter 3: Operation Remove grip jaws - G1-style crossheads Equipment required All equipment must be supplied by the customer unless noted as “supplied”. For a list of equipment that was supplied with the system, refer to “Ancillary parts” on page 87. •... - Page 51 Size of Quantity Size of Frame (per Hex Key (per Hex Key Model Size crosshead) Torque Needed Size crosshead) Needed 34 N-m 300DX-G7 M8 x 25 mm 6 mm M12 x 20 mm 8 mm (25 ft-lbs) Product Support: www.instron.com...
- Page 52 Chapter 3: Operation Table 12. Specifications for cap screws. Guide Plate SHCS Grip Dust Cover BHCS (item 7, Figure (item 10, Figure Quantity Size of Quantity Size of Frame (per Hex Key (per Hex Key Model Size crosshead) Torque Needed Size crosshead) Needed...
- Page 53 14. Access hole for retainer setscrew (600DX only) 15. Grip pocket View A 16. Guide slot for guide pin 17. Push plate and piston View B View C Figure 11. Components of the grip assemblies for G7-style crossheads. Product Support: www.instron.com...
- Page 54 Chapter 3: Operation 300DX Frames 600DX Frames 1. Grip jaw 6. Jaw carrier 2. Locating boss Magnet (300DX only) 3. Alignment hole 8. Retainer button (600DX only) 4. Alignment pin 9. Retainer setscrew (M8) (600DX only) 5. Jaw carrier recess Figure 12.
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Page 55: Remove Grip Jaws - G7-Style Crossheads
For 600DX frames, loosen the retainer setscrew (9) through the access hole on the front guide plate (6, Figure 11) (use 4 mm hex key). Only loosen the setscrew enough to release the grip jaw. 3. Remove the grip jaw from the grip pocket. 4. Repeat for each grip jaw. Product Support: www.instron.com... -
Page 56: Insert Specimen
Chapter 3: Operation Insert specimen Warning These grips 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 grips! Be sure to use a specimen of sufficient length to meet the minimum gripping requirements; see “Specimen guidelines”... -
Page 57: Run A Test
This document presumes that customer training (by Instron Service Engineer) has been completed and that at least one procedure has been created in the controlling software. - Page 58 Chapter 3: Operation Determine if it is necessary to make any adjustments to the frame configuration to attain the required test opening that was determined in step 6: a. For tension tests: Raise or lower the tension crosshead as necessary - see “Adjust the position of the tension crosshead”...
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Page 59: Shut Down The System
Use the jog controls to move the piston if necessary - typically a separation of 6 mm (0.25 in) is sufficient. Product Support: www.instron.com... -
Page 60: Loss Of Power
If possible, remove any specimens from the frame. If power can not be restored to the frame and it is necessary to retract the piston into the hydraulic cylinder, contact your local Instron Services department as directed on page for a solution. -
Page 61: Maintenance
General maintenance recommendations Only the maintenance procedures outlined in these instructions should be performed by the customer or their representative. All other maintenance and repairs should be performed by Instron Service personnel only. Preventative maintenance schedule Table 14 outlines a recommended preventative maintenance schedule for system components. - Page 62 Chapter 4: Maintenance Table 14. Recommended preventative maintenance schedule. (Continued) Frequency Component Maintenance Task • Daily or after every 50 For 600DX frames: The tightness of the retainer setscrew should be consecutive tests: Grip assemblies checked daily or after 50 consecutive tests are performed with the same of G7-style set of grip jaws.
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Page 63: Make Daily Checks Of System
If any of these checks reveal a potential problem, the problem should be investigated and corrected before the system is operated. For assistance in troubleshooting the system, contact your local Instron Services department as directed on page 20. -
Page 64: Remove And Install Base Covers
Chapter 4: Maintenance Remove and install base covers To perform any maintenance on the electrical panel or HPS it is necessary to remove one or more of the base covers. Refer to the following procedures to remove covers as needed for a given maintenance task. The only equipment required is a 4 mm hex key (supplied). - Page 65 Preventative maintenance schedule 1. Front cover 2. Left side cover 3. Rear cover 4. Front/side screws 5. Rear screws Figure 14. Base covers. Product Support: www.instron.com...
