Instron 3400 Series Operator's Manual

This document and the information that it contains are the property of Illinois Tool Works Inc. (ITW). Rights to duplicate or otherwise copy this document and rights to disclose the document and the information that it contains to others and the right to use the information contained therein may be acquired only by written permission signed by a duly authorized officer of ITW. Trademarks Instron® is a registered trademark of Illinois Tool Works Inc. (ITW). Other names, logos, icons and marks identifying Instron products and services referenced herein are trademarks of ITW and may not be used without the prior written permission of ITW. Other product and company names listed are trademarks or trade names of their respective companies. Original Instructions Copyright © 2019 Illinois Tool Works Inc. All rights reserved. All of the specifications shown in this document are subject to change without notice. Worldwide Headquarters Instron 825 University Avenue Norwood, MA 02062-2643 United States of America European Headquarters Instron Coronation Road High Wycombe, Bucks HP12 3SY United Kingdom

General Safety Precautions Materials testing systems are potentially hazardous. Materials testing involves inherent hazards from high forces, rapid motions, and stored energy. You must be aware of all moving and operating components in the testing system that are potentially hazardous, particularly force actuators or a moving crosshead. Carefully read all relevant manuals and observe all Warnings and Cautions. The term Warning is used where a hazard may lead to injury or death. The term Caution is used where a hazard may lead to damage to equipment or to loss of data. Instron products, to the best of its knowledge, comply with various national and international safety standards, in as much as they apply to materials and structural testing. We certify that our products comply with all relevant EU directives (CE mark). Because of the wide range of applications with which our instruments are used, and over which we have no control, additional protection devices and operating procedures may be necessary due to specific accident prevention regulations, safety regulations, further EEA directives or locally valid regulations. The extent of our delivery regarding protective devices is defined in your initial sales quotation. We are thus free of liability in this respect. At your request, we will gladly provide advice and quotations for additional safety devices such as protective shielding, warning signs or methods of restricting access to the equipment. The following pages detail various general warnings that you must heed at all times while using materials testing equipment. You will find more specific Warnings and Cautions in the text whenever a potential hazard exists. Your best safety precautions are to gain a thorough understanding of the equipment by reading your instruction manuals and to always use good judgement. It is our strong recommendation that you should carry out your own product safety risk assessment.

unsafe condition exists. The Emergency Stop button removes hydraulic power or electrical drive from the testing system and brings the hazardous elements of the system to a stop as quickly as possible. It does not isolate the system from electrical power, other means are provided to disconnect the electrical supply. Whenever you consider that safety may be compromised, stop the test using the Emergency Stop button. Investigate and resolve the situation that caused the use of the Emergency Stop button before you reset it. Flying Debris Hazard - Make sure that test specimens are installed correctly in grips or fixtures in order to eliminate stresses that can cause breakage of grip jaws or fixture components. Incorrect installation of test specimens creates stresses in grip jaws or fixture components that can result in breakage of these components. The high energies involved can cause the broken parts to be projected forcefully some distance from the test area. Install specimens in the center of the grip jaws in line with the load path. Insert specimens into the jaws by at least the amount recommended in your grip documentation. This amount can vary between 66% to 100% insertion depth; refer to supplied instructions for your specific grips. Use any centering and alignment devices provided. Hazard - Protect electrical cables from damage and inadvertent disconnection. The loss of controlling and feedback signals that can result from a disconnected or damaged cable causes an open loop condition that may drive the actuator or crosshead rapidly to its extremes of motion. Protect all electrical cables, particularly transducer cables, from damage. Never route cables across the floor without protection, nor suspend cables overhead under excessive strain. Use padding to avoid chafing where cables are routed around corners or through wall openings.

High/Low Temperature Hazard - Wear protective clothing when handling equipment at extremes of temperature. Materials testing is often carried out at non-ambient temperatures using ovens, furnaces or cryogenic chambers. Extreme temperature means an operating temperature exceeding 60 °C (140 °F) or below 0 °C (32 °F). You must use protective clothing, such as gloves, when handling equipment at these temperatures. Display a warning notice concerning low or high temperature operation whenever temperature control equipment is in use. You should note that the hazard from extreme temperature can extend beyond the immediate area of the test. Crush Hazard - Take care when installing or removing a specimen, assembly, structure, or load string component. Installation or removal of a specimen, assembly, structure, or load string component involves working inside the hazard area between the grips or fixtures. When working in this area, ensure that other personnel cannot operate any of the system controls. Keep clear of the jaws of a grip or fixture at all times. Keep clear of the hazard area between the grips or fixtures during actuator or crosshead movement. Ensure that all actuator or crosshead movements necessary for installation or removal are slow and, where possible, at a low force setting. Hazard - Do not place a testing system off-line from computer control without first ensuring that no actuator or crosshead movement will occur upon transfer to manual control. The actuator or crosshead will immediately respond to manual control settings when the system is placed off-line from computer control. Before transferring to manual control, make sure that the control settings are such that unexpected actuator or crosshead movement cannot occur. Robotic Motion Hazard - Keep clear of the operating envelope of a robotic device unless the device is de-activated. The robot in an automated testing system presents a hazard because its movements are hard to predict. The robot can go instantly from a waiting state to high speed operation in several axes of motion. During system operation, keep away from the operating envelope of the robot. De-activate the robot before entering the envelope for any purpose, such as reloading the specimen magazine. Warnings

waveforms or tests. Operational limits are included within your testing system to suspend motion or shut off the system when upper and/or lower bounds of actuator or crosshead travel, or force or strain, are reached during testing. Correct setting of operational limits by the operator, prior to testing, will reduce the risk of damage to test article and system and associated hazard to the operator. Electrical Hazard - Disconnect the electrical power supply before removing the covers to electrical equipment. Disconnect equipment from the electrical power supply before removing any electrical safety covers or replacing fuses. Do not reconnect the power source while the covers are removed. Refit covers as soon as possible. Rotating Machinery Hazard - Disconnect power supplies before removing the covers to rotating machinery. Disconnect equipment from all power supplies before removing any cover which gives access to rotating machinery. Do not reconnect any power supply while the covers are removed unless you are specifically instructed to do so in the manual. If the equipment needs to be operated to perform maintenance tasks with the covers removed, ensure that all loose clothing, long hair, etc. is tied back. Refit covers as soon as possible. Hazard - Shut down the hydraulic power supply and discharge hydraulic pressure before disconnection of any hydraulic fluid coupling. Do not disconnect any hydraulic coupling without first shutting down the hydraulic power supply and discharging stored pressure to zero. Tie down or otherwise secure all pressurized hoses to prevent movement during system operation and to prevent the hose from whipping about in the event of a rupture. Hazard - Shut off the supply of compressed gas and discharge residual gas pressure before you disconnect any compressed gas coupling. Do not release gas connections without first disconnecting the gas supply and discharging any residual pressure to zero. Warnings

Explosion Hazard - Wear eye protection and use protective shields or screens whenever any possibility exists of a hazard from the failure of a specimen, assembly or structure under test. Wear eye protection and use protective shields or screens whenever a risk of injury to operators and observers exists from the failure of a test specimen, assembly or structure, particularly where explosive disintegration may occur. Due to the wide range of specimen materials, assemblies or structures that may be tested, any hazard resulting from the failure of a test specimen, assembly or structure is entirely the responsibility of the owner and the user of the equipment. Hazard - Ensure components of the load string are correctly pre-loaded to minimize the risk of fatigue failure. Dynamic systems, especially where load reversals through zero are occurring, are at risk of fatigue cracks developing if components of the load string are not correctly pre-loaded to one another. Apply the specified torque to all load string fasteners and the correct setting to wedge washers or spiral washers. Visually inspect highly stressed components such as grips and threaded adapters prior to every fatigue test for signs of wear or fatigue damage. Warnings

Table of Contents Chapter 1: Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 System Description and Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Principle of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Hardware Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 System Safety and Information Labeling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Conformity with EU directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Product Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Product Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Location of your Preinstallation manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Chapter 2: Risk reduction and safe use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Rapid crosshead motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Pinching fingers between grip jaw faces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Impact of debris from breaking specimens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Operator Protection Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Chapter 3: Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Level the load frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Power supply compatibility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Set the input voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 System components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Dual column table model load frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Connect the system components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Bluehill® Operator Dashboard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 First time startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Power input connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Emergency Stop button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Frame Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Bluehill® software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Home Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Operator Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Move between modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Jog at High Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Operator Protection Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Bluehill® Operator Dashboard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Basic touch functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Touchscreen gestures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Pneumatic Grips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 How Operator Protection works with grips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Operate grips using footswitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Operate grips using toggle switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Grips not in use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Chapter 5: Assemble the load string . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Select a load cell. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Before you begin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Install the load cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Install a 2530 load cell (capacities 5 N through 5 kN) . . . . . . . . . . . . . . . . . . . . . . . . 76 Install a 2530-10kN load cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Install a 2530 load cell (capacities 30kN and 50kN) . . . . . . . . . . . . . . . . . . . . . . . . . 80 Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Base adapters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Coupling adapters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Select Grips and Fixtures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Insert Jaw Faces into Grips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Install grips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Preload the load string. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Unload the load string . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Chapter 6: Testing specimens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Testing a sample. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Testing with no interlock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Testing with an interlock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Create a new sample . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Calibrate a transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Automatic calibration of a force or strain transducer. . . . . . . . . . . . . . . . . . . . . . . . . . 99 Manual calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Set the zero displacement point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Crosshead limit stops. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Set the crosshead limit stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Move Off a Crosshead Limit Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Set the limits for a transducer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Balance a transducer configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Stop a test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Emergency Stop Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Crosshead Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Software Event . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Shut down the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Turn the system off. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 A Software Transducer Limit Trips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 A Crosshead Travel Limit Trips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 You press the Emergency Stop button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Chapter 7: Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Preventive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Daily Maintenance Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Periodic Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

114 General Maintenance Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Test Limit Stops. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Replace a Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Troubleshooting for Load Cells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Ancillary parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Chapter 1 Introduction • System Description and Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 • System Safety and Information Labeling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 • Conformity with EU directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 • Product Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 • Product Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 These instructions are intended to get you started working with your testing system. They assume the following: • you are an operator familiar with the operation of materials testing systems in general • your system consists of a load frame with integral controller, a load cell, a set of manually-operated grips and Bluehill® test control software • the system has been installed by an Instron® service engineer • Bluehill® test methods that are appropriate for your testing requirements are available These instructions include the following information: • installing and connecting all the system components together (carried out by an Instron® service engineer for first-time installation) • configuring the system before you start testing (carried out by an Instron® service engineer for first-time installation) • routine maintenance of the system • spare parts Using these instructions you will be able to: • check the interconnections between all elements of the basic system • install the grips and preload the load string • prepare a set of specimens (sample) for testing

• view the test results and print a test report. • perform routine maintenance of the system These instructions do not include the development of Bluehill® test methods. This is covered in more advanced training that can be provided by the Instron® Service and Training departments.

