u-series instruction manual 820-7001_15issue_03

7/21/2019 U-Series Instruction Manual 820-7001_15Issue_03

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TINIUSOLSENLTD

H150KU Tensile Test Machine

Instructions For UseDoc. Ref. 820-7001_15

Issue 03


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Tinius Olsen Ltd 820-7001_15 Issue 3 Page 1

Contents

1.

Introduction...................................................................................................................................2

1.1. Preface .......................................................................................................................................21.2. Overview ....................................................................................................................................2

2.

Major Options................................................................................................................................3

2.1.

Strain (Aux.) Display Option(s)...................................................................................................3

2.2. Navigator ....................................................................................................................................33.

Specifications ...............................................................................................................................4

3.1. Load Frame................................................................................................................................43.2. Control System...........................................................................................................................43.3.

Force Measurement ...................................................................................................................4

3.4. Extension Measurement ............................................................................................................43.5. Speed Control ............................................................................................................................43.6.

Hardware Options ......................................................................................................................5

3.7. Dimensions.................................................................................................................................53.8. Weight ........................................................................................................................................53.9.

Power Supply .............................................................................................................................5

3.10. Environmental ............................................................................................................................53.11.

CE Markings...............................................................................................................................5

3.12.

Manufacturer ..............................................................................................................................5

4. Installation.....................................................................................................................................64.1. Inspection ...................................................................................................................................64.2.

Contents .....................................................................................................................................6

4.3. Location......................................................................................................................................74.4. Connection to Power Supply......................................................................................................84.5.

Load Cell ..................................................................................................................................10

4.6. Connection to a PC ..................................................................................................................114.7. Connection to auxiliary equipment (optional)...........................................................................12

5. Checks before powering up ......................................................................................................136. Power on......................................................................................................................................14

6.1. Turn the machine On................................................................................................................146.2.

Check Machine Operation........................................................................................................15

7. Operation.....................................................................................................................................177.1. Handset ....................................................................................................................................177.2.

Handset Functions ...................................................................................................................19

7.3. Special Key Functions. .............................................................................................................217.4. Machine Protection...................................................................................................................217.5.

Typical Settings........................................................................................................................23

7.6. Replacing Loadcells .................................................................................................................248. Tooling.........................................................................................................................................25

8.1.

Attaching to the Machine..........................................................................................................25

9. Conducting a test .......................................................................................................................289.1. Basic Operation........................................................................................................................289.2.

Testing Using The Handset......................................................................................................28

9.3.

Testing Using Optional Software..............................................................................................30

10. Safety ...........................................................................................................................................3110.1.

Warnings ..................................................................................................................................31

10.2. Protective Screens ...................................................................................................................3211. Training........................................................................................................................................3312. Maintenance................................................................................................................................34

12.1. Electrical...................................................................................................................................3412.2. Calibration ................................................................................................................................3412.3. Lubrication................................................................................................................................34

13. Storage ........................................................................................................................................3514. Appendix .....................................................................................................................................36

14.1.

Dimensions...............................................................................................................................36


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1. Introduction

1.1. Preface

The purpose of this manual is to provide the user with sufficient information for installation,operation, care and maintenance of this test machine and its accessories. Therefore, it is

recommended that the entire manual be read and understood before working with the machine.Questions that arise should be directed to Tinius Olsen or its authorised representative.

A Calibration Certificate and Test Report are supplied for each Load Cell and Instrumentprovided with the machine. Re-calibration of the machine and instruments should be performedafter installation and regularly at yearly intervals or as required. Tinius Olsen Ltd maintains aCalibration and Service Department. At a nominal cost to the customer, periodic calibration andservicing, as required, can be provided. Complete information on this service can be providedby our Service Department or our authorized representative upon request

1.2. Overview

The Tinius Olsen H150KU Testing Machine with Strain Gauge Load Cell Weighing System is amodern precision Tension/Compression test machine designed for the Research Laboratory

and/or Production Testing where the load requirements demand a machine with a large range ofcapacities. It is also designed for fast, accurate and convenient operation in the testing ofvarious types of specimens.

The first line of the 602 main display on the handheld will show the Force, measured by a straingauge load cell and conditioner module (typically allocated to channel 1). The second line willshow the crosshead position, measured by an incremental encoder and its conditioner module(allocated to channel 2). The third line of the display (Auxiliary) is not generally used unless anoptional LVDT or strain gage based measuring instrument and its conditioner is to be used.Such a device may be used to measure strain (extensometer) or deflection (deflectometer) inthe specimen.

The H150KU testing machines with their versatile, easy-to-use software packages are ideal for

determining the mechanical and physical properties of materials in Tension, Compression,Flexure and Shear. Many other physical properties may also be investigated.

The H150KU machines cater for capacities of up to 150,000N utilising a twin screw arrangementfor high capacity.

There may be aspects of material testing not covered in this operation manual in particular thetype of grips used and additional optional equipment, such as Extensometers. See theaccessory instructions provided for these options.


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2. Major Options

2.1. Strain (Aux.) Display Option(s)

Test Lite is a software package that will allow the operator to have simple control of the machineand setup basic test parameters to gather data from a test. This data can then be printed or

exported at the users discretion.

Please note that Test Lite does not calculate any test results. However, it will report maximumvalues and dimensions can be entered for flat or round specimens and report Stress units.

Test Lite also includes the (password protected) Calibration program necessary to configure andcalibrate the machine.

2.2. Navigator

The software will control all the 602 Display settings.The software can start the test, control the speed of the machine, stop the machine after thetest, and return the crosshead to its Start Test PositionThe Software will plot the test on the computer display, perform the calculations, and the

operator can either reject or save the Test Results along with the Curve (Data Points). Aprintout of the Results and Curve can be made after a test and/or recalled later. When providedwith an optional Printer, the printed curves can also be used to calculate results not reported bythe software and multiple tests can be printed on one chart. Other options with the softwareinclude interfacing Digital Micrometers or Callipers, or other auxiliary devices.

A simplified version of Test Lite is provided with the Navigator Software for operating themachine remotely.

The Navigator software comes in three levels:-

StanPacVersion where the user must pick from a set of reports that cannot bechanged.

StandardVersion where the user can edit or create reports, headings, simple results,etc.

PlusVersion where the user can create their own reports, headings, simple results, etc.In addition, the user can edit the formulas used for any customer defined results andexpanded Import capability.

NOTEThese software packages require the use of a Windows (NT/2000/XP) computer with a vacant

RS232 port. Should an RS232 port not be available, a USB port may be used in conjunctionwith an adaptor.

A suitable computer and or adaptor is available from Tinius Olsen.

For customers intending to supply their own computer, please ensure that it meets the minimumsystem requirements as stated in the quote for the software.

.