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Page 66: Electronics
HPS. Tighten any loose connections that you may find. • Inspect all cables for deterioration. Check for abrasions, cuts, etc. Replace cables as necessary. If you notice any problems resulting from this inspection, contact your local Instron Services department as directed on page for immediate assistance. -
Page 67: Adjustable Crosshead
Check for binding and abnormal noise. The crosshead should move smoothly. If you notice any problems resulting from this inspection, contact your local Instron Services department as directed on page for immediate assistance. - Page 68 Note: Use only petroleum based oils, such as good quality motor oil, with a viscosity equivalent to SAE30 or specifically petroleum based roller chain lubricants. Do not use penetrating lubricants, such as WD-40, to lubricate or clean the chain. 1. Can be purchased from Instron. See Table 18 on page for part numbers.
- Page 69 10. M6 button head cap screw Side view of 600DX with side cover removed (some internal parts also removed for clarity). Rear view of 600DX with rear cover removed (HPS also removed for clarity). Figure 15. Lubrication of components for adjustable crosshead. Product Support: www.instron.com...
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Page 70: Inspect The Hydraulic Cylinder
Chapter 4: Maintenance Warning Entanglement hazard exists. It is necessary to start up the system in order to complete lubrication. Remove all body parts from the frame before starting the system. Be sure that all equipment is removed from the frame. Start the system;... - Page 71 Increases and decreases in the load reading could indicate that the piston is binding. If you notice any problems resulting from this inspection, contact your local Instron Services department as directed on page for immediate assistance.
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Page 72: Grip Assemblies - G1-Style And G7-Style Crossheads
Use of Molykote type GN metal paste (high pressure lubricant) is necessary for proper operation of the grips. Instron recommends only this brand and type of high pressure lubricant. Use of any other lubricant risks damage to the grip components. This damage would not be covered under warranty. -
Page 73: Clean And Inspect Grip Components
77); a grease gun and two grease cartridges are supplied with the grips and additional quantities can be purchased from Instron. The grease fittings apply grease to the rear and sides of the jaw carriers. Use the following procedure to lubricate each jaw carrier. - Page 74 Chapter 4: Maintenance Equipment and supplies required All equipment and supplies must be supplied by the customer unless noted as “supplied”. For a list of equipment that was supplied with the system, refer to “Ancillary parts” on page 87. • A suitable stable platform such as a man-lift, stairs, or ladder.
- Page 75 If damage is found along the edge of the recess, the edge can be filed smooth. • Check for any cracks, particularly around the upper portion of the recess. If any cracks are found, the jaw carrier must be replaced. Product Support: www.instron.com...
- Page 76 Light scoring should be smoothed with a file or pneumatic sander. If deformation of the pocket or severe scoring is noticed, contact your local Instron Services department as directed on page 20. It may be possible to correct problems by machining.
- Page 77 5. Guide pin page for size and quantity) (one on each side of jaw carrier) 13. Grease fitting plug 6. Grip jaw 14. Grease fitting Grip pocket Figure 17. Components of the grip assemblies for G7-style crossheads. Product Support: www.instron.com...
- Page 78 Chapter 4: Maintenance Inspect and replace the pinion - G1-style crossheads For frames with G1-style crossheads, a pinion should be replaced if it no longer operates the grip jaws correctly. For correct operation, the ends of the grip jaws should always be aligned with each other as they are opened or closed (see Figure 18).