Product Support: www.instron.com System Description and Terminology Figure 1. 3400 Dual Column Table Model with Bluehill® Operator Dashboard - Front View 5 9 2 8 3 6 4 7 1 10

Label Component 1 T-slots 2 Top plate 3 Column cover 4 Load cell 5 Upper limit switch 6 Limit switch actuator 7 Lower limit switch 8 Emergency stop button 9 Frame control panel 10 Bluehill® Operator Dashboard (optional)

Product Support: www.instron.com Figure 2. 3400 Dual Column Table Model - Rear View 5 9 2 8 3 6 4 7 1

Components The major components of an Instron® electromechanical testing system include: • Load frame with integral controller • Load cell mounted to the crosshead • Grips for tension testing or table-mounted anvils on a platen for compression testing. • Instron® approved computer system with Instron Bluehill® software. Special fixtures are available for applications such as flexure and peel testing. For strain measurement, an optional strain gauge extensometer attaches to the specimen. You can use non-contacting extensometers with specimens that are unable to support a contacting extensometer. Contact your regional Instron® office or check our web site at www.instron.com for assistance with Instron’s grips and fixtures. The following table defines the components of the testing system: Label Component 1 Power inlet connection and power switch 2 System ID label 3 Rear panel 4 Controller panel 5 Frame base 6 Base beam 7 Base adapter 8 Crosshead 9 Ballscrew cover

Product Support: www.instron.com Principle of Operation The system communicates primarily through the controller. The controller contains sensor conditioning cards for the system transducers and transfers data between the transducers and the computer. The controller also communicates with the load frame via a Safety Monitoring Board (SMB) via a Break Out Board (BOB) inside the load frame. The Break Out Board links all the electrical components of the frame together. Hardware Controls The hardware controls consist of: • Emergency stop button - to be used whenever you need to stop the crosshead immediately because an unsafe condition exists. Table 1. Testing System Components Component Description Load Frame The load frame comprises a base, one or two columns, a moving crosshead, and a top plate. It is a high stiffness support structure against which the test forces react. Each column comprises a guide column and a ballscrew. The crosshead is mounted on both the guide column and the ballscrew. Rotation of the ballscrew drives the crosshead up or down while the guide column provides stability. Controller The hardware that controls the frame and any ancillary equipment connected to the testing system. The controller panel contains all the connectors for load cells, extensometers and any other sensors that are required for testing. Frame Control Panel This panel holds all of the controls and indicators for the testing system. Load String Comprises all of the components that you install between the moving crosshead and the load frame base (or fixed crosshead). Typically this involves a load cell, a set of grips, any adapters that are required to connect the components, and the specimen to be tested. Typically, you mount a load cell on the crosshead, then a pair of grips or fixtures on the load cell and frame base. The grips or fixtures secure the specimen and when you start a test the crosshead moves up or down applying a tensile or compressive load to the specimen. The load cell converts this load into an electrical signal that the software measures and displays. Bluehill® Software Instron® testing software that controls the testing system, running tests and analyzing test data to produce test results. Specimen A single piece of material to be tested.

load string components against unexpected crosshead movement. • Frame control panel - holds all the controls and indicators for the testing system. Software Control of the testing system is carried out via Instron Bluehill® software. Setting test parameters, operating the system, and collecting test data is done through the software program. System Safety and Information Labeling Table 3 on page 20 explains the meanings of any safety and information labels that may be attached to any part of the testing system. Table 2. Software Terminology Term Description Test Method In Bluehill® software, a test method is a file that contains a set of defined parameters that the system uses to run tests, analyze the test data, and produce calculated results. Sample A group of material specimens, whose properties are studied and compared to gain statistical or quality assurance information. For example, you could take a specimen from different parts of a single manufacturing run of a material to form a sample of the material. The sample is then representative of the complete run and you can test it to ensure that the material quality has remained stable over the complete run. You perform the same test on each specimen in a sample. Table 3. Safety and Information Labeling Descriptions Label Meaning Purpose Electrical hazard Indicates that an electrical hazard exists from high voltage and/or electrical current.

Product Support: www.instron.com Disconnect power supply Disconnect the power supply before servicing machine. Electrical - fuse warning Indicates an electrical hazard exists. Advises disconnecting power mains before changing fuses and using only specified fuses. Belt entanglement hazard Indicates that a hazard exists from the drive belt and pulley system. High temperature hazard Indicates that a heat hazard exists. Stay clear of area when operating the machine. Rotating machinery hazard Indicates that a rotating hazard exists. Keep clear of these areas (and tie back long hair and loose clothing). Ground stud Indicates a ground stud. Read the manual Read and understand the operator’s manual before using the machine. Crosshead direction Indicates the direction to turn the pulley to manually move the crosshead upward. Pulleys can be turned by hand when power is disabled. Table 3. Safety and Information Labeling Descriptions (Continued) Label Meaning Purpose

Instron® declares under our sole responsibility that 34SC and 34TM testing systems are in conformity with all relevant provisions of the following regulations: • Machinery Directive 2006/42/EC • EMC Directive 2014/30/EU • ROHS Directive 2011/65/EU including substances added by amendment 2015/ 863/EU Instron® testing systems are CE marked. A signed CE declaration of conformity is supplied with each system. Crush hazard Indicates the crush hazard of the moving crosshead and instructs the user to read and understand the operator’s manual before using the machine. Waste Electrical and Electronic Equipment (WEEE) In accordance with the European Union’s WEEE directive, the crossed out wheeled bin symbol indicates that the equipment must be disposed of separately from other waste at the end of its usable life. For advice on the disposal of electrical and electronic equipment in your country, contact your local Instron representative. Table 3. Safety and Information Labeling Descriptions (Continued) Label Meaning Purpose Crush hazard. Keep clear of test area when machine is in motion. Read and understand operator's manual before using this machine. ! WARNING

Product Support Instron® provides documentation, including manuals and online help, that can answer many of the questions you may have. It is recommended that you review the documentation sent with the system you purchased for possible solutions to your questions. If you cannot find answers in these sources, contact Instron® Service directly. A list of Instron® offices is available on our website at www.instron.com. In the US and Canada, you can call directly at 1-800-473-7838. Product Documentation Instron® offers a comprehensive range of documentation to help you get the most out of your Instron products. Depending on what you have purchased, your documentation may include some or all of the following: We welcome your feedback on any aspect of the product documentation. Please email [email protected] with your comments. Location of your Preinstallation manual A copy of the Preinstallation manual for your model was sent upon receipt of your order to assist you to prepare for the arrival of your shipment. Operator’s Guide How to use your system components and controls, procedures for setting limits, calibration and other frequently performed operating tasks. Information about system installation, set up and configuration, transducer connection and calibration. Routine maintenance and spare parts. Preinstallation Manual System requirements and specifications, instructions for lifting and handling to transport the system to its final location before installation. Reference Help Software products come complete with context sensitive help, which provides detailed information on how to use all software features. Equipment Reference How to set up and use any accessories you have purchased, for example grips, fixtures, extensometers, transducers, and environmental chambers.

system. This drive contains your Bluehill® software. The Preinstallation manuals are stored in a directory named: Frame Manuals The following table lists the manuals for dual column table model load frames: The manual numbers listed are in English (EN). To find a different language, match the two letter extension on this Operator’s Guide to the equivalent language Preinstallation manual, e.g. M10-xxxxx-FR for French. Model number Manual number 34TM-5 (5 kN) M10-17319-EN 34TM-10 (10 kN) M10-17320-EN 34TM-30 (30 kN) M10-17321-EN 34TM-50 (50 kN) M10-17322-EN

Chapter 2 Risk reduction and safe use • Residual risks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 • Operator Protection Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Residual risks The equipment described in this documentation is designed with features to reduce the risk of injury to an operator. There are, however, always residual risks in the use of this equipment, influenced by: • the test application • the design of the test method or procedure • the jog, return and test speeds used • the type of specimen being tested • the size of the specimen being tested • the design of grips and test fixtures • the experience of the operator using the equipment It is our strong recommendation, therefore, that you carry out your own risk assessment for your particular equipment setup and testing application. Each of the following sections describes a specific hazard zone of the testing system and lists the most common risks for testing using this equipment. Use the information in the following sections, together with the instructions in the remainder of this manual, to conduct your own risk assessment.

26 M10-17318-EN Rapid crosshead motion Warning Crush hazard to fingers or hands. This hazard relates to grips and fixtures coming together as a result of rapid crosshead motion, crushing hands or fingers. For example, an operator inadvertently commands the system to jog or return while their hands are in test area. This may also happen if the operator, in an attempt to be more efficient, reaches in to remove broken specimen pieces while simultaneously returning the crosshead to zero displacement. Recommendations In all situations: • Set up test methods so that operators do not need to have their hands in the space between fixtures while the crosshead is moving. • Use the Operator Protection feature in Bluehill® software. This uses a reduced jog speed (default 600 mm/min) during set up and you can set a lower jog speed if your risk assessment requires it. • Set appropriate travel limits every time you change the grips and adjust the crosshead. In addition, if the gap between grips and fixtures is less than 50 mm:

• Use a specimen insertion tool and other appropriate equipment and practices to keep fingers out of the space between the fixtures. In addition, if the gap between grips and fixtures is less than 25 mm: • Use a specimen insertion tool to keep fingers out of the space between the fixtures. • Use an interlocked shield to limit or disallow motion when the shield door is open. When the space is less than 25mm, the crush hazard is very significant, so this is the best option.

28 M10-17318-EN Pinching fingers between grip jaw faces Warning Pinch hazard to fingers. This hazard relates to grip jaws closing quickly, pinching fingers. Recommendations For 2712 Series pneumatic grips: • In the documentation supplied with the grips, read and follow the safety recommendations for installing a specimen. • Use the Operator Protection feature in Bluehill® software. This uses a reduced initial grip pressure (default 15 psi) during set up and you can set a lower initial grip pressure if your risk assessment requires it. Refer to “Pneumatic Grips” on page 66 for more details. • Use jaw face shields. • Use the thumb screw knobs on the sides of the grip (2712-04x grips only) to reduce the jaw face gap to the smallest practical gap for your specimens. Correct:

Incorrect: Impact of debris from breaking specimens Warning Hazard from flying debris. This hazard relates to brittle or composite specimens that can explode when they break. Recommendations For less dangerous debris (specimen dust or fibers, for example): • Use personal protection equipment (for example safety glasses). For more dangerous projectile debris (brittle composite specimens, for example): • Use an interlocked shield.

30 M10-17318-EN Operator Protection Overview The majority of hazards for operating materials testing systems are associated with: • rapid movement of the crosshead causing crush injuries • rapid closing of pneumatic grips causing pinch injuries Operator Protection in Bluehill® provides a mechanism that lets you limit crosshead jog speed and reduce grip closing pressure while you are setting up a test. The default conditions during test set up are: • crosshead jog speed reduced to a maximum of 600 mm/min, and can be set lower if your risk assessment requires it • grip closing pressure reduced to a default of 15 psi, and can be set lower if your risk assessment requires it. Refer to “How Operator Protection works with grips” on page 66 for more details. Operator Protection lets an Administrator configure the testing system to be consistent with the risk assessment for that system. Access to the controls for Operator Protection is password protected. If you have Administrator rights you can modify Operator Protection in the Admin tab in Bluehill®. Refer to “Operator Protection” on page 55 for more details.