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3. Specifications

3.1. Load Frame

Designation

CapacityStyleMax Crosshead TravelMax Specimen DiameterFrame StiffnessConstruction

U Series

150kN (15,000kg)Floor Mounting1200mm650mm200kN/mm at normal load pointsSolid steel -crossheads with sheet steel panellingPrecision Anti-Backlash Ball ScrewsBallscrew cover/protection bellowsPre-loaded Lead Screw Thrust RacesPrecision Brushless DC Servo MotorProgrammable crosshead Limit SwitchesEmergency Stop Switch

3.2. Control System602 Remote Handset

3.3. Force Measurement

Load Cell Shear Web TypeConforms to EN10002, ASTM E4, DIN 51221, ISO 75001Range 2% to 100% with Guaranteed Accuracy of 0.5% of applied forceExtended Range down to 1% with Guaranteed Accuracy of 1%Rapid Change Load Cells Available:-Unique ID and calibration for each load cellMax Force Limit = 1.09x FS Load (N).Force sampling rate typically 100 Samples/Second

(Up to approx. 350 samples/sec possible with 2 channelsand high speed computer running appropriate software)Load cell resolution 1 part 130,000 for +/- FSDigital Load Tear 20% whilst maintaining full load cell capacity

3.4. Extension Measurement

Extension Measurement by Precision optical encoder or optional external extensometer.Single measurement range 0 to 1200mmResolution 0.0001mmAccuracy 0.01mm/300mm

3.5. Speed Control

2 Pre-settable Speeds Under Manual ControlFully Variable Speeds Under Test Navigator Software Control1 Return SpeedVelocity Speed Range:-Testing 0.01 mm/min to 500 mm/minReturn Speed 0.01 mm/min to 700 mm/minSpeed Velocity Programmable in 0.01 mm/min stepsSpeed accuracy 0.5% of full speedDrive system:- Brushless Servo MotorAutomatic Over/Under Speed AlarmsMotor Drive Alarms on Under/Over Voltage, Current, and Temperature


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3.6. Hardware Options

Tinius Olsen range of Contact and Non-Contact ExtensometersTinius Olsen range of Displacement TransducersTinius Olsen range of Grips and AttachmentsTinius Olsen range of Guarding Options

3.7. Dimensions

mm InchHeight 2,465 97Width 1,135 44.75Depth 700 27.5

3.8. Weight

1,035 Kg1,290 Kg Including Packaging

3.9. Power Supply

3 Phase 415+/-10% VAC

3.10. Environmental

Temperature

Humidity

Operating 0C to 38CStorage10% to 90% Non-Condensing Wet Bulb Method

3.11. CE Markings

EMC Directive 89/336/EEC, and conforms to the following Generic EMC specificationfor Commercial and Light Industrial products.Emissions EN 50081-1Immunity EN 50082-1

Low Voltage Safety Directive 73/23/EEC, and conforms to the following specification.EN 61010-1 (Safety requirements for Measurement, Control and Laboratory use)

3.12. Manufacturer

Tinius Olsen Ltd6 Perrywood Business ParkHoneycrock LaneSalfordsRedhillSurreyRH1 5DZEngland


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4. Installation

4.1. Inspection

After unpacking, thoroughly check the machine controls for any damage.

4.2. ContentsThe machines are shipped completely assembled except for the optional accessories . Thebasic machines are supplied with the following items, please ensure that these are included forthe installation.

4.2.1. H150KU Testing Machine

4.2.2. Loadcell (Optional)

This will normally be of a shear web type 150kN, other sizes & types may be specified

4.2.3. Loadcell Bolt (Optional)

Bolt with hexagonal head (41mm A/F) for securing the loadcell to the crosshead.

4.2.4. Nose Piece (Optional)Nose piece with 2 off locking collars for attaching tooling to the loadcellNose piece with 2 off locking collars for attaching tooling to the base plate

4.2.5. Grip Pin (Optional)

2 off supplied Pins to suit nose pieces specified

4.2.6. PC Connection Lead

D type 9 way socket RS232 Serial Port Lead for external computer control.

4.2.7. Manual

Operating instruction manual and load cell calibration certificate


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4.2.8. Other Parts

Additional parts may be supplied, which are not listed above and will depend on thesystem configuration.

4.3. Location

4.3.1. Moving the Machine

The machine will require a forklift truck or similar to move it.

When moving the machine with a forklift truck, place protective materials (rubber sheetor cardboard) on the forks and lift the machine from the underside of the cross head

4.3.2. Levelling

The machine is designed to be placed on a flat level floor. If this is not available, jackingscrew points are provided located at each corner. Level the machine by screwing anM20 screw into the jacking screw holes and then insert packing material between thefeet and the floor.

If desired the machine can be bolted to the floor using any combination of the 8 off holeslocated at the corners of the machine.

See Appendix for bolt dimensions and positions

4.3.3. Power Supply

The machine requires to be hard wired to a suitable 3 phase supply, this is normally:-15 Amp Cont. 30A Peak

415 V +/-10% (374 456)50/60Hz


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Other operating voltages may be used, please contact Tinius Olsen Ltd for furtherdetails

The supply must be fitted with a power disconnect switch that is easy to operate andreach. The machine should be positioned as close as practical to the supply to avoid

trailing leads and or conduit across the floor.

4.4. Connection to Power Supply

Electrical connections must be made by qualified personnel and it is their responsibilityfor using the proper power disconnect along with the correct size and type of wire andconduit that conforms to all applicable local electrical codes when connecting themachine to the buildings main power.

The machine must be earthed, Under no circumstance must the machine be operatedwithout an earth connection

4.4.1. Electrical Disconnect

The electrical box must have a power disconnect switch that is easy to operate andeasy to reach. It must also meet IEC 60947-1 and IEC 60947-3 standards.

Recommended circuit breakers would be ones that are of the thermal magnetic typewith characteristics suitable for large inductive loads (D-type trip characteristic).

If fuses are used it is recommended that they are of the time delay type with dualelements. These recommendations should be followed to avoid nuisance tripping.

4.4.2. Cable Size

The machine will require either a 4 core cable (3 power 1 earth) or individual cablesrunning in a trunking. The minimum wire gauge for the H150KU is 12 AWG (3.3mm

2),

the earth wire must be of the same size or greater.

4.4.3. Cable Entry

A blanking plate is fitted to the side of the machine adjacent to the circuit breakers, thisplate can be drilled to suit the required gland or conduit fitting.


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4.4.4. Connections

Before the cables can be attached to the machine the gland plate, rear panel and MCBshield must first be removed.

Rear Panel MCB Shield Gland Plate

The cables must be connected as follows

L1 L2 L3 Earth


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When connecting the earth, ensure that the both the first nut and lock nut are fullytightened.