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Page 79: Hydraulic Power Supply (Hps)
If the oil appears dirty, it should be changed (see “Change the oil” page 83). In the United States and Canada, an oil sample test kit is available for purchase from Instron Services; contact your local Instron Services department as directed on page for more information about the test kit. -
Page 80: Check The Oil Cleanliness
Chapter 4: Maintenance Recommended procedure Refer to Figure 20 on page for identification of components. 1. Remove the right side cover from the frame base. Refer to “Remove and install base covers” page 64. 2. Clean the area around the fill hole and air breather filter (3 and 2) to remove all dust, dirt and grime. 3. - Page 81 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. Reservoir Figure 20. Components of the HPS. Product Support: www.instron.com...
- Page 82 Hydraulic fluid, for fluid specifications and amount required see “Oil type and quantity” page • New oil filter element - for Instron part number see Table 18 on page • New air breather filter - for Instron part number see...
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Page 83: Change The Oil
8. 12. Insert a clean funnel with a mesh filter into the fill hole and fill the reservoir with the recommended hydraulic fluid. Fill the reservoir to the top of the sight gauge. Product Support: www.instron.com... -
Page 84: Change The Air Breather Filter
Table 18 on page When ordered from Instron, the air breather filter includes a new air breather fitting and plastic screen. The only part needed is the air breather filter. However, you can replace the existing air breather fitting and plastic screen with the new parts if desired or necessary (due to damage, etc.). -
Page 85: Inspect The Hydraulic Hoses
Approximate reservoir capacities for the various models of DX frames can be found in Table Table 16. Approximate capacity of HPS reservoir. Frame Model Reservoir Capacity 300DX 34 L (9 gal) 600DX 34 L (9 gal) Product Support: www.instron.com... -
Page 86: Ancillary Parts
Chapter 4: Maintenance Ancillary parts DX systems are provided with operating tools and other accessories that are either: required to complete installation of the frame; required for use or maintenance of frame; or required for set up of accessories on the frame. These ancillary parts are included with the frame upon delivery. Ancillary parts for the various DX systems are listed in Table 17. -
Page 87: Ancillary Parts
Lubricate grip assemblies 300DX-G7 300-8899-10682 600DX-G7 Lubricant, Molykote GN metal Lubricate grip assemblies 300DX-G7 300-8894-9059 paste, 14 oz cartridge 600DX-G7 Adhesive, Loctite 246 Maintain grip assemblies Threadlocker high temperature/ 300DX-G7 300-8899-10741 medium strength, 10 mL 600DX-G7 (0.34 oz) Product Support: www.instron.com... - Page 88 Tighten and loosen various fasteners 300-8875-9290 1.5 - 10 mm ball end 1. Part numbers are listed for reference only. Some parts can not be ordered using these numbers; contact your local Instron Services department as directed on page to order parts.
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Page 89: Consumable Parts
Spare and replacement parts The Instron Services department can supply parts for your system. In the event that your system requires replacement parts, or if you choose to keep spare parts in stock, please contact your local Instron Services department as directed on page for the proper part. - Page 90 Chapter 4: Maintenance M47-17027-EN...
- Page 91 900 Liberty Street, Grove City, PA, 16127, USA Name and address of the person authorised to compile the technical file: Name: Jonathan Snell Address: Instron - Division of ITW Limited, Coronation Road, High Wycombe, Buckinghamshire, HP12 3SY, United Kingdom Herewith we declare that Model Number: Serial Number:...
- Page 92 Appendix : CE Certificate This page is intentionally blank.
- Page 93 Table 19 lists the catalog numbers and specifications of grip jaws that are available. In addition, other grip jaws can be ordered and made to customer specifications; contact your regional Instron office or check our web site at www.instron.com for assistance.
- Page 94 Appendix : Grip Jaws Table 19. Available grip jaws and their specifications. (Continued) Grip Jaw Catalog Specimen Tooth Jaw Face Size Minimum Frame Model Number Type Range Profile (W x H) Engagement W-5246-A 0-16 mm (0-0.63 in) 20 tpi, W-5246-B Flat-face 16-32 mm (0.63-1.26 in) horizontal,...
- Page 96 Product Support: www.instron.com...
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