Chapter 3 Installation • Level the load frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 • Power supply compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 • System components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 • First time startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Level the load frame Level the load frame immediately after you position it for installation. This prevents the base from rocking and provides a level test surface for more accurate results. Refer to Figure 3 on page 31 and follow the procedure. Figure 3. Adjust the leveling feet You need the following equipment (supplied in the ancillary parts kit unless specified otherwise): 1 2

• 19mm combination wrench (part no. P632-484) • 16mm thin open-ended wrench (part no. P632-482) Caution Make sure that the full weight of the frame is bearing down on the feet. If it is not, you will not be able to adjust the feet. 1. Place a spirit level on the center of the base beam. 2. Use the 19mm wrench to loosen the lock nut (1) on each leveling foot. 3. Use the 16mm thin open-ended wrench to turn the level adjuster nut (2) on each foot while you monitor the spirit level reading. Warning As you make adjustments, make sure that no more than 12 mm (0.5 in) of thread is exposed. If you expose more than 12 mm (0.5 in) of thread, there is a risk that the threaded adapter can separate from the foot. 4. Rotate the spirit level 90 degrees to verify that the load frame is level side to side and front to back. 5. When the machine is level, use the 16mm thin open-ended wrench to hold the level adjuster nut (2) while using the 19mm wrench to tighten the lock nut (1) on each foot. Power supply compatibility The first step in the installation is to verify that the voltage and electrical plug are compatible with the location’s power supply. The power cord set and plug is based on the country to which the frame was shipped and is compatible with the electrical requirements for that country. Warning Frames may overheat or suffer damage if connected to a power supply greater than 15% above the configured voltage.

Product Support: www.instron.com Caution Frames may not be able to run at rated speeds if connected to a power supply more than 10% below the configured voltage. Before proceeding with installation, verify the following: • The machine’s voltage is compatible with the main power supply of your facility. Refer to “Determine the voltage setting” on page 34. • The machine’s power cable can reach the electrical power supply with some slack in the cable. • The plug is compatible with the electrical power outlet. If your power source is not the voltage originally specified on your purchase order, you can follow the instructions in “Change the voltage setting” on page 34 to change the voltage. Ensure that you use the appropriate electrical plug when changing voltages. Warning Hazard - Do not remove covers to any component of your system, unless it is specified in a procedure. There are dangerous voltages and rotating machinery inside the machine that may cause bodily injury or damage to equipment. Warning Electrical hazard - to ensure safety and Electromagnetic Compatibility (EMC) the facility’s receptacle must be a 3-wire grounded receptacle. The ground must be a low impedance earth ground in accordance with national and/or local regulations. The frame operates from a single-phase, two-wire grounded power source that applies 240 volts rms or less between the supply conductors or between the ungrounded supply conductor and earth ground. The connector on the power cable must be compatible with the power source. If the power cable supplied with your system does not fit your power source outlet, add a male plug to the cable that is compatible with the voltage. Observe the CEE wire color code as follows: • Brown - high (live) • Light blue - low (neutral)

Set the input voltage The load frame voltage is factory set according to the voltage that was specified at the time of purchase. Use the following procedures only if the facility power source does not match the frame voltage setting. This situation may arise if the system is moved to another location with a different voltage rating from the factory setting on the frame. Determine the voltage setting Figure 4. Power input connector with voltage setting 1. Locate the power input connector on the rear of the testing machine base. 2. Inspect the power input connector and refer to Figure 4 on page 34. The indicated voltage in Figure 4 is 120V. Change the voltage setting Use the following procedure only if the facility power source does not match the frame voltage setting. This situation may arise if the system is moved to another location with a different voltage from the factory setting on the frame.

Product Support: www.instron.com You will need the following equipment (not supplied): • Small flat-head screwdriver or probe • Long-nose pliers Warning Electrical hazard - shut off the main power switch and disconnect the power to the frame before changing the power setting. There are dangerous voltage levels inside the fuse holder. Warning Hazard - Do not remove covers to any component of your system, unless it is specified in a procedure. There are dangerous voltages and rotating machinery inside the machine that may cause bodily injury or damage to equipment. 1. Ensure that the power switch is in the Off (0) position and disconnect the power cable from the power source. Verify that no LEDs are illuminated on the frame control panel. 2. Insert a small flat-head screwdriver into the slot indicated in Figure 5 on page 35 and pry out the fuse holder. Figure 5. Prying out the fuse holder 3. Remove the fuse holder (1) from the power input connector. 4. Using long-nose pliers, remove the voltage selector unit (see Figure 6 on page 36).

5. Re-insert the voltage selector unit into the connector so that the required voltage faces front. 6. If necessary, change the fuse holder. Refer to“Replace a Fuse” on page 117 for instructions on replacing a fuse. 7. Re-install the fuse holder into the connector. Ensure that the indicator pin now indi- cates the correct input voltage. See Figure 4 on page 34 for reference. 8. Reconnect the power cable to mains power and turn on the system. Verify that the white DISABLED indicator on the frame control panel illuminates. 9. Before you carry out any testing, perform the procedure described in “First time startup” on page 47. System components Instron® Service installs your testing system. These diagrams and instructions are provided as a reference if you need to move the system after the initial installation.

Dual column table model load frame Figure 7. Frame connections Legend for Figure 7 1 5 2 4 3 8 6 10 9 7 11 Label Component More detail 1 Mains cable and plug

“Ground connection detail” on page 41 3 To Bluehill® Operator Dashboard or separate computer (not shown in Figure 7) 4 System ID label 5 and 6 Exhaust vents Leave at least 152 mm (6 in) of space behind the frame to allow for ventilation and periodic access. 7 Cable clip Use T-nut, cable clips, cable tie hooks and loops to secure load cell cables and pneumatic grip connections 8 Rear panel “Rear panel connections detail” on page 39 9 Controller panel “Controller connections detail” on page 40 10 Adjustable feet “Level the load frame” on page 31 11 Power inlet connection, power switch, fuses and voltage selector “Power supply compatibility” on page 32 Label Component More detail

Rear panel connections detail Figure 8. Rear panel connections detail Legend for Figure 8 5 4 3 2 1 6 Label Component More detail 1 Pneumatic grips - grip 1 connector (typically upper grip) 2 Pneumatic grips - grip 2 connector (typically lower grip) 3 Pneumatic grips - air inlet connector 120 psi (8.3 bar) maximum

In some situations, unexpected grip motion can result. To prevent this, do not link the exhaust ports (for example with a “T” or “Y” fitting). The two exhaust ports must remain separate. Controller connections detail Figure 9. Controller connections detail Legend for Figure 9 4 Pneumatic grips - air exhaust connector Install air muffler or connect to exhaust system 5 Pneumatic grips - air exhaust connector Install air muffler or connect to exhaust system 6 Ethernet (to Bluehill® Operator Dashboard) or separate computer Label Component More detail 1 2 3 4 5 6 7 8 9 Label Component More detail 1 Encoder connector Connects to various accessories, including AVE2 and AutoX extensometers

Ground connection detail If the electrical supply is not grounded, you must use this functional ground connection to connect the frame to a suitable ground in the building. This connection can also be used in certain cases when auxiliary equipment, such as an automatic extensometer or a monitoring device, requires grounding for functional reasons or for EMC compliance. Any instructions for connection to this ground will be in the documentation for the accessory. Refer to Figure 10 on page 42 for connection details. 2 Foot switch connector 3 Status indicators 4 PIP jack 5 Strain connectors Optional 6 Status indicators 7 Force connector Connects to load cell 8 Sync connector 9 Service connectors For use by Instron® Service only Label Component More detail

Legend for Figure 10 Connect the system components Instron® Service installs your testing system. These instructions are provided as a reference if you need to move the system after the initial installation. This procedure describes the connections for the basic components of the system. If you purchased additional accessories for your system, you need to refer to the documentation for those accessories for proper installation. Warnings Electrical hazard - Do not connect power cables when the power is on. Turn the power off to avoid hazardous voltages and component damage. 1 2 3 Label Description 1 Sheet metal 2 Connect ground cable for frame here 3 Connect ground cable for any accessories here

Hazard - Do not remove covers to any component of your system, unless it is specified in a procedure. There are dangerous voltages and rotating machinery inside the machine that may cause bodily injury or damage to equipment. 1. Ensure that the power switch is set to Off (O) and the mains power cable to the machine is disconnected. 2. Connect the load cell cable to the FORCE connection on the controller (see “Controller connections detail” on page 40). 3. If using pneumatic grips, connect the grips and the air supply to the appropriate connectors on the rear panel (see “Rear panel connections detail” on page 39). 4. If you are using pneumatic grips with a foot switch, connect the foot switch to the FOOT SWITCH connector on the rear panel (see “Controller connections detail” on page 40). 5. Use the cable clips on the column to secure the load cell cable and pneumatic grip connections (see “Dual column table model load frame” on page 37). 6. Instron® systems provide an option to measure strain. If your system is equipped to measure strain, connect the extensometer to the STRAIN 1 connection on the controller (see “Controller connections detail” on page 40). Always use STRAIN 1 as the primary connection for strain. STRAIN 2 is an available option that you can use to connect another extensometer or other strain device to the system. Caution The connectors labeled SERVICE are for the use of Instron® Service only. Never connect any equipment to any of the SERVICE connectors. 7. If the frame or any accessories require a ground (earth) connection, make the connections (refer to “Ground connection detail” on page 41). 8. Connect the Ethernet connection on the Bluehill® Operator Dashboard to the Ethernet connection on the rear panel (see “Rear panel connections detail” on page 39). 9. Verify the following: a The machine’s voltage is compatible with the main power supply of your facility. Refer to “Determine the voltage setting” on page 34. If it is not, refer to “Change the voltage setting” on page 34. b The plug is compatible with the electrical power outlet. Warning Frames may overheat or suffer damage if connected to a power supply greater than 15% above the configured voltage.

than 10% below the configured voltage. 10. Connect the mains power cable to the IEC connector on the rear of the machine and to the electrical power supply (see “Dual column table model load frame” on page 37). 11. Connect the mains power cable on the Bluehill® Operator Dashboard to the electrical power supply. The system is now ready to be turned on. Refer to “First time startup” on page 47. Bluehill® Operator Dashboard The Bluehill® Operator Dashboard provides a touch-friendly interface for controlling your testing machine using Bluehill® software. Adjustment and connection Instron® Service will install the Bluehill® Operator Dashboard on your system. 1. You can adjust the height of the Bluehill® Operator Dashboard for the comfort of different operators. Loosen the lock (1 in Figure 11 on page 45) and slide the arm mounting (2 in Figure 11 on page 45) to the desired height. Re-tighten the lock.

Figure 11. Height adjustment 2. Connect the Ethernet connector on the rear of the Bluehill® Operator Dashboard to the Ethernet connector on the rear panel of the testing machine. 3. Connect the mains power cable to the electrical power supply. Disconnection and moving If you need to move the testing system you must disconnect and remove the Bluehill® Operator Dashboard as follows: 1. Ensure that the power switch is set to Off and the mains power cable is disconnected. 2. Disconnect all cables that connect to or from the Bluehill® Operator Dashboard. 1 2

3. If necessary, loosen the set screw on the side of the “elbow” on the mounting arm (1 in Figure 12 on page 46). 4. Operate the release mechanism on top of the “elbow” (2 in Figure 12 on page 46) and lift the Bluehill® Operator Dashboard clear of the mounting arm (Figure 13 on page 47). 1 2

Product Support: www.instron.com Figure 13. Lift to remove 5. Place the Bluehill® Operator Dashboard face down on a soft material to avoid scratching the screen. First time startup When the testing system is installed, you need to configure Bluehill® to communicate with the testing hardware. 1. Ensure that all cables are properly installed and securely connected.