4.4.5. Re Fit Panels

IMPORTANT- Before applying power to the machine, ensure all covers are re-fitted

4.5. Load Cell

The load cell is fixed to the underside of the crosshead using the bolt supplied.NOTE - Before mounting any load cell to the crosshead, always check to ensure that thecontact surfaces are clean

Loadcell Bolt

Crosshead

RJ45 Connector

Loadcell

4.5.1. Place the mounting bolt through crosshead and lift the loadcell into position. Screw thebolt into the load cell. Hold load cell in position ensuring it is parallel to the crossheadthen fully tighten with a suitable spanner.

WARNING High capacity loadcells are heavy. Assistance may be required to lift theloadcell

4.5.2. Each loadcell is supplied with a strain module, this module must be used with thesupplied loadcell. Strain modules hold identification & calibration information and arenot interchangeable.

Attach the strain module to the crosshead using the bracket supplied

Connect the RJ45 plug connector into load cell socket located beneath and tothe right of the moving crosshead.

Connect the round connector into the socket on the loadcell and twist to tighten.


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RJ45 Connector Strain Module

4.6. Connection to a PC

The machine is connected to a PC using the supplied D type 9 way RS-232 Serialcable, this connection allows the computer to communicate with the testing machinesinternal electronics.

Before attempting to connect the RS-232 Serial cable, ensure that both Testing Machineand PC computer are SWITCHED OFF.

NOTE - Only use the cable supplied with the machine

4.6.1. The RS-232 Port is located on the right hand side of the machine towards the rear.Simply align the 9 way D type cable socket connectors to its mating plug on the

machine, taking care not to bend any pins, whilst held in this position tighten the twosocket jack screws until the connector is fully engaged.

The picture overleaf indicates the position of machine RS-232 Port.


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RS-232 Port RJ11 Connector

4.6.2. The other end of the RS-232 serial cable connects to a Personal Computer RS-232Com Port normally located at the rear of the PC Base Unit. The method is the same asused on the machine by aligning the 9 way D-type connectors then tighten the two jackscrews.

If your computer does not have a vacant RS-232 port a USB port may be used inconjunction with an adaptor. A suitable adaptor is available from Tinius Olsen.

4.6.3. Connect the coiled lead between the handset and machine, the RJ11 connector is theuppermost connector on the side of the machine near to the RS-232 Serial Port.

The handset rests on the bracket at the front of the machine.

WARNING- Do not plug the RJ11 connector of the handsets cable into any of the RJ45connectors for the modules or you will damage the handheld device

4.7. Connection to auxiliary equipment (optional)

4.7.1. Auxiliary equipment (extensometers etc) suitable for use with this machine are availablefrom Tinius Olsen.

4.7.2. Mechanical attachment methods vary according to the type of auxiliary equipment,these instructions will be supplied with the equipment.

4.7.3. To connect the equipment to the control system, slide the interface module, suppliedwith the equipment, into a vacant slot above the RS-232 port and plug the attachedRJ45 connector from the module into its adjacent socket.

NOTE Only use the module supplied with the auxiliary equipment as this contains

identification & calibration data.


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5. Checks before powering upBefore powering up the machine ensure the following:-

The handset is plugged in.

The power supply is attached and switched on.

Both circuit breakers are on. These are located on the rear panel near the bottom of themachine. The breakers are on when the levers are facing upwards.

NOTE There are 2 breakers, one 3 pole (3 phase supply) and one 2 pole (internal powersupply)

See below for location of Circuit Breakers.

Circuit Breakers(shown in on

position)

The E-stop button is released.

To check if the emergency stop switch is in its normal position rotate the top part of theswitch clockwise (direction shown by arrows on top of switch). If the switch had beenpreviously activated, on rotation the top will spring upwards. If no upwards movement isfelt the switch is already in its normal position


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6. Power on

6.1. Turn the machine On

Apply power to the machine using the on/off switch on the front panel: When power is firstapplied to the test machine, the remote terminal should boot up after 10 - 20 seconds.

Whenever power is first applied to the 602 System, the handset display will show the followinginformation.

6.1.1. Installed Version Number

Firmware version and serial number are displayed.

6.1.2. Transducer details

The display will indicate the attached conditioner modules, these will be:-

Force Xducer on line 1

Position Xducer on line 2

Aux Xducer (if fitted) on line 3.

If any of these modules are removed or replaced while the 602 system is displaying themain screen, the 602 system will recognize this and read in the data from the newmodule.NOTE- Power will be removed from the motor drive during the reading process, andreturn to the main screen.If any new modules are connected while the 602 is displaying one of the Menu Screens,the 602 will not be able to read in that module until exiting the Menu section

Typical Boot up sequence is shown below

Handset Boot Up Screen 1 Handset Boot Up Screen 2

Handset Boot Up Screen 3 Machine Ready


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6.2. Check Machine Operation

The machine powers up in IDLE mode, the crosshead will not move unless the motor drive isenabled, to enable or disable the motor drive the keys HI CL or LO CL are used.

NOTE- Hi Cl and Lo Cl perform the same function on this machine. Press the Hi Cl key once toactivate it, again to deactivate it. Or press the Lo Cl key once to activate, again to deactivate it.The motor drive will be disabled when neither Hi nor Low is selected.

Return

Motor Enable

Up

Motor Enable

Stop

Down

Handset Controls

6.2.1. Enable drive

To enable the motor drive you must first select either the [Hi Cl] or [Lo Cl] keys. Hi orLow will appear in the corner of the display Pressing the button a second time willdisable the motor drive.

6.2.2. Move Crosshead Pressing one of the direction keys (Up or Down) after enabling the drive will

move the crosshead in the relevant direction at the first set speed, pressing thebutton a second time will move the crosshead at the second set speed.Subsequent presses will toggle between the set speeds

Pressing the stop key will stop the crosshead

Pressing the Return key will move the crosshead either up or down at the setreturn speed until the position indicator returns to 0.00

IMPORTANT When using the return function ensure that there is sufficient space forthe crosshead or anything attached to it to move to the zero position without collidingwith anything placed on or attached to the machine.


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6.2.3. Travel limits

The travel limits are set by releasing the blocks mounted on the alarm rod in front of theleft hand cover and sliding them to the required position.To confirm function of the limit switch, run the crosshead upwards then pull the alarmrod up, the machine should stop. Next run the crosshead downwards and pull the alarmrod down, the machine should stop

Release Upper Limit Switch, move

crosshead to new position, slide limitswitch to crosshead striker, re-tighten

Release Lower Limit Switch, move

crosshead to new position, slide limitswitch to crosshead striker, re-tighten.

IMPORTANT if the machine fails to stop when the limit alarm is tested DO NOT usethe machine until the problem has been remedied.NOTE If the crosshead is allowed to contact the alarm block, the machine will stop, inthis case in order to restart the machine, release and move the block away from thecrosshead. If it is not possible to move the block away from the crosshead then theinterlock override function must be used. (See 7.4.5)

6.2.4. Emergency Stop

Pressing the emergency stop button (located on the front panel) will immediately stop

the machine and disable the drive.The button will remain down after being released, to reset the switch, rotate the top partof the switch clockwise (direction shown by arrows on top of switch), on rotation the topwill spring upwards. If no upwards movement is felt the switch is already in its normalposition.IMPORTANT if the machine fails to stop when the emergency stop switch is testedDO NOTuse the machine until the problem has been remedied.