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

Chapter 4 Function of controls • Power input connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 • Emergency Stop button. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 • Frame Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 • Bluehill® software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 • Operator Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 • Bluehill® Operator Dashboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 • Pneumatic Grips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Before you start the system, make sure you familiarize yourself with the following controls:

50 M10-17318-EN Power input connector Figure 14. Power input connector Legend for Figure 14 The power input connector, shown in Figure 14 on page 50, performs the following functions: • connects the load frame to the electrical power supply • contains the ON/OFF switch • holds the power fuse • controls the voltage setting. The voltage setting can be changed if necessary, refer to “Power supply compatibility” on page 32. Refer to Figure 2 on page 17 to see the location of the power input connector on your load frame. 1 2 3 4 Label Component 1 IEC inlet connector 2 Power switch 3 Selected voltage 4 Fuse carrier and voltage selector access

Product Support: www.instron.com Emergency Stop button Figure 15. Emergency Stop button The Emergency Stop button is a large, round, red button on the testing system. Press this button to stop the test as soon as possible when a condition develops that: • could affect the safety of anyone operating the system • could damage the specimen, load frame, or test fixtures Warning If you are using an integrated air kit with a foot switch to control a set of pneumatic grips, be aware that pressing the Emergency Stop button to disable the frame will also deactivate the grips, causing them to open. With an integrated air kit, any action that disables the frame will also open the grips. Frame Control Panel All the controls and indicators for the testing system are on the frame control panel:

52 M10-17318-EN Figure 16. Frame Control Panel Legend for Figure 16 Label Description 1 JOG buttons When in SET UP mode, the jog speed is restricted to 600 mm/min or less. When in CAUTION or TESTING mode, the jog speed is unrestricted, i.e. any speed up to the maximum speed for the frame. 2 STOP button Stops crosshead motion, e.g. during jogging, testing, or returning to zero. If you need to disable the frame, press and hold the STOP button for 2 seconds. 3 Mode indicators - different color LEDs that indicate the current mode of the frame. • DISABLED (white) • SET UP (blue) • CAUTION (yellow) • TESTING (red)

The white LEDs above the UNLOCK, TEST and RETURN buttons indicate availability. In Figure 16, the unlock button is available. Bluehill® software The software controls: • setting test parameters • collecting and analyzing test data Refer to the Bluehill® online help and reference for more details. Home Screen Bluehill® software opens at the Home screen, with the following components: 4 RETURN button - returns the crosshead to zero displacement. Return speed is set in Bluehill® software and can be any value up to the maximum speed for the frame. The button is only available after the frame has transitioned to CAUTION mode. When you press this button, the frame runs in TESTING mode until the return is completed. 5 START TEST button - press the button to start a test. Bluehill® software must be in the Test screen before you can start a test. • The button is only available after the frame has transitioned to CAUTION mode. • When you press this button, the frame runs in TESTING mode until the test is completed or you initiate another action. 6 UNLOCK button - switches the frame between the following modes: • DISABLED to SET UP, i.e. enable the frame • SET UP to CAUTION, e.g. prepare to start a test 7 EMERGENCY STOP button - press this button to disable the frame from any mode when a hazardous situation exists. Refer to “Emergency Stop button” on page 51. Label Description

54 M10-17318-EN • Console area at the top and bottom of the screen. Provides important information about the system. Always visible and available from any screen. • Buttons to access other parts of the software - creating test methods, running tests, analyzing data, producing reports. Buttons Console area The console area provides important information during testing and is also where you can edit system wide settings. At the top of the screen: • Live displays track values of parameters that you choose Table 4. Buttons on the Home screen Button Function Test Perform tests on specimens. The software displays a sequence of screens where you: 1 choose a test method from which to load test parameters. 2 perform tests. 3 name the sample and select a location to store the test data. Method Create, edit and save test method files. Analysis (optional) Modify an existing sample or replay a sample with parameters from a different test method. Admin Change the configuration of the testing system. Logout Log out the current user and let a new user log in to the software. When you log out you do not exit the program. This button is hidden if Security is not enabled. Instron® Connect Uses an Internet connection to check the status of the system, including verification status of transducers. Checks for software updates. You can also use this connection to contact Instron® Service for assistance and upload files to Instron® Service for diagnosis. Help Open the online help. Exit Exit the program.

• System button opens the System details dialog where you can view system information, view the event logs, and change settings including: • set up the load frame and any connected transducers • set up live displays • set up soft keys • set up the test area, specimen protect, jog rate, return rate and collision mitigation • enable features on pneumatic grips At the bottom of the screen: • soft keys that you have set up in the soft keys screen appear here Status Bar The status bar appears at the bottom of every screen and provides status information for: • Security - the name of the currently logged in user or a statement that security is off. • Machine - is the software connected to a testing machine or running in No machine mode. • Test type - e.g. tension, compression, metals. • Sample - the name of the current sample file that is open, if any. • Method - the name of the current method file that is open, if any. • Report - the name of the current report template that is open, if any. • Progress messages - various messages indicating progress, for example “Opening”, “Closing” and “Generating”. Operator Protection Operator Protection in Bluehill® provides a mechanism that lets you limit crosshead jog speed and reduce grip closing pressure while you are setting up a test.

56 M10-17318-EN Operator Protection lets an Administrator configure the testing system to be consistent with the risk assessment for that system. Access to the controls for Operator Protection is password protected. If you have Administrator rights you can modify Operator Protection in the Admin tab in Bluehill®. Operating Modes Bluehill® displays the current system mode corresponding to the four LEDs on the control panel: Disabled Bluehill® displays gray border with white text, Frame is disabled. DISABLED (white) LED illuminates on the frame control panel. This is the default state of the frame upon start up after the software is opened. If the frame is not connected to the software, the LED flashes. When the frame is disabled: • crosshead cannot move • pneumatic grips cannot operate DISABLED (white) SET UP (blue) CAUTION (yellow) TESTING (red)

The frame disables when: • Emergency stop button is pressed • A frame fault occurs • You press and hold the STOP button for 2 seconds. When the frame transitions from any other mode to disabled, any pneumatic grips connected to the integrated air kit will open automatically. To proceed to SET UP mode, you press the UNLOCK button. Set Up Bluehill® displays blue border with white text, Ready to set up. SET UP (blue) LED illuminates on the frame control panel. This is a restricted state of the frame. The indicator LED flashes blue whenever the crosshead is moving, e.g. jogging. When the frame is in set up mode: • crosshead can jog at the operator protect jog speed (no greater than 600 mm/min) • pneumatic grips can close at the initial grip pressure (default value of 15 psi) The frame returns to set up mode when: • the test is paused (e.g. during extensometer removal) • after a test is complete • after a return is complete

58 M10-17318-EN • when an interlocked shield is opened To proceed to CAUTION mode, you press the UNLOCK button. Caution Bluehill® displays yellow border with white text, Ready to test. Yellow warning message, Keep clear of test area, disappears after a few seconds. CAUTION (yellow) LED illuminates on the frame control panel. This is an unrestricted state of the frame. The indicator LED flashes yellow whenever the crosshead is moving, e.g. responding to the software specimen protect setting. When the frame is in caution mode: • pneumatic grips, previously closed at initial grip pressure in the set up state, clamp at full test pressure • the frame returns to set up mode if a test is not started within 2 seconds (unless a debris shield with interlocks is present and closed) To start the test, you press the START TEST button. To return the crosshead after completing a test, you press the RETURN button. Testing Bluehill® displays a red border with white text, Test in progress. The border flashes while the crosshead is moving.

Red warning message, Keep clear of test area, disappears after a few seconds. TESTING (red) LED illuminates on the frame control panel and flashes while the crosshead is moving. This is an unrestricted state of the frame. When the frame is in testing mode: • frame is currently running a test • frame is currently returning to zero displacement after a test The frame also enters this mode during high-speed jogging, which can be initiated by pressing and holding the UNLOCK button while simultaneously pressing one of the JOG buttons. Once the jog has started, you can release the UNLOCK button so long as you maintain pressure on the JOG button. Crosshead speed ramps up gradually to the maximum speed of the frame. Move between modes The following table shows how the controls on the frame control panel move the system between modes to set up and run a test.

60 M10-17318-EN Table 5. Move between modes Initial condition Action Result 1 DISABLED (white) Press SET UP (blue) 2 System remains in set up mode until you make a change. During this time you can: • move the crosshead at the restricted speed set up in the Admin tab, up to a maximum of 600 mm/min • operate pneumatic grips at the initial pressure set up in the Admin tab, up to a maximum of 15 psi When the specimen is installed and Bluehill® is displaying the Test screen, you can move on. 3 SET UP (blue) Press CAUTION (yellow) Pneumatic grips clamp to full pressure. 4 CAUTION (yellow) Press (within 2 secs) TESTING (red) 5 TESTING (red) Test runs to completion. SET UP (blue)

Additional notes: • Once the frame is enabled, the default mode when it is idle is SET UP mode with the light above the UNLOCK button illuminated. If you want to disable the frame, press and hold the STOP button for 2 seconds. • When you enter CAUTION mode, and if you are using a footswitch to control the grips, pneumatic grips clamp to full pressure. If you do not press the START button within 2 seconds, the frame returns to SET UP mode. The grips, however, remain at full pressure until you run a test. If you are using toggle switches on the grips to control them, the grips are at full pressure only during TESTING mode. Typical test flow “Move between modes” on page 59 describes each of the test controls and how they are used to move between testing modes. 6 SET UP (blue) Press CAUTION (yellow) 7 CAUTION (yellow) Press (within 2 secs) TESTING (red) Crosshead returns to zero position at speed set in the software. 8 TESTING (red) Crosshead returns to zero position. SET UP (blue) Table 5. Move between modes (Continued) Initial condition Action Result

62 M10-17318-EN For a step-by-step description of a typical test flow using these controls, refer to “Testing a sample” on page 91. This section contains two procedures, one for systems using an interlock and one for systems without an interlock. Jog at High Speed Under normal conditions, in SET UP mode, jog speed is limited to 600 mm/min or less. There may be situations, such as moving the crosshead into position at the start of a testing session, where this low speed in inconvenient. Jogging at high speed involves more risk so the process involves pressing both the UNLOCK and JOG buttons at the same time, as follows: Additional notes: • Although you must press the UNLOCK and JOG buttons together to start the jog at full speed, you can release the UNLOCK button once the crosshead starts to move. The crosshead ramps up to full speed and continues to move while you are pressing the JOG button. Table 6. High speed jog Initial condition Action Result SET UP (blue) Press and together TESTING (red) Crosshead moves up, ramping up to the maximum speed set in the software. SET UP (blue) Press and together TESTING (red) Crosshead moves down, ramping up to the maximum speed set in the software.

• You would typically use this functionality when initially setting up test fixtures and bringing the crosshead to the correct position to install specimens. Thereafter, you can use the RETURN button to bring the crosshead back to the zero displacement position. Operator Protection Controls If you have Administrator rights, you can make changes to the Operator Protection settings, via Admin > Frame > Operator Protection. For more details on the operation of these software controls, refer to the Bluehill® online help and reference. Operator Protection options define the restrictions on the system when it is in SET UP mode. Control Description Jog rate Sets the restricted speed of the crosshead when the system is in SET UP mode. Default setting is 600 mm/min, which is also the maximum permitted. If the maximum speed of the crosshead is less than 600 mm/min, then the restricted speed is limited to the maximum speed of the frame. Initial grip air pressure Sets the maximum grip pressure allowed when the system is in SET UP mode. Allows the operator to close the grips on the specimen with sufficient pressure to hold the specimen in place but reduces the risk of injury from pinching. Override point of control Default is disabled, which means that the primary point of control for the system is at the load frame. The operator must use the buttons on the frame to start a test or position the crosshead. When this option is enabled, the system can be configured to use the software to initiate these actions. Override point of control - Start test and return Default is Frame Controls, i.e. start test and return using the buttons on the frame. Only choose Remote if you are using an interlock accessory. The interlock automatically transitions the system to CAUTION mode when the interlock is closed. If there is no interlock, you must press the UNLOCK button to transition to CAUTION mode.

64 M10-17318-EN Bluehill® Operator Dashboard The Bluehill® Operator Dashboard provides a touch-friendly interface for controlling your testing machine using Bluehill® software. Pneumatic grips Enables and disables pneumatic grips connected to the testing system with the integrated air kit. Grip control (when pneumatic grips are enabled) Default is Footswitch. You close both grips using the integrated air kit and foot switch. Toggle switch lets you use the toggle switches on the grips with the integrated air kit. The footswitch is disabled when you choose this. Remote lets you control the grips via a software program operating through the API. Upper footswitch/lower remote applies only if your test method includes pretension. Upper grip closes with the foot switch and the lower grip closes automatically after the specified load threshold is achieved. Behavior when the interlock is tripped If the testing system includes an accessory with an interlock, then Operator Protection defines the behavior of the frame when the interlock is tripped. For example, when an interlocked door is opened and the operator has access to the test area. Disable frame - the frame is disabled when the interlock is tripped. This is the recommended setting as it is the safest.1 Allow limited motion - the frame remains enabled when the interlock is tripped. This allows an operator access to the test area while allowing limited crosshead movement as specified in Operator Protection. Although this option can facilitate installing a specimen or removing an extensometer during a test, it also increases the risk of injury. You should perform a risk assessment before selecting this option. 1. If you choose this option, be aware that the operation of pneumatic grips is also disabled. If you want no crosshead motion when the interlock is tripped but need pneumatic grips to function, select Allow limited motion and set Jog rate to 0 mm/min. Control Description

Product Support: www.instron.com Basic touch functions Basic touch screen functions in Bluehill®: • tap a control to select it (equivalent to clicking in non-touch interfaces) • to enter text in a field, tap the field and, if the keyboard is not already displayed, tap the keyboard icon to display it • to enter numbers in a field, tap the keypad button to the right of the field • if there is a task menu associated with part of a screen (accessed via right-click in non-touch interfaces), there will be a Menu button on the screen. Tap it to open the menu. • if there is a Properties dialog associated with part of a screen, there will be a Properties button on the screen. Tap it to open the dialog. • enable/disable controls (check boxes in non-touch interfaces) are toggle controls. Tap the control to enable or disable it. Enabled is colored, disabled is gray. Touchscreen gestures Gestures supported in Bluehill®: • graph - pinch to zoom (must also be enabled in the Admin screen) • test workspace component - if the component is maximized, you can move between components by selecting the appropriate icon in the tool bar below the maximized component • test workspace setup - when editing test workspace layout, swipe left or right to move between available components • test workspace specimen selector - swipe up (portrait orientation) or swipe left (landscape orientation) to display a panel that lets you quickly include or exclude a specimen from the sample • any scrollable screen component - flick up or down, left or right to quickly scroll through the list

66 M10-17318-EN Pneumatic Grips Table 7 on page 66 lists the pneumatic grips recommended for use with these testing systems, combined with the optional integrated air kit and footswitch. They utilize the grip control features of Operator Protection including reduced initial grip pressure, which reduces the speed and force of closing while setting up a test, thus reducing the risk of injury. Warning Always disable the frame before installing or changing pneumatic grips. When the frame is enabled, the integrated air kit is pressurized. If you attach a grip to the system in this state, the grip could close. Other pneumatic grips can be used with the system, including operation with the integrated air kit and footswitch, but they may not be designed to utilize the full range of features of Operator Protection. Contact Instron® Service for advice. How Operator Protection works with grips When in SET UP mode, pneumatic grips close at a reduced initial grip pressure. The lower the pressure, the lower the force and speed at which the grips close. You should therefore set this speed to the minimum required to close the grips and grip the specimen within a reasonable time, but taking into account that even low pressures can cause injury. The default value is 15 psi. The following table lists recommended initial grip pressures for the pneumatic grips listed in Table 7 on page 66: Table 7. Recommended pneumatic grips Grip model number Grip capacity 2712-041 1 kN 2712-042 2 kN 2712-045 5 kN 2712-046 10 kN 2712-052 250 N 2712-051 50 N1 1. These low capacity grips do not include the toggle switch.

Minimum pressure may be slightly higher or lower for any given grip due to age, environmental conditions and use. Warning Be aware that even at these recommended initial grip pressures, the force exerted by the closing grips can cause injury. For example, a 10 kN grip closing at the default initial pressure of 15 psi exerts a minimum force of 4kN (900 lbf). The same grip closing at 7 psi exerts a minimum force of 1.9kN (420 lbf), still a significant force that can cause injury. Warning Be aware also that setting initial grip pressure too low may result in the grip not closing completely at the initial grip pressure. This may cause a hazard when the grips transition to full pressure. If the grips do not close completely at the initial pressure, they will close at full force when the grips transition to full pressure. Warning If the grips feature an air inlet flow adjustment control (see below), make sure that the flow adjustment is set to fully open (screw fully counterclockwise). Do not use the air inlet flow adjustment control to reduce air flow as you risk transitioning from initial pressure to full pressure before the grips have closed. If the Grip model number Grip capacity Recommended initial grip pressure - psi (bar) 2712-051 50 N 15 (1.03) 2712-052 250 N 12 (0.83) 2712-041 1 kN 9 (0.62) 2712-042 2 kN 5 (0.34) 2712-045 5 kN 8 (0.55) 2712-046 10 kN 7 (0.48)

68 M10-17318-EN grips do not close completely at the initial pressure, they will close at full force when the grips transition to full pressure. In addition to the hazard caused by reducing the air flow, operation of the air inlet flow adjustment control can result in an inaccurate grip pressure reading which may disable the frame. You can remove the air inlet flow adjustment control and connect the 1/8” NPT quick disconnect directly to the grip or via a 1/8” NPT right angle male to female adapter, as shown below. Operate grips using footswitch The recommended pneumatic grip configuration is one of the grips listed in Table 7 on page 66 combined with the integrated air kit and footswitch.

If for any reason you have to disconnect the footswitch from the frame controller, you must cycle power on the frame to re-establish communication between the footswitch and the frame. The operation of this configuration with Operator Protection is described in “Operator Protection using the footswitch” on page 69. Caution The pneumatic-only, single pedal footswitch (Cat. no. 2701-004) is NOT suitable for use with these systems. Operator Protection using the footswitch The point of control for grips in the Operator Protection control dialog must be set to Footswitch. The footswitch operates as follows: • tap right pedal once, closes grip connected to port 1 (typically the top grip) • tap right pedal again, closes grip connected to port 2 (typically the bottom grip) • tap left pedal once, opens both grips The footswitch integrates with Operator Protection as follows: • in SET UP mode, you can open and close the grips • in CAUTION mode, you can open the grips • in DISABLED or TESTING mode, the footswitch does not operate Warning If your grips have toggle switches installed, do not use them when the point of control for grips is set to Footswitch. If you intend to always use the footswitch, you should replace the toggle switches on the grips with the blanking plugs provided with the grips in the ancillary parts kit. 1. Starting with the system in DISABLED mode, press the UNLOCK button. The system moves to SET UP mode. 2. Operate the system in SET UP mode and install the specimen using the footswitch to open and close the grips at the initial pressure set in the software. 3. Press the UNLOCK button to transition to CAUTION mode. The grips pressurize to full pressure.

70 M10-17318-EN 4. Within 2 seconds, press the START TEST button to start the test. If you do not start the test immediately and the system returns to SET UP mode, the grips continue at full pressure until you run a test or release the grips. The system transitions to TESTING mode. 5. Stop the test, or the test ends. The system reverts to SET UP mode but the grips are maintained at full pressure until you open them using the footswitch. Warning Do not operate the toggle switches when the testing system is in TESTING mode and the grips are pressurized to full pressure.The system may detect an error and disable the frame. You must not operate the toggle switches when the grips are at full pressure. The grips will open but when you use the toggle switch again to close the grips, the grips will close at full pressure and the system may detect an error and disable the frame. You may start a test with one grip closed if desired. If you move to CAUTION mode after closing one grip, you cannot close the second grip, even if you transition back to SET UP mode. You must use the footswitch to open the first grip in order to proceed. Operate grips using toggle switches The recommended pneumatic grip configuration is one of the grips listed in Table 7 on page 66 combined with the integrated air kit and footswitch. If you are using the integrated air kit but prefer to use toggle switches on the grips instead of a footswitch there are some differences in the operation of the grips that you should be aware of: • Grips maintain full pressure during TESTING mode only. At the end of a test, when the system reverts to SET UP mode, the grip pressure reduces to the initial grip pressure. This may cause problems if the specimen has stored energy which could cause the specimen to slip out of the grips. If that is a concern, you should use a footswitch to run your tests. • You must not operate the toggle switches when the grips are at full pressure. The grips will open but when you use the toggle switch again to close the grips, the grips will close at full pressure and the system may detect an error and disable the frame. The operation of this configuration with Operator Protection is described in “Operator Protection using the toggle switches” on page 71.

Operator Protection using the toggle switches The point of control for grips in the Operator Protection control dialog must be set to Toggle switch. If you have a footswitch connected to the system, it will not operate. Warning Make sure that the toggle switches are in the open position. If the toggle switches are in the closed position, the grips will close immediately when the system transitions to SET UP mode. 1. Starting with the system in DISABLED mode, press the UNLOCK button. The software displays a message, warning you to make sure that the toggle switches are in the open position. 2. Press the UNLOCK button again to transition to SET UP mode. 3. Operate the system in SET UP mode and install the specimen using the toggle switches to open and close the grips at the initial pressure set in the software. 4. Press the UNLOCK button to transition to CAUTION mode. The grips are maintained at the initial grip pressure. 5. Within 2 seconds, press the START TEST button to start the test. The system transitions to TESTING mode and the grips pressurize to full pressure. 6. Stop the test, or the test ends. The system reverts to SET UP mode and the grip pressure returns to the initial grip pressure.

72 M10-17318-EN Caution If your test ends and the specimen has stored energy, e.g. the specimen did not break, the specimen may slip out of the grips when the grip pressure reduces at the end of the test. If this could be an issue, it is recommended that you set the point of control for grips to Footswitch and use a footswitch for your tests. When using a footswitch, pneumatic grips remain at full pressure after the test ends until you release them using the footswitch. Warning Do not operate the toggle switches when the testing system is in TESTING mode and the grips are pressurized to full pressure.The system may detect an error and disable the frame. You must not operate the toggle switches when the grips are at full pressure. The grips will open but when you use the toggle switch again to close the grips, the grips will close at full pressure and the system may detect an error and disable the frame. Grips not in use There may be situations where you want to remove the grips from the load string, placing them on a bench alongside the system perhaps while you perform different types of tests. Be aware that if the point of control for grips is set to Toggle, the grips could present a hazard. Warning If you remove the pneumatic grips from the load string but do not disconnect them from the integrated air kit, you should disablethe grips in the Operator Protection controls in the software. If the point of control for grips in the software is set to Toggle, and you remove them from the load string without disconnecting them from the integrated air kit, the grips will close at initial pressure and cycle between full pressure and initial pressure as you continue your testing.