6.2.5. Load cell

Press the ZERO FORCE key to zero the force displayed on the handsetWith the crosshead stationary, pull down and push up the underside of the load cell andcheck the force display on the handset.When the loadcell is pulled down, the load should be positive

When the loadcell is pushed up, the load should be negative.

IMPORTANT to prevent damage to the loadcell when using low capacity loadcells donot use excessive force.

6.2.6. Overload alarm

A load limit alarm is flagged when the machine or load cell capacity is exceeded eitherin tension or compression. The value of the alarm depends upon the load cell fitted andis approximately 9% greater than load cell capacity. E.g. If a 100KN load cell is fittedthe alarm would be triggered at 109kN in tension or compression. This system shouldnot be relied on to protect the machine or operator, as the machines ability to stop priorto damage is greatly reduced at high crosshead speeds.

The alarm is indicated by the flashing load and position indication on the handset. Thealarm can be cleared by backing the crosshead off in the opposite direction to reduce


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the applied force using the interlock override function (See 7.4.5). If the alarm persistsit is possible that the load cell has been damaged.The user is able to set a lower load limit if desired

7. Operation

7.1. HandsetThe handset will always show Force on the top line of the main display. This reading comesfrom a strain gage load cell and its conditioner module (typically channel 1). The second lineindicates crosshead position. It comes from an incremental encoder and its conditioner module(channel 2). The third line may be blank or it may display the reading from an Auxiliary devicelike an extensometer or deflectomer. Tinius Olsen supplies LVDT and strain gage based straindevices which, in conjunction with the appropriate module, may be selected

The bottom two lines will display Status information. The second to last line will show SBD

on the left if the Sample Break is ON, HI or LOW in the middle to show which Clutch Rangeis selected, and PK= on the right if Peak Hold (for Force) is on. The last line will show thecurrent mode of operation on the left, this will be IDLE when the system is first booted or whenleaving a Menu screen, READY once the [Test/Clear] key is pressed, TEST while a test isrunning, HOLD when the [Stop] key is pressed, and an Error message when an error isdetected. The right side of the last line will show the speed setting or current speed during atest. If the 602 is not running a test then pressing Up or Down will show on the last line.

NOTE The user should first press the [STOP] key before pressing [TEST/CLEAR] to ensurethat the crosshead does not drift whilst in the Ready mode.

Before testing, select the drive by pressing either Hi or Low Clutch and then press Stop (Hold).Then press Test/Clear (status shows Ready) and then press either Up or Down to start the

crosshead moving and begin the Test. The Peak Hold and Sample Break (if selected) will onlywork in the Test mode


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602DisplayMainMenuSelecti

ons

1.MachineControl

1.Speed

sThetwoTestSpeedSettings.ReturnSpeed&ProportionalGa

inscanbedisplayedandedited.

2.Positi

onControlTheHOMEPosition

,ThresholdandtheHOLDGains

canbedisplayedandedited.

3.Limits

TheFORCE,POSITION&DACLimitscanbedisplayedandedited.

4.Samp

leBreakDetectTheSampleBreakDetectorissettoStop/Return

onBreakoristurnedOFF.

5.Samp

leBreakSetTheForceStartLo

ad(%fs)&Dropoff(%pk)areset

fortheSampleBreakDetector.

2.Display

1.Units

TheForce,Position,AuxiliaryCh

annel&SpeedUnitscanbechan

ged.

2.PeakholdThe602ForcePeakHoldFunctioncanbeturnedONorOF

F.

3.BacklightThe602DisplayBacklightc

anbeturnedON,OFForsettoa10minutetimeddelay.

4.Contra

stThecontrastofthe602Displaycanbeadjustedfrom

116.

5.LanguageTheoperatorwillbeableto

choosethelanguagefortheMenuScreens.

3.Configuration

1.Force

Theoperatorcanselectwhichfo

rcetransducertodirecttothemainForceDisplay.

2.Positio

nTheoperatorcanselectwhich

positiontransducertodirecttoth

ePositionDisplay.

3.Auxilia

ryTheoperatorcanselectwhichmoduletodirecttotheAuxiliary

Display.

4.CPUThiswillbringuptheTitleScreen

withthe602Version.

4.Protected*

1.Interloc

kThiswillbringupaScreenon

aMechanicalMachinetooverridetheCrossheadLimitSwitches.

2.Lock/UnlockThiswilllockandunlockthe602MachineControl&ConfigurationMenus.

3.Bootloa

derThisisusedwhenflashing

aprogram

intothe602CPU.Pow

ermustberemovedtogetoffthisscreen.

4.DACTe

stThisscreenwillallowtheope

ratortoselectcertainDACoutputlevelsfortestingtheDACSignal.

5.Filter

ThiswilldisplaytheBandwidth&Deltasettingsforthethree602DisplayChannelsForce,Position

&Aux.

6.AdditionalSetstheHoldRate&SamplingRate.The602willre-bootafterexiting.

5.Refresh

Thiswillrefreshthe602display.Thisisonly

neededforolderhandsets

*-

Ag

eneralPasscode(602602)isneededtoentertheProtectedMenuS

elections.

TheStop

keyisusedas

an[Enter]keywhenonaMenuScreen.

7.1.1. Handset Menu


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7.2. Handset Functions

7.2.1. Zero Channel Keys

These function keys are used to zero the three display channels between tests while onthe LiveScreen.

Pressing the [Zero Force]key will zero the force reading on the first line. This shouldbe done beforeinserting the specimen in the grips or holders.

Pressing the [Zero Pos.]key will zero the position reading on the second line. Thisshould be zeroed when the crosshead is at the Start Test position. This zero positionis where the crosshead will go to when the [Return]key is pressed.

Pressing the [Zero Aux.]key will zero the reading on the auxiliary line. When using anextensometer, it should be zeroed afterclamping it on the specimen just prior to starting

a test.

Pressing one of these keys for any given channel causes the display value for thatchannel to be automatically zeroed. If the transducer is mechanically so far off zero thatit cannot be electrically zeroed, the display will not change. The transducer should thenbe checked and/or adjusted, and the "zero" key pressed again. Strain GaugeConditioner Modules will zero up to 20%, LVDT Conditioner Modules will zero up to50%, and Encoder Modules will zero any value. The zero keys WILL WORKduring atest but SHOULD NOT BE USEDunless intended.

7.2.2. Menu KeyPressing the [Menu]key will bring up the 602 Main Menu Screen. From this menu, theoperator can press a number key for one of the choices or press the [Menu]key to exitthe menu mode. Refer to the 602 Instructions provided after this booklet for the Menusand their functions

7.2.3. Drive Enable or

Pressing the [HI CL] or [LO CL] will ready the motor drive, once an instruction to movehas been given the drive will enable and remain enabled until the button is pressed asecond time. These are also the [4] & [7] keys when using the Menu Screens

7.2.4. Return Crosshead Key

Pressing the [Return]key will activate the return function of the 602 system. If thecrosshead is beyond the threshold value, the crosshead will attempt to return at theSpeed set on the Speeds Menu 1-1. As the crosshead is returning, the lower left handcorner of the 602 remote will show RETURN. As the crosshead approaches thethreshold value, the 602 will switch to a HOLDSegment as set up on the PositionControl Menu 1-2. The bottom status line will show the system in a HOLDMode whileat the home position. This key can be pressed at anytime; if a test is being conducted, itwill end the test. This is also the [8]key when using the Menu Screens


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7.2.5. Max Key

The [Max.]key will display the maximum value obtained for each display Channelduring the last test performed until the [Test/Clear]key is pressed for the next test.Pressing the [Test/Clear]key after a test will reset the current maximum values. If

higher values are obtained after the test has been ended by the operator pressing the[Stop]key or by the Sample Break Detector, they will not register as maximum values.The [Max.]key can pressed during a test but will continue to update while pressed.This is also the [9]key when using the Menu Screens.

7.2.6. Test / Clear Key

Pressing the [Test/Clear]key resets the stored maximum values from the last test,resets the Sample Break Detector (if enabled), resets any overload errors and placesthe display into a "READY" Mode for the next test as shown on the bottom status line.Do not press this key until the maximum values are recorded for the prior test, asit will clear those values

7.2.7. Upper Directional Key

Pressing the raise [] once will start to run the crosshead up at the Speed 1 setting onthe Speeds Menu 1-1. Pressing this same key again will advance the machine to theSpeed 2 setting on the Speeds Menu 1-1. This key will not do anything unless the driveis enabled and the 602 display is in the IDLE or HOLDMode

7.2.8. Lower Directional Key

Pressing the lower []once will start to run the crosshead down at the Speed 1 settingon the Speeds Menu 1-1. Pressing this same key again will advance the machine to theSpeed 2 setting on the Speeds Menu 1-1. This key will not do anything unless the driveis enabled and the 602 display is in the IDLE or HOLDMode.

7.2.9. Stop (Hold) Directional Key

On the Live Screen, the [Stop]key will stop the crosshead by immediately executing aPosition Hold (as shown on the bottom Status Line) on the current position. Dependingon the speed that the crosshead is running, the crosshead will stop and return a little tothe position value at the time the [Stop]key was pressed. This key will also end atest, if in the TEST Mode. In the Menu Mode, its the [Enter] key to accept an entry

7.2.10. Speed Increase Adjust Key

When running a speed (Speed1 or Speed2) pressing the [Speed]key once willcause the current speed setting to be incremented and momentarily show the change inthe setting. Pressing and holding this key will continue to increase the selected speed ingreater increments. After showing the setting change, the bottom line of the 602 displaywill return to the current rate display. This is also the [0]key when on one of the MenuScreens.


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7.2.11. Speed Decrease Adjust Key

When running a speed (Speed1 or Speed2) pressing the [Speed]key once willcause the current speed setting to be decremented and momentarily show the changein the setting. Pressing and holding this key will continue to decrease the selected

speed in greater increments. After showing the setting change, the bottom line of the602 display will return to the current rate display. This is also the decimal [.]key whenon one of the Menu Screens.

7.2.12. Non-Function Keys

These six keys have no function except when on a Menu Screen for entering thenumber on the key or the minus (-)sign for entering negative values.

7.3. Special Key Functions.

7.3.1. Force Calibration Check Number

Pressing the [Menu]key, the [Zero Force]key and the [Menu]key in sequence willactivate or deactivate the Cal-Check for that pressure transducer or load cell directed tothe Force Channel. The Cal-Check number will be shown on the first 602 channel andthe left side of the bottom status line will show Cal-Check. Repeat the key sequenceagain to deactivate the cal-check. The force display line must first be properly zeroedbefore reading the cal-check number. This only works with Strain Gauge ConditionerModules. This value is recorded at Calibration and noted on the Report and/or sticker.This value should not change by more than 1% for any given Load Cell. It is anindication that the system's electronics are operating properly but is not a substitution forverification of the system's accuracy to approved standards.

NOTE- The Cal Check number changes if the initial conditions change. The best way touse this function is to let the load cell warm up, remove any weight such as grips, zerothe Force, then activate the Cal-Check and record this number

7.4. Machine Protection

7.4.1. Zero Motion Detect

Should the machine detect no change in position when the crosshead should be movingafter a certain amount of time then the drive will be disabled and the error Pos will bedisplayed on the handset. This protects the machine should the encoder bedisconnected or faulty. Pressing [Test/Clear] will clear this condition.

7.4.2. Travel Limits

Damage to the load cell, tooling etc. caused by overtravel of the crosshead can beprevented by the operator properly setting the Adjustable Limit Switch Blocks located onthe long rod on the left hand side of the machine.

When one of the Position Limit Switches is activated, the 602 display will flash and theproper error message UprLmtor LwrLmtwill be shown in the lower left handcorner. This will also disable the motor drive.

To clear this alarm, the operator can manually move the adjustable block on the limitswitch rod if possible and then run the machine away from the limit switch collar. If thecollar cannot be moved anymore, there is an Interlock Override feature on the 602 that

will allow the operator to force the crosshead to move regardless of the Limit Switch.(See 7.4.5)


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CAUTION:

When using the Interlock Override be sure that the Crosshead is moved in theOPPOSITE direction AWAY from the activated Limit Switch Collar. DO NOT MOVE

the Crosshead in the same direction as it will go through the limit switch and willdamage the Limit Switch Arrangement. Overtravel may also damage the loadcelland tooling.Should this occur please contact Tinius Olsen for advice before continuing to usethe machine.

7.4.3. Loadcell Overload

The maximum force limit is 1.09 x FS capacity (N). The Positive and Negative Limitsmust be set for their respective limits. The user may enter smaller limits if desired.Should the loadcell be subjected to excessive load, the lower left hand corner of theremote will show Ovrld, the display will flash and the drive will be disabled.If the load can be removed or reduced then pressing the [Test/Clear] button will re-setthe display.If it not possible to remove the load, the crosshead can be backed off using the overridefeature. (See 7.4.5)

CAUTION:

When using the Interlock Override be sure that the Crosshead is moved in theOPPOSITE direction AWAY from the applied load. DO NOT MOVE the Crossheadin the same direction as damage will be caused to the loadcell

7.4.4. Position Limit

The position limit is set using the Menu [1] [3], this limit is normally set to +/-1199mm.Should the limit be exceeded, the lower left hand corner of the remote will show Pos,

the channel displays will flash and the drive will be disabled.The machine crosshead can be moved back into a valid position by simply re-zeroingthe position or using the override feature (See 7.4.5)

7.4.5. Operation of Interlock Override

To get to the Interlock Override press:-

The [Menu] key

The [4] key for the Protected Mode

Type the Passcode (602602)

The [1] key for Interlock Override

The following menu will display.