Chapter 5 Assemble the load string • Select a load cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 • Before you begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 • Install the load cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 • Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 • Coupling adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 • Select Grips and Fixtures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 • Preload the load string . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 • Unload the load string. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 The load string consists of all the hardware components between the crosshead and the base of the testing machine. It includes the load cell, grips, the specimen and any adapters that let you connect any of these components together. Instron® Service sets up the testing machine during installation, but you may need to change one or more of these components for different types of testing. When creating a load string, keep in mind the maximum capacity for all the components making up the load string. The expected test load should not exceedthe maximum capacity of any load string components including, but not limited to: • load frame • load cell • adapters • grips or fixtures Select a load cell If you know the approximate tensile or compressive strength of the material that you are testing, use these guidelines to choose a load cell:

74 M10-17318-EN • Make sure that the load cell is verified for the range of force that you anticipate for your testing • If there is a choice between two different load cells because of overlapping ranges: • select a higher capacity load cell when you require minimum deflection of the load cell • select a lower capacity load cell when you require maximum long term balance or stability If you don’t know the tensile strength of the material, refer to a Properties of Materials handbook to obtain an approximate strength. To calculate the tensile strength in force units for a specimen, use the following equation: tensile strength x cross-sectional area For example, for a standard ASTM tensile specimen (0.502 in wide, 0.125 in thick) made with a material of tensile strength 5200 psi (from Materials Handbook) perform the following calculation: 5200 x 0.502 x 0.125 = 328 lbf This produces a recommendation of the 5 kN (1000 lb, 500kg) capacity load cell. If you cannot determine an approximate value of tensile strength, use the highest capacity load cell rated for the frame. Perform a preliminary test at a very slow speed to obtain the load range required. You can then determine if a lower capacity load cell can provide improved resolution. Table 8 on page 74 lists the load cells that are recommended for use with these frames. If you have a load cell that is not listed, contact Instron® for advice on compatibility and adapters that may be available for your load cell. Table 8. 2530 Series Catalog no. Capacity N (lbf) Effective length mm (in) Mechanical fitting Interface size 2530-5N 5 N (1) 48 (1.89) 2.5 mm clevis pin and 6 mm clevis pin OOf Of 2530-10N 10 N (2.25) 48 (1.89) 2.5 mm clevis pin and 6 mm clevis pin OOf Of 2530-50N 50 N (11) 48 (1.89) 2.5 mm clevis pin and 6 mm clevis pin OOf Of

Product Support: www.instron.com Before you begin Check the following before installing a load cell: • You have all the parts required for installation. Refer to the appropriate figure for your load cell in “Install the load cell” on page 76. • Mounting screws are lubricated. • A torque wrench is available. • All threads, bores and mating surfaces are clean and free of damage. • The crosshead is positioned below its travel midpoint so that you can easily and safely access the crosshead. • The frame is in the disabled state, i.e. the white LED above the DISABLED indicator on the frame control panel is illuminated. 2530-100N 100 N (22) 48 (1.89) 2.5 mm clevis pin and 6 mm clevis pin OOf Of 2530-500N 500 N (112) 91 (3.58) 6 mm clevis pin Of 2530-1KN 1 kN (225) 91 (3.58) 6 mm clevis pin Of 2530-2KN 2 kN (450) 91 (3.58) 6 mm clevis pin Of 2530-5KN 5 kN (1125) 101 (3.98) 12.5 mm clevis pin Df 2530-10KN 10 kN (2250) 122 (4.80) 12.5 mm clevis pin Df 2530-30KN 30 kN (6750) 148.2 (5.83) 12.5 mm clevis pin Df 2530-50KN 50 kN (11250) 148.2 (5.83) 12.5 mm clevis pin Df Table 8. 2530 Series (Continued) Catalog no. Capacity N (lbf) Effective length mm (in) Mechanical fitting Interface size

76 M10-17318-EN Install the load cell Install a 2530 load cell (capacities 5 N through 5 kN) Figure 17. Install a 2530 series load cell - capacities 5 N through 5 kN Legend for Figure 17 1 2 6 5 7 4 3 5N - 5kN Label Component Part number 1 (34TM-5 and 34TM-10) Screw, M10 x 90 201V62 1 (34TM-30 and 34TM-50) Screw, M10 x 140 71-63-1169 2 (34TM-5 and 34TM-10) M10 load washer 610J9 2 (34TM-30 and 34TM-50) Two M10 load washers 610J9 3 M10 spacer T604-90 4 Load cell anti-rotation pin 705K84 5 Locating ring T1335-1048 6 Crosshead 7 2530 load cell - 5 N through 5 kN

Product Support: www.instron.com 1. Refer to Figure 17 on page 76 and its associated legend. Caution Check items 1 and 2 in the legend carefully. The screw, washer and number of washers required depends on the frame model. 2. Collect together the correct mounting screw, washer, anti-rotation pin and locating ring for your combination of load frame and load cell. 3. Assemble the mounting screw and washer, as shown in the figure. 4. Place the mounting screw and washer assembly into the top of the central bore of the crosshead. 5. Insert the anti-rotation pin into one of the holes on the bottom of the crosshead. There are four pin holes on the bottom of the crosshead that let you position the load cell either straight on or at an angle. 6. Place the locating ring into the top surface of the load cell that connects to the cross- head. 7. Place the load cell against the bottom of the crosshead, ensuring that the anti-rota- tion pin and locating ring fit securely in place against both the crosshead and load cell. Place the cable to the left side of the column. 8. Tighten the mounting screw by hand so that it secures to the load cell underneath the crosshead. 9. Lower the crosshead to a position below the center of the travel range to prevent tipping. Caution When applying torque to the mounting screw, prevent the load frame from sliding by holding the crosshead with one hand while applying torque with the other. 10. Use the torque wrench to tighten the mounting screw to 40 N-m (29.5 ft-lb). 11. Connect the load cell cable to the FORCE connector on the controller. Ensure that the connector is fully engaged in the socket. 12. Press the load cell cable into the clips on the column cover to prevent it from inter- fering with your test. 13. Calibrate the load cell (refer to “Calibrate a transducer” on page 99). 14. Leave the system on for at least 15 minutes to allow the load cell circuitry to stabilize. After this warm-up period, calibrate the load cell again.

78 M10-17318-EN Install a 2530-10kN load cell Figure 18. Install a 2530-10kN load cell Legend for Figure 18 1. Refer to Figure 18 on page 78 and its associated legend. 2. Collect together the correct mounting screw, washer, anti-rotation pin and locating ring for your combination of load frame and load cell. 3. Assemble the mounting screw and washer, as shown in the figure. 1 2 4 6 7 5 3 10kN Label Component Part number 1 Screw, M16 x 100 201V85 2 M16 load washer 610J12 3 M17x50x3 mm washer 610K12 4 Locating ring adapter 40/ 20 mm diameter T604-101 5 Load cell anti-rotation pin 705K84 6 Crosshead 7 2530 load cell - 10 kN

Product Support: www.instron.com 4. Place the mounting screw and washer assembly into the top of the central bore of the crosshead. 5. Insert the anti-rotation pin into one of the holes on the bottom of the crosshead. There are four pin holes on the bottom of the crosshead that let you position the load cell either straight on or at an angle. 6. Place the locating ring into the top surface of the load cell that connects to the cross- head. 7. Place the load cell against the bottom of the crosshead, ensuring that the anti-rota- tion pin and locating ring fit securely in place against both the crosshead and load cell. Place the cable to the left side of the column. 8. Tighten the mounting screw by hand so that it secures to the load cell underneath the crosshead. 9. Lower the crosshead to a position below the center of the travel range to prevent tipping. Caution When applying torque to the mounting screw, prevent the load frame from sliding by holding the crosshead with one hand while applying torque with the other. 10. Use the torque wrench to tighten the mounting screw to 60 N-m (44.3 ft-lb). 11. Connect the load cell cable to the FORCE connector on the controller. Ensure that the connector is fully engaged in the socket. 12. Press the load cell cable into the clips on the column cover to prevent it from inter- fering with your test. 13. Calibrate the load cell (refer to “Calibrate a transducer” on page 99). 14. Leave the system on for at least 15 minutes to allow the load cell circuitry to stabilize. After this warm-up period, calibrate the load cell again.

80 M10-17318-EN Install a 2530 load cell (capacities 30kN and 50kN) Figure 19. Install a 2530 series load cell - capacities 30kN and 50kN Legend for Figure 19 1 2 4 6 5 3 30kN - 50kN Label Component Part number 1 Mechanical tensioner, M16 x 2 thread with matching washer 52-2-82 2 Threaded rod, M16 x 170 mm long T620-978 3 Crosshead 4 Locating ring adapter 40/20 mm diameter T604-101 5 Load cell anti-rotation pin 705K84 6 2530 load cell - 30 kN through 50 kN

Product Support: www.instron.com 1. Refer to Figure 19 on page 80 and its associated legend. 2. Assemble the mechanical tensioner (52-2-82) with its matching washer onto one end of the threaded rod (T620-978) as shown in the figure. 3. Place the assembly into the top of the central bore of the crosshead. 4. Insert the anti-rotation pin into one of the holes on the bottom of the crosshead. There are four pin holes on the bottom of the crosshead that let you position the load cell either straight on or at an angle. 5. Place the locating ring into the top surface of the load cell that connects to the cross- head. 6. Place the load cell against the bottom of the crosshead, ensuring that the anti-rota- tion pin and locating ring fit securely in place against both the crosshead and load cell. Place the cable to the left side of the column. 7. Tighten the mounting assembly by hand so that it secures the load cell underneath the crosshead. Caution Make sure that the tensioner assembly is in contact with the crosshead before tightening any of the set screws on the assembly. 8. Lower the crosshead to a position below the center of the travel range to prevent tipping. 9. Use the torque wrench (80-9-11) with the matching 5 mm hex drive socket (67-4-29) supplied in the mechanical tensioner kit (A636-160) to tighten the four set screws (shown in Figure 5) on the mechanical tensioner to 14 N-m (10.3 ft-lb) according to the following procedure:

82 M10-17318-EN Figure 20. Mechanical tensioner assembly a Tighten 2 bolts on opposite sides to 7 N-m (5.1 ft-lb) (50% of the recommended torque). b Tighten the remaining 2 bolts to 14 N-m (10.3 ft-lb) (100% of the recommended torque). c Moving in a circular pattern, re-tighten all bolts to 14 N-m (10.3 ft-lb) (100% of the recommended torque). 10. Connect the load cell cable to the FORCE connector on the controller. Ensure that the connector is fully engaged in the socket. 11. Press the load cell cable into the clips on the column cover to prevent it from inter- fering with your test. 12. Calibrate the load cell (refer to “Calibrate a transducer” on page 99). 13. Leave the system on for at least 15 minutes to allow the load cell circuitry to stabilize. After this warm-up period, calibrate the load cell again. Adapters Adapters let you connect grips or fixtures to the frame when the interfaces have different connection sizes. There are two types of adapters: base adapters and coupling adapters.

Base adapters Base adapters let you connect grips and fixtures to the base of the load frame. The load frame is supplied with a Type D base adapter installed. If you need to remove and re- install the base adapter, for example to change the orientation, use the following procedures. Remove the base adapter 1. Remove the compression spring located inside the adapter. 2. Insert a 14 mm hex key into the base adapter, ensuring that it fits into the screw at the base of the adapter. 3. Loosen and remove the screw inside the adapter. 4. Lift the adapter away from the base beam.