Once the crosshead has moved enough to clear the fault position press the [Menu]key

to exit back to the live screen. It may be necessary to press [Test/Clear] to clear out theold fault status.

Interlock Override

Use up and down arrowKeys to move crosshead.Press Menu key to exit.

Use Caution whenmoving Crosshead.


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7.5. Typical Settings

When set at the factory, the handset will typically display the following settings. Settingshighlighted should not be altered under normal circumstances and may be locked on thehandset (see Error! Reference source not found.[Menu # 4 2])

7.5.1. Speed [Menu # 1 1]

Speed 1 0.01 500 mm/min

Speed 2 0.01 500 mm/min

Return Speed 0.01 750mm/min *

Gain 1 0.5

Gain 2 0.5

Gain Return 0.25

(*) Max speed will depend upon supply voltage.

7.5.2. Position Control [Menu # 1 2]

Home 0 Threshold 2

Hold P Gain 0.25

Hold I Gain 0

7.5.3. Limits [Menu # 1 3]

+ Force +150000N *

- Force -150000N *

+ Position +1199.9mm

- Position -1199.9mm

+ DAC +99.98

- DAC -99.98

(*) Force limit will depend upon loadcell fitted.

7.5.4. Units [Menu # 2 1]

Force N

Position mm

Speed mm/min

7.5.5. Hold / Sample Rate [Menu# 4 1 6]

Hold Rate 1000

Sample Rate 100


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7.6. Replacing Loadcells

7.6.1. Fitting

To change Load Cells, the primary load cell must be removed and the new Load Cell

mounted (See 4.5.1) With each load cell there must a cable with a Strain GaugeConditioner Module. Mount the module onto the crosshead and plug the 8-pin RJ45jack into the receptacle on the side. The 602 will read in the new module and theConfiguration Screen for that module will be shown and then return to the live screen.DO NOT PLUG ANY NEW MODULES DURING A TEST BECAUSE THE 602 WILLSTOP THE DRIVE DURING THE READ IN PROCESS.

7.6.2. Selecting Device

Once the read in process is done, the operator must direct the new Load cell to theForce Display (top line) by pressing [Menu], the [3] key on the Main Menu forConfiguration, the [1] key on the Select Channel Menu for Force, and then [1] on theXducer Menu for Select Transducer. The 602 will show a list of any connected ForceModules by description. Press the number for the description of the new Load cell to be

used. If the desired cell is not listed, check that it is connected correctly. The 602 willexit back to the live screen. Press the [Zero Force] key to zero the load cell, thenmanually push up on the base of the loadcell and check that the Force Display showsan appropriate response. If optional software is being used, this can be done by thesoftware settings and the operator doesnt have to use the 602 menus.

NOTE- Only modules that are intended to be used should be plugged in to the RJ45connectors. That is because any device with the RJ45 connectors plugged in isconsidered active by the 602. Too many connected devices reduces the bandwidth ofthe system, particularly at higher sample rates. It is recommended that the total numberof connected devices be limited to 3 or 4

7.6.3. Setting Force Limits

Note that for the Force Limits to apply, the load cell must be directed to the first (Force)line on the 602. When a lower capacity load is read into the 602, the Force LimitSettings will be rewritten 1.09 x FS capacity (N), but when adding a higher capacity loadcell the operator MUST enter the higher limits manually or have them entered in thesoftware settings and let it load them in.


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8. ToolingTinius Olsen manufacture a wide range of sample tooling, please contact Tinius Olsen or localauthorised distributors to discuss your requirements.

8.1. Attaching to the Machine

8.1.1. A large proportion of tooling uses the same method of attachment to secure the toolingto the machine / load cell.

In general this comprises:-Nose PieceLocking Collar (X 2)Grip pin

The diagram below indicates attachment parts.

8.1.2. Nose pieces have a threaded section to screw into the loadcell / machine and a parallelsection to fit inside the tooling. The parallel section includes a hole for a grip pin to beinserted to attaching to the tooling.

The size of the nose piece is determined by the maximum load to be applied as follows:-

Load (kN) Nose Piece Dia Grip Pin Dia

0 - 20 5/8 inch (15.875mm) 5/16 inch (7.9375mm)20 50 3/4 inch (19.05mm) 3/8 inch (9.525mm)50 100 30mm 1/2 inch (12.7mm)100 40mm 16mm

150 50mm 20mm200 - 300 60mm 24mm

The attachment fixing threads range from M6 to M42, depending on the capacity of loadcell used. The tooling attachment for the fixed crosshead is M36 and standard loadcellis M33, an adaptor is available to reduce this if required.

8.1.3. Before attempting to install the tooling attachments check the following :-

a) Size of fixing thread in load cellb) Size of female noise piece used on toolingc) Size of grip pin

8.1.4. To install the tooling attachment to the load cell, first ensure both locking collars arecentralised on the tooling attachment. Align the fixing thread to the load cell and rotatein a clockwise direction to engage. Once engaged rotate a further 6 to 8 times. This isto ensure the correct amount of thread has been inserted. Ensure the toolingattachment hole is facing forward. Now rotate the fixing locking collar clockwise until itmakes contact with load cell. Do not tighten the attachment locking collar at this stage.Repeat the above procedure for the fixed crosshead, this will require a M33 fixing threadtooling attachment.

The diagrams below indicate tooling attachments for load cell and fixed crosshead.


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8.1.5. Installing Tooling

Depending on the type of tooling to be installed, this procedure may require additionalhelp (tooling may be heavy). Ensure the distance between the load cell and the fixedcrosshead is sufficient for installation of tooling, the distance may require to beincreased using the direction control keys.

8.1.6. Align tooling female nose piece with load cell attachment male nose piece, slide the two

together until daylight can be seen through both grip pin hole in tooling and attachment.Insert the grip pin from the front, make small adjustments to the tooling position toenable the grip pin to slide in freely. Repeat the above procedure for the fixedcrosshead tooling.

The diagram below indicates the HW20 Wedge Grip fitted to the load cell.

NOTE- The HW20 Wedge Grip is shown as an example, the same principals apply toall tooling using this type of attachment.

8.1.7. Tooling Alignment

Tooling alignment is extremely important to obtain realistic measurements.Misalignment distorts the test sample leading to irregular loading and in extreme casesgenerates large errors in extension measurement. Alignment problems can be greatlyreduced by the method used to tighten the attachment and tooling locking collars.


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8.1.8. Ensure the fixed crosshead tooling is parallel to the crosshead. Whilst held in thisposition lightly tighten both attachment and tooling locking collars. Repeat thisprocedure for the tooling attached to the load cell. Check alignment in all three axis. Ifalignment is out , loosen the tooling locking collars, reposition tooling and retightencollars. Repeat this procedure until the tooling is aligned. Fully tighten the fixedcrosshead locking collars with the breaker bar supplied. Care must be taken whentightening locking collars attached to a load cell as lower capacity load cells can bedamaged from excess torque. To minimise risk of damage ensure the sensitive area ofthe load cell is supported when tightening these locking collars. The same care must betaken when removing tooling from the load cells.

8.1.9. As a general rule load cell capacities from 25 to 100N only require locking collars fingertight. Load cells from 200N to 2kN should be lightly tightened with breaker bar. Loadcells from 5kN to 10kN can be fully tightened with breaker bar, and above 10kN thebreaker bar limits torque that can be applied. Note Load cells below 25N can bedamaged by handling alone. When installing low capacity load cells, extreme care mustbe taken.


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9. Conducting a test

9.1. Basic Operation

These are some typical precautions to be observed when operating a Tinius Olsen H150KUTesting Machine. The Load Cell Weighing System of the H150KU is considered a very "HARD"

type of weighing system. The force-measuring element (Load Cell) will only deflectapproximately 0.1mm at the full rated capacity. This "HARD" weighing system permitsextremely sensitive and accurate load indication. The following information is included tocaution the operator as to unintentional misuse and resulting damage to the load cell.

9.1.1. Overloads

The Load Indicating System of this test machine is provided with protective OverloadLimit Switch Circuitry that removes power from the drive motor whenever the loadexceeds full scale. The purpose of this feature is to prevent damage that can be causedby exceeding the capacity of the weighing system or the tooling being used for the test.However, the overload protection is only effective when the machine is being operatedwithin the response capabilities of the load indicator. Obviously, the overload protectioncannot prevent overloading and the resulting damage if a rigid specimen is impacted at

a high rate of speed.

9.1.2. Clearance

Care must be taken whenever running the crosshead up or down, that the Load Cell andany attached tooling or specimens do not contact any part of the machine or any tooling,specimens, etc

9.1.3. Mounting of Specimens

Care must be taken to insure that the specimen is always cantered in the grips, etc.,when testing in tension or centred between the compression platens when testing incompression. Off centre loading can result in an erroneous load reading and possibledamage to the load cell or tooling.

9.1.4. Use of Low Capacity Loadcells

The load cells are designed for some overloading, but if the load exceeds 150% of therated capacity this can result in zero shift, span changes and possible damage orbreakage. EXTREME CAREshould be taken when using low capacity load cells thatthey are not dropped or overloaded when mounting tooling. Overloading a load cell willusually result in the inability to zero the load cell or an offscale reading. As load celldamage can be difficult to see visually and where load cells may be damaged, theextent and responsibility is to be determined solely by the manufacturer.

9.2. Testing Using The Handset

The following assumes that the machine is set up, all grips are fitted and all handset settings

have been made. See this manual for further details.

CAUTION:

DURING A TEST, ALWAYS CHECK THE CLEARANCES IN THE AREA AROUNDTHE CROSSHEAD. IF INSUFFICIENT, STOP THE TEST BEFORE THE TRAVEL OFTHE CROSSHEAD CAN CAUSE DAMAGE.

9.2.1. Preparing the Machine

With the proper grips or holders installed, run the crosshead to the desired startingposition and press the [Zero Pos]key to zero the Position Channel at this position.The Force Channel can also be zeroed now by pressing the [Zero Force]key.


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9.2.2. Mount Specimen

Secure the specimen properly in the grips or holders. When securing a specimen theremight be some amount of preload applied to the specimen. The operator can start thetest with a small preload on the specimen, or they can run the crosshead slowly in theproper direction until zero force is displayed. DO NOT USE THE FORCE CHANNELZERO TO ELIMINATE PRELOAD ON A SPECIMEN.

9.2.3. Mount Aux Instruments (if applicable)

If Strain data is to be recorded, mount the Strain Instrument following the instructionsprovided for the instrument, the Strain System and/or Computer being used.

Mount the module into the rack at the rear of the machine and plug the adjacent8-pin RJ45 jack. The 602 will read in the new module and the ConfigurationScreen for that module will be shown and then return to the live screen. DONOT PLUG ANY NEW MODULES DURING A TEST BECAUSE THE 602WILL STOP THE DRIVE DURING THE READ IN PROCESS

Once the read in process is done, the operator must direct the new instrumentto the Aux Display (third line) by pressing [Menu], the [3] key on the Main Menu

for Configuration, the [3] key on the Select Channel Menu for Aux, and then[1] on the Xducer Menu for Select Transducer. The 602 will show a list of anyconnected Aux Modules by description. Press the number for the descriptionof the new instrument to be used. If the desired cell is not listed, check that it isconnected correctly. The 602 will exit back to the live screen.

NOTE- Only modules that are intended to be used should be plugged in to theRJ45 connectors. That is because any device with the RJ45 connectorsplugged in is considered active by the 602. Too many connected devicesreduces the bandwidth of the system, particularly at higher sample rates. It isrecommended that the total number of connected devices be limited to 3 or 4

9.2.4. Install Protective Devices (if applicable)

If necessary, install protective devices around the test specimen or test machine toprevent injury to the operator or personnel in the area. (See 10.2)

9.2.5. Set Speeds

The machine uses the programmable Speeds on the Speeds Menu # 1-1 or optionalSoftware to set the speed(s) of the test. Set a crosshead speed or rate that meets theapplicable test specification; in some cases, it may be necessary to calculate the loadingspeed from known or given data. In the absence of a testing specification, a good ruleto follow is to select a loading speed (rate) slow enough that the force display can beaccurately read at any time.NOTE- typically Speed 1 is set for a slow speed (e.g. pre-yield speed) and Speed 2 isset for a faster speed (e.g. post-yield speed or jog speed).

9.2.6. Start Test Ensure that the drive is enabled by pressing [Hi]or [Low]

Press [STOP]to keep the 602 in Hold mode

Before starting the test, the [Test/Clear]key must be pressed, placing the 602into a "READY" Mode. If the 602 remote is not in the READYMode beforestarting a test, the Peak Hold and Maximum Values will not be retained, and theSample Break Detector is not active.

Press either the lower directional key (compression test) or upper directional key(tension test) once to start running a test at the programmed Speed #1 and the602 display should show TEST in the bottom left corner of the display. Ifneeded, press the directional key a second time to go to Speed #2. Theoperator can see the actual crosshead rate in the bottom right corner of the 602

display.