84 M10-17318-EN Re-install the base adapter Figure 21. Type D base adapter Legend for Figure 21 5 4 3 1 2 6 8 7 Label Component Part number 1 Grip 2 Compression spring 66-4-23 3 M16x40 mm screw 4 Clevis pin T29-515 5 Clevis pin clip T1223-1053

1. Insert the adapter into the base beam, noting the orientation of the locating pin on the bottom of the adapter. There are a number of locating pin holes on the base beam to allow for different orientations of the base adapter. 2. Insert a 14 mm hex key into the base adapter, ensuring that it fits into the screw at the base of the adapter. 3. Use the torque wrench to tighten the screw according to the following list: • for 34TM-5 and 34TM-10 frame, torque to 60 N-m (44.3 ft-lb) • for 34TM-30 frame, torque to 120 N-m (88.5 ft-lb) • for 34TM-50 frame, torque to 200 N-m (147.5 ft-lb) 4. Remove the hex key and insert the compression spring. Coupling adapters Coupling adapters let you attach grips and fixtures of different sizes to the load cell and base adapter, providing more options for testing. There are two primary types: • For tension testing only: Tension coupling adapters, also known as self-aligning coupling adapters, which provide a swivel connection and connect between clevis pin type interfaces. The swivel action allows the grip or fixture to self-align in the direction of the test load, thus minimizing any bending load on the specimen. • For tension or compression testing: Rigid coupling adapters which also connect between clevis pin type interfaces but use check nuts to provide fixed connections. This type can also have a threaded interface. These couplings are not self-aligning and the load string alignment is dependent on the accuracy of load cell alignment during installation. When assembling the load string, you may need to use adapters if the load cell interface, or base adapter interface, differs from your grip interface. A coupling adapter creates a secure connection between these two different interfaces. If your grip or fixture interface is the same size as your load cell interface, then you can connect these directly and you do not need an adapter. If, however, you need the self- 6 Type D base adapter 7 Load cell anti-rotation pin 705K84 8 Load frame base beam Label Component Part number

86 M10-17318-EN aligning feature that the adapter offers, you should use the appropriate self-aligning coupling adapter. Coupling types are listed from the load cell towards the accessory or from the frame base towards the accessory. For example, if you need to connect a load cell with a Type D (female) connector to a grip with a Type O (male) connector you require a Type Dm to Of adapter. Select Grips and Fixtures A set of grips are installed on the system during installation by a service engineer. If your testing requires it, you may need to install a different set to obtain optimum test results. The selection of grips depends on the material, geometry and strength of the test specimen. In compression testing, the diameter or area of the anvil is important, in addition to the maximum loading capacity. For tensile testing: • Make sure the tensile strength of the specimen does not exceed the maximum loading capacity of the grips. • Minimize the risk of slippage by: • selecting jaw faces with a surface area large enough to cover the tab (for dumbbell-shaped specimens) or as much surface area as possible for parallel- sided specimens. • ensuring that the specimen is gripped by at least 75% of the available jaw face length. • using serrated jaw faces • Breaks at the jaw face may be caused by: • Screw action grips - you may be using too much force when tightening the grips. Use a torque wrench or switch to pneumatic grips for a consistent force. • Pneumatic grips - the pressure may be too high. Drop the pressure, but not to the point where you get slippage. • Serrated faces - the serrations are damaging the specimen. Change to faces that have more serrations per inch (less bite) or cover with masking tape or similar material to soften the bite and prevent damage to the specimen.

Product Support: www.instron.com Insert Jaw Faces into Grips Different grips use different mechanisms for attaching jaw faces. Refer to the documentation supplied with the grips for more information. Install grips Before you begin, check the following: • There is sufficient space between the load cell and the load frame base to install the grips. • The crosshead is stationary. • The frame is in the disabled state, i.e. the white LED above the DISABLED indicator on the frame control panel is illuminated. • The crosshead limit stops on the load frame are set to prevent the upper and lower grips from colliding with each other (refer to “Set the crosshead limit stops” on page 104). • The mating surfaces of the grips, load cell and the base adapter are free of dirt or debris. Refer to Figure 22 on page 88 when following this procedure. 1. For the upper grip, insert the adapter on the grip into the female clevis socket (1 in Figure 22) on the load cell adapter. 2. Align the clevis holes (2 in Figure 22)and insert the clevis pin (3 in Figure 22) through the holes. 3. Secure the clevis pin in position with the clevis pin clip (4 in Figure 22). 4. Repeat steps 1 through 3 to install the lower grip onto the load frame base adapter. 5. When both grips are installed, follow the procedure to preload the load string (refer to “Preload the load string” on page 88).

88 M10-17318-EN Figure 22. Typical grip installation Preload the load string This procedure eliminates backlash and deflections within the load string which can degrade the integrity of test results, especially when testing at high loads. The procedure involves preloading the entire load string and then hand-tightening all the lock nuts on all the grips and couplings. Even when using self-aligning couplings on the upper grip, it is good practice to preload the lower grip. You will need a rigid specimen that is strong enough to sustain the preload value without breaking. This means a specimen that can sustain a load that is: • 10% above the expected test load, or • the maximum load rating of the weakest component of the load string (grips or load cell) 4 3 1 2

Product Support: www.instron.com whichever is less. For example, if your grips are rated at 1kN, the load cell at 2kN and your expected test load is 500N then you should preload to at least 550N but not more than 1kN. Before inserting the specimen ensure that: • The grips and couplings are installed but the lock nuts are not tightened. • Crosshead travel limits are set (refer to “Set the crosshead limit stops” on page 104). • The value of load in the live display is near zero. If it is not, balance the load (refer to “Balance a transducer configuration” on page 105). • The load limits are set in the software to a value that matches the maximum load capacity of the weakest component in the load string. 1. Install the strong specimen. 2. Increase the load on the load string to the chosen preload value. Caution Do not attempt to increase the load by jogging the crosshead. The collision mitigation feature will stop the crosshead before the system reaches the desired load value. a Start Bluehill® and prepare to run a test using the specifically-designed test method, named Preload Grips. This method is located in the Templates directory within Bluehill®. b Enter values for Rate and Force and start the test. The crosshead drives at the designated rate until it reaches the chosen preload value and the test stops. 3. Hand tighten all the locknuts on the grips and any intermediate couplings. 4. Reduce the load to zero. 5. Remove the specimen. The load string is now preloaded and all the locknuts are tight and should not move during subsequent testing. The system is now ready to test. When you next need to change grips or any other part of the load string, the locknuts will be too tight to loosen by hand. You will need to follow the procedure “Unload the load string” on page 90

90 M10-17318-EN Unload the load string If you have followed the procedure to preload the load string (“Preload the load string” on page 88) you will need to follow this procedure before you can change grips or any or any other part of the load string. The locknuts will be too tight to loosen by hand. 1. Install the strong specimen. 2. Increase the load on the load string to the chosen preload value. Caution Do not attempt to increase the load by jogging the crosshead. The collision mitigation feature will stop the crosshead before the system reaches the desired load value. a Start Bluehill® and prepare to run a test using the specifically-designed test method, named Preload Grips. This method is located in the Templates directory within Bluehill®. b Enter values for Rate and Force and start the test. The crosshead drives at the designated rate until it reaches the chosen preload value and the test stops. 3. Loosen all the locknuts on the grips and any intermediate couplings. 4. Reduce the load to zero. 5. Remove the specimen. The loadstring is now unloaded and all the locknuts are loose so that you can change any component.

Chapter 6 Testing specimens • Testing a sample . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 • Create a new sample. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 • Calibrate a transducer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 • Set the zero displacement point. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 • Crosshead limit stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 • Set the limits for a transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 • Balance a transducer configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 • Stop a test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 • Shut down the system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 • Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Materials testing systems are inherently hazardous. Read the chapter “Risk reduction and safe use” on page 25 before using the testing system. Testing a sample The following two procedures are guidelines for steps that you would typically go through when testing a group of specimens. Some steps include references to more detail in separate sections. These scenarios assume that a test method has already been created that satisfies your testing requirements and provides required test parameters (e.g. specimen dimensions, testing notes) on the test workspace. The two scenarios describe testing with and without an interlock. An interlock is an optional accessory that changes the behavior of the system depending on whether the interlock circuit is open or closed. For example, the door on a protective shield may include an interlock. When the interlock circuit is open (e.g. the

92 M10-17318-EN shield door is open), the circuit is interrupted and the system is either disabled or restricted as defined by the Operator Protection settings. Testing with no interlock This test scenario assumes the system has no accessories with an interlock and that the start test method in Operator Protection settings is set to Frame control (the default). Warnings Set the load frame limit stops to limit crosshead travel, and set adequate transducer limits to ensure the safe operation of the testing system. Set all available limits before using the system to avoid crosshead overtravel, contact between grips and fixtures, overloading any component of the load string, or overtravel of a contacting extensometer. Hazard - do not allow more than one person to operate a testing machine. Operator injury may result if more than one person operates the testing machine. For example, injury can occur if one person moves the crosshead or actuator while the other is working inside the hazard area between the grips or fixtures. Crush hazard - take care when installing or removing a specimen, assembly, structure or load string component. Installation or removal of a specimen, assembly, structure or load string component involves working inside the hazard area between the grips or fixtures. When working in this area, ensure that other personnel cannot operate any of the system controls. Keep clear of the jaws of a grip or fixture at all times. Keep clear of the hazard area between the grips or fixtures during actuator or crosshead movement. Ensure that all actuator or crosshead movements necessary for installation or removal are slow and, where possible, at a low force setting. Flying Debris Hazard - Make sure that test specimens are installed correctly in grips or fixtures in order to eliminate stresses that can cause breakage of grip jaws or fixture components. Incorrect installation of test specimens creates stresses in grip jaws or fixture components that can result in breakage of these components. The high energies involved can cause the broken parts to be projected forcefully some distance from the test area. Install specimens in the center of the grip jaws in line with the load path. Insert specimens into the jaws by at least the amount recommended in your grip documentation. This amount can vary between 66% to 100% insertion depth; refer to supplied instructions for your specific grips. Use any centering and alignment devices provided.