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9.2.7. End Test

The test can be ended and the crosshead returned to its start test position automaticallyby the Sample Break Detector if there is a detectable drop-off in force. If there is nodrop-off or failure during a test, the operator must end the test manually using the[Stop]key. The 602 display will then go to HOLDMode and hold that crossheadposition. When you are ready to return the crosshead to its starting position press the

[Return]key. For tensile testing, the Sample Break Detector is normally set to triggerat a large amount of "drop off in load" such as 75% to ensure that the specimen hasbroken completely.

NOTE- A small Start Load % of Full Scale (typically 1-10 % FS) is required to preventfalse triggering of the Sample Break Detect

9.2.8. Record Results

Record the test data required the Peak Force will be shown on the right side of thesecond to last line on the 602 or the maximum values for three Display Channels can berecalled by pressing the [Max.]key. Remove the tested specimen, then press the[Test/Clear]key on the 602 remote to clear the maximum values being held, reset the

602 Display and Sample Break Detector, if enabled, for the next test.

NOTE- Do not press the [Test/Clear]key until the results from the prior test arerecorded, because once the [Test/Clear]key is pressed the prior results are cleared.

9.2.9. Next Test

The machine should always be left in its Start Test(Home) Position until the next test isready to be started. If the 602 display in the READYmode simply press thedirectionalkey to start the next test. The user must press [Test/Clear]to clear the oldresults and re-arm the 602 for the next Test

9.3. Testing Using Optional Software

For machines provided with optional Tinius Olsen Test Software, the computer will send all theneeded information to the 602 Display to run the test remotely. In addition, all the controls onthe 602 are available on the Top Tool Bar in the Software. Setup the test the same asdescribed in section 9.2, but start the test in the software instead using the directional key.Once the test has started, the program monitors the test and advances the segments accordingto the program and the Machine Control Settings being used for that test. After the test is over,and the results are saved, etc., the program will prompt the operator to choose whether to havethe 602 automatically return the crosshead or to return it manually by using the [Return]key.

WARNING- the user must take care if using the handheld in conjunction with the computerbecause of possibility of conflict. When using a computer, it is best to configure the system andrun the machine entirely from the computer to avoid potential conflicts


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10. Safety

10.1. Warnings

Under NO circumstances must the machine/tooling be used if damaged.

Under NO circumstances should the machine/tooling be modified without consent

from Tinius Olsen. When left unattended always disable the drive by pressing the E-Stop or taking it

out of Hi/Low clutch mode. Do not rely on the simply pressing [STOP] as thedrive is still active

Installation of the machine must be carried out as described in section 4 of thismanual.

Only trained operators should use the machine. (Including operation of software)

Operator must wear appropriate clothing. (No loose clothing)

Eye protection must be worn at all times when operating the machine.

Operator must not place any part of their body within the test area when themachine is moving.

Mains Supply isolator must not be obstructed and be within easy reach.

Machine Emergency Stop switch must not be obstructed.

The machine should never be left unattended in a loaded condition. Service/Repair of the machine must be carried out by trained personal


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10.2. Protective Screens

10.2.1. Standard machines are not supplied with protective screens. Depending on the type ofmaterial being tested a protective screen may be required. Please contact Tinius Olsenif you require screens for your application.

10.2.2. Prior to conducting any testing, the operator must assess the type of sample failurelikely to occur. This assessment will enable the correct protective screen to be selected.

As a general rule, if there is any possibility of fragments being ejected from the machinewhen a sample fails then a protective screen should be fitted.Where high loads and large extensions are required to break a sample failure oftenbecomes more violent, in this case interlocked screens should be fitted.

In case of doubt or for more advice on protective screens please contact Tinius Olsenor your local authorised distributor to discuss your requirements.

Illustration shows a fully enclosed guarding solution.


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11. TrainingTinius Olsen or local authorised distributors with qualified factory trained engineers can giveoperator training at the time of machine installation. Training covers both machine hardwareand computer software. Training can be further extended to give a more in-depth knowledge ofsystem on request.

Contact Tinius Olsen or local authorised distributors to discuss your requirements.

For details of your nearest distributor, please check our website at www.tiniusolsen.com.

Tinius Olsen Ltd6 Perrywood Business ParkHoneycrock LaneSalfordsRedhillSurreyRH1 5DZEngland


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12. MaintenanceThe mechanics within the machine are designed for a minimum amount of maintenance.Typically the replacement and re-adjustment of the drive belts should be performed by qualifiedservice personnel and should not be attempted by the customer unless instructed on how to dothe required service.

12.1. Electrical

12.1.1. Supply

The H150KU machine operates from a 3ph phase 415V +/- 10% 50/60 Hz 15AmpContinuous, 30A peak.

12.1.2. Electronics

All the electronics in the machine are solid state and do not require any maintenance.

12.1.3. Circuit Breakers

To protect the machine two circuit breakers have been incorporated at the rear of the

machine. In the event of either circuit breaker repeatedly tripping please contact TiniusOlsen or one of our authorised distributors.

12.2. Calibration

12.2.1. The internal force and extension range calibration adjustments on this machine are setto factory specifications and should not be changed in the field. Each load cell has itsown calibrated conditioner module. All the load cells supplied will already be calibratedand a calibration certificate provided.

12.2.2. It is also recommended that routine calibration of the load cell(s) in Tension and/orCompression be performed by qualified personnel since improper use or adjustment ofthe load cell could result in calibration errors or possibly damage to the machine.

12.2.3. Re-calibration of the machine and auxiliary equipment should be performed regularly atyearly intervals or as required. Tinius Olsen maintains a Calibration and ServiceDepartment within the UK or through local authorised distributors with qualified factorytrained technicians.

For details of your nearest distributor, please check our website at www.tiniusolsen.com.

12.3. Lubrication

12.3.1. Bearings

Bearings are pre-packed with grease on assembly and should not require additionallubrication.

12.3.2. Guide columns

The columns (adjacent to the ballscrews) use DU dry self lubricating bearings. Ifrequired the shaft can be lubricated using most lubricating oils that do not chemicallyattack the PTFE/Lead overlay or the porous bronze interlayer.

12.3.3. Ballscrews

The ballscrew nuts require a lithium soap based grease Number 2. They will requireapproximately 2cc of grease per 12,000-15,000m of travel.


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13. StorageLong Term StorageIf the machine is not to be used for some time ensure that it is unloaded and the mains power isdisconnected. To help to keep the machine clean cover with a protective cover. If the machineis to be stored outside its normal working environment repack into its original packing case assupplied. The storage environment should be clean and dry and out of direct sun light with an

ambient temperature range of -10C to 45C. Under certain conditions condensation can formwithin the packing and cause parts within the machine to rust. To reduce this problem place atleast one desiccator within the packing case.


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14. Appendix

14.1. Dimensions

u-series instruction manual 820-7001_15issue_03

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