Product Support: www.instron.com Flying Debris Hazard - Brittle specimens may shatter upon failure. The high energies involved in testing can cause broken parts of a specimen to be projected forcefully some distance from the test area. Wear eye protection and use protective shields or screens whenever a risk of injury to operators and observers exists from the failure of a test specimen. Select the correct test area for the test. An incorrectly set test area can cause unanticipated crosshead behavior. Press the Emergency Stop button if the frame moves in an unexpected direction. An incorrectly set test area can cause unanticipated crosshead behavior and create a safety hazard that may damage the specimen or load cell. Verify the test area and test direction before starting a test. 1. Collect all specimens together that will make up the testing sample. 2. Identify each specimen, e.g. by marking. Identifying each specimen helps match it to the appropriate specimen number in the completed sample test report. 3. Start the frame and open the software. The system is in DISABLED mode. 4. Ensure that the crosshead travel limits are set. Refer to “Set the crosshead limit stops” on page 104. 5. Ensure that limits are set for each transducer (displacement, force, strain, and user- defined). Refer to “Set the limits for a transducer” on page 105. 6. Press the UNLOCK button on the frame control panel to transition the system to SET UP mode. The system is now restricted to the Operator Protection settings specified on the Configuration > Frame screen on the Admin tab. 7. In the software, create a new sample file. Refer to “Create a new sample” on page 98 8. Verify that the test area is correct in System Details. Select Frame under Method settings. 9. If necessary, calibrate the transducer configurations required by the test method. Refer to “Calibrate a transducer” on page 99. If the frame was previously off, allow the load cell to warm up for at least 20 minutes to ensure stable readings. 10. Measure the required specimen dimensions for each specimen and enter the values into the appropriate fields in the operator inputs component of the test workspace. 11. Use the jog controls to move the crosshead to its starting position and set zero displacement. Refer to “Set the zero displacement point” on page 103. 12. Balance the Force transducer configuration. Refer to “Balance a transducer configuration” on page 105

94 M10-17318-EN 13. Install the specimen into the grips. Refer to the documentation provided with the grips for details. If the system includes pneumatic grips, refer to “Pneumatic Grips” on page 66. 14. Verify that the specimen is aligned properly in the grips. 15. Balance each of the remaining transducer configurations, e.g. strain. Refer to “Balance a transducer configuration” on page 105 16. Press the UNLOCK button to transition the system to CAUTION mode and then press the START button on the frame control panel to start the test. CAUTION mode remains active for approximately two seconds after the unlock button is released. You must start the test before the system reverts back to SET UP mode. The test will only start if the software displays the test workspace. 17. Upon starting the test, the various components on the test workspace update as the test proceeds. Some components will not update until the test is complete. 18. To stop the test before it completes, press the STOP button on the frame control panel. Warning In an emergency situation, press the large, round, red button on the frame to stop the test immediately and disable the frame. Refer to “Emergency Stop Button” on page 106. 19. After the test is complete, the system transitions to SET UP mode. 20. Remove the specimen/specimen pieces from each grip. If the specimen did not break, use the jog controls to relieve the applied force from the specimen before releasing the grips. 21. Complete any post-test inputs that the test method requires, e.g. final specimen dimensions, specimen notes. 22. If necessary, press the UNLOCK button to transition the system to CAUTION mode and then press the RETURN button on the frame control panel to return the cross- head to its starting position. When the crosshead returns to its starting point, the system transitions to SET UP mode for the next specimen. 23. After all specimens are tested, select Finish sample on the Test tab.

Product Support: www.instron.com Testing with an interlock This test scenario assumes the system has an accessory with an interlock and that the start test method in Operator Protection settings is set to Frame control (the default). Warnings Set the load frame limit stops to limit crosshead travel, and set adequate transducer limits to ensure the safe operation of the testing system. Set all available limits before using the system to avoid crosshead overtravel, contact between grips and fixtures, overloading any component of the load string, or overtravel of a contacting extensometer. Hazard - do not allow more than one person to operate a testing machine. Operator injury may result if more than one person operates the testing machine. For example, injury can occur if one person moves the crosshead or actuator while the other is working inside the hazard area between the grips or fixtures. Crush hazard - take care when installing or removing a specimen, assembly, structure or load string component. Installation or removal of a specimen, assembly, structure or load string component involves working inside the hazard area between the grips or fixtures. When working in this area, ensure that other personnel cannot operate any of the system controls. Keep clear of the jaws of a grip or fixture at all times. Keep clear of the hazard area between the grips or fixtures during actuator or crosshead movement. Ensure that all actuator or crosshead movements necessary for installation or removal are slow and, where possible, at a low force setting. Flying Debris Hazard - Make sure that test specimens are installed correctly in grips or fixtures in order to eliminate stresses that can cause breakage of grip jaws or fixture components. Incorrect installation of test specimens creates stresses in grip jaws or fixture components that can result in breakage of these components. The high energies involved can cause the broken parts to be projected forcefully some distance from the test area. Install specimens in the center of the grip jaws in line with the load path. Insert specimens into the jaws by at least the amount recommended in your grip documentation. This amount can vary between 66% to 100% insertion depth; refer to supplied instructions for your specific grips. Use any centering and alignment devices provided. Flying Debris Hazard - Brittle specimens may shatter upon failure. The high energies involved in testing can cause broken parts of a specimen to be projected forcefully some distance from the test area. Wear eye protection and use protective shields or screens whenever a risk of injury to operators and observers exists from the failure of a test specimen.

96 M10-17318-EN Select the correct test area for the test. An incorrectly set test area can cause unanticipated crosshead behavior. Press the Emergency Stop button if the frame moves in an unexpected direction. An incorrectly set test area can cause unanticipated crosshead behavior and create a safety hazard that may damage the specimen or load cell. Verify the test area and test direction before starting a test. 1. Collect all specimens together that will make up the testing sample. 2. Identify each specimen, e.g. by marking. Identifying each specimen helps match it to the appropriate specimen number in the completed sample test report. 3. Start the frame and open the software. The system is in DISABLED mode. 4. Ensure that the crosshead travel limits are set. Refer to “Set the crosshead limit stops” on page 104. 5. Ensure that limits are set for each transducer (displacement, force, strain, and user- defined). Refer to “Set the limits for a transducer” on page 105. 6. Press the UNLOCK button on the frame control panel to transition the system to one of the following: • SET UP mode. System transitions to this mode if the interlock is open and an operator has access to the test area. The system is now restricted to the Oper- ator Protection settings specified on the Configuration > Frame screen on the Admin tab. If the interlock behavior is set to Disable frame then pressing the UNLOCK button with the interlock open has no effect. You must close the interlock to enable the frame. • CAUTION mode. System transitions to this mode if the interlock is closed and there is no access to the test area. The system can operate up to its full capacity. 7. In the software, create a new sample file. Refer to “Create a new sample” on page 98 8. Verify that the test area is correct in System Details. Select Frame under Method settings. 9. If necessary, calibrate the transducer configurations required by the test method. Refer to “Calibrate a transducer” on page 99. If the frame was previously off, allow the load cell to warm up for at least 20 minutes to ensure stable readings. 10. Measure the required specimen dimensions for each specimen and enter the values into the appropriate fields in the operator inputs component of the test workspace. 11. Use the jog controls to move the crosshead to its starting position and set zero displacement. Refer to “Set the zero displacement point” on page 103.

Product Support: www.instron.com 12. Balance the Force transducer configuration. Refer to “Balance a transducer configuration” on page 105 13. Open the interlock. The system behavior depends upon how the interlock behavior is configured under Operator Protection: • Disable frame option: the system transitions to DISABLED mode when the interlock is open. You must close the interlock to enable the frame and move the crosshead, if necessary. • Allow limited motion option: the system transitions to SET UP mode when the interlock is open. You can use the jog keys to move the crosshead when the interlock is open. The crosshead is limited to the jog rate specified under Operator Protection. 14. Install the specimen into the grips. Refer to the documentation provided with the grips for details. If the system includes pneumatic grips, refer to “Pneumatic Grips” on page 66. 15. Verify that the specimen is aligned properly in the grips. 16. Balance each of the remaining transducer configurations, e.g. strain. Refer to “Balance a transducer configuration” on page 105 17. Close the interlock. The system transitions to CAUTION mode. 18. Press the START button on the frame control panel to start the test The test will only start if the software displays the test workspace. 19. Upon starting the test, the various components on the test workspace update as the test proceeds. Some components will not update until the test is complete. 20. To stop the test before it completes, press the STOP button on the frame control panel. Warning In an emergency situation, press the large, round, red button on the frame to stop the test immediately and disable the frame. Refer to “Emergency Stop Button” on page 106. 21. After the test is complete, the system transitions to CAUTION mode. If the specimen did not break, use the jog controls to relieve the applied force from the specimen before opening the interlock to remove the specimen.

98 M10-17318-EN 22. Open the interlock to remove the specimen pieces from each grip. The system behavior depends upon how the interlock behavior is configured under Operator Protection: • Disable frame option: the system transitions to DISABLED mode when the interlock is open. You must close the interlock to enable the frame and move the crosshead, if necessary. • Allow limited motion option: the system transitions to SET UP mode when the interlock is open. You can use the jog keys to move the crosshead when the interlock is open. The crosshead is limited to the jog rate specified under Operator Protection. 23. Close the interlock. The system transitions to CAUTION mode. 24. Complete any post-test inputs that the test method requires, e.g. final specimen dimensions, specimen notes. 25. If necessary, press the RETURN button on the frame control panel to return the cross- head to its starting position. 26. After all specimens are tested, select Finish sample on the Test tab. Create a new sample To create a sample, you can either select an existing test method that contains the settings and parameters for the test (see below) or create a new method for the sample (refer to the Bluehill® online help and reference). To select an existing method file: 1. Select Test on the Home screen. 2. Under New Sample, select a test method. You can either: • select a method shown under Methods. These are the most recently used method files. • select Browse methods to find a specific method file. The system creates a sample based on the test parameters specified in the method file and advances to the Test tab.

Product Support: www.instron.com The sample is initiated when the system advances to the Test tab. It is not yet saved as a file. The sample will be saved as file upon finishing the sample or when you select the Save button on the Test tab. Calibrate a transducer Automatic calibration of a force or strain transducer Warning Do not adjust the current calibration point value for an automatic calibration without first contacting Instron® Service. Adjusting the calibration point can negatively affect the validity of the data from the transducer. A strain transducer can be an LVDT transducer. If the system identifies the strain transducer as an LVDT transducer, the Calibration point field becomes available for automatic calibration. The calibration point field is intended primarily for Instron® Service and should only be used by the service personnel. Contact Instron® Service for assistance. 1. Select in the console area to open System Details. 2. In the System Settings area, select the icon for the transducer to open the Transducer Settings dialog. 3. Under Settings, select the transducer configuration in the Transducer configuration field. 4. Ensure that Calibration type is set to Automatic. Automatic calibration uses the following basis for the calibration point value: 5. Set the transducer to its zero point. For force, zero point means no load on the system. For strain, zero point means the starting point of the strain transducer (e.g. exten- someter) 6. Select Calibrate. 7. Follow the instructions provided in the Transducer Settings dialog and then select OK to proceed with the calibration. Calibrating... displays in the transducer live display area during calibration. Force 50% of the full-scale load transducer Strain 100% of the full-scale strain transducer

100 M10-17318-EN 8. The calibration was successful if a value displays in the transducer live display area and the transducer icon in System Details is no longer grayed. 9. Close the Transducer Settings dialog. 10. Close System Details. The calibration is saved with the transducer configuration and is restored whenever the transducer configuration is selected. The transducer is now calibrated and ready for testing. The transducer must be associated with a measurement in a method. Verify that the method used for testing includes a measurement that is linked to the transducer configuration for this transducer. Manual calibration During a manual calibration, you apply a measured physical force to the transducer and the system calibrates on the signal that is output as a result of that force. For force calibration, you can hang a measured weight from the load cell. For strain calibration, you can install the extensometer on a specially designed calibration jig to apply a precise deflection to the extensometer. The system only saves the values entered for a manual calibration after there is a successful calibration. If you select a different transducer configuration or close the dialog before calibrating a transducer configuration, the calibration fields revert to the default values for that configuration. Manual calibration of a rationalized force or strain transducer 1. Select in the console area to open System Details. 2. In the System Settings area, select the icon for the transducer to open the Transducer Settings dialog. 3. Under Settings, select the transducer configuration in the Transducer configuration field. 4. Set Calibration type to Manual. 5. Enter a value for the calibration point. This value is the force (for a load cell) or deflec- tion (for an extensometer) that you apply to the transducer during calibration. For example, to calibrate a 100 kN load cell using a 50 kN weight, the full scale value is 100 kN and the calibration point is 50 kN. The range for a valid calibration point value is between: