Zwick_universal_tester_chap_1&_2_&_ intro
Contents
1. 15 OVEIVIEW 0 0 e re eees 21 Technical data 10 Proper use ornnnrnnnnenee 22 Technical details Be Technical data 22 Maximum operational force 27 TC OPSOOHZ Measurement amplifier ed 25 Technical data KREE A 23 Measurement bridge Technical data mse Pr 30 32 Materials testing machine gt un 10 N TC MODCSCC module 2 22 Noise level 17 Meed Me Eege geg a Nominal force 37 Vi leg extensometer a Technical details 7 O Temperature influence 00 uns 28 rements men 35 Operating conditions 35 bauer sn 35 Operating data ype of protection orrravrr ae Materials testing machine 13 V Overview Load cell 0 29 31 Video extensometer TC EXVIDEO 002 Materials testing machine 9 Function description 0000001000 33 TC MODCSCC module uen 21 LIMNAUONS Lin nnnsrvisestdeine 34 Video extensometer use 33 OVEIVIEW 0 0 eee cccccccse essen eecenseeanees 33 Proper USE rrrnrrrrnrnnvnnnnnnvnnvvrenne 34 p System description 000 34 Technical data 34 Permissible torque 28 Power consumption 13 W Proper use Limitations occ n 15 Vater S Load cell oo eee 30 32 Materials testing machine ua 15 TC MODCSCCmodule verne 22 Video extensometer ae 34 R Rated values 13 Requirements for fixing 38 S Serial number plate2. 6 Static limit lateral force 28 Storage temperature 35 Strain gauges 25 Structural requirements 38 System description Zwick technical documentation 01 02 THIndex V2 0 if 62069 0 09 3 HW PZ ZOOZ eco a Environmental and operating conditions Zwick Roell Installation plan The space requirements are listed in the Technical manualunder paragraph Technical data Storing accessories Depending upon the accessories to be stored you should have a lockable storage place Cabinet or similar This furniture hasn t been taken into consideration for the installation plan Why a cabinet that can be locked up Extensometers load cells and physical measurement units such as Vernier gauges micrometers scales are measuring devices and must be well protected against damage Structural requirements The specific loading of the floor for the materials testing machine is listed in the technical data Please note that the height of the room must be approx 20 cm higher than the test machine s maximum height see the respective technical data Requirements for fixing The materials testing machine is normally free standing however some hydraulic testing machines are fixed to the floor Align the machine and pay attention that it stands safely on its own ona level floor 38 Zwick technical documentation 05 04 TUmgeb V3 0 uN 620680 OD 9 HAD EZ FOE G Environmental and operati
3. Setup Maintenance and repairs Tuition on the above is offered by Zwick The test system s user must make sure that the following is observed Due diligence The test system may only be used according to its proper use Only safe tests may be run with the test system The test system may only be used if it is in perfect working order Anything that could impede safety has neither been added nor converted Safety devices have not been manipulated Check all safety devices Safety devices limit switches proximity switches and EMERGENCY OFF button for evident malfunctions Should the test system malfunction in any way further operation is permitted only following consultation with the responsible safety officer If necessary please ask Zwick All safety remarks and warning signs attached to the test system must not be removed and must be legible 10 05 Sicherheit V2 9 Zwick technical documentation i Safety aiim ZWICK Roell hende for the operating personnel Workplace The operator s workplace is in front of the materials testing machine during operation Table p al T Materials testing machine LET eee wee installed by a wall CC ro E E i La Workplace lt H o ie Li CG d ef g 7 Workplace L Dee a TT Recommended minimum distance to walking lanes 5 Materials testing machine setup free S in a room 8 Lateral and rear protection lt w i a g Recommended de
4. D Technical data Order no BTC EXVIDEO 002 This order no for the video extensometer includes a video camera a picture processing software and a PC hardware dongle The technical data for the video camera can be taken from the separate video camera instruction manual System description The measurement system is a digital video camera with a picture processing system The resolution and measurement range can be adapted to the properties of the materials to be tested by a suitable selection of camera lenses The picture of the specimen digitised by the video camera is processed ina PC supported video processor in real time Proper use The video extensometer makes non contact and high resolution tensile and compressive deformation measurements on all types of plastics metals rubber laminates wafers and foils Limitations There is a risk of fogging in a temperature chamber when this extensometer is used in conjunction with Co or LN cooled temperature chamber It may eventually be necessary to wait several minutes before proceeding with the test The temperature range of the temperature chamber is limited to 40 to 120 C when using measurement marks on the specimen being tested Zwick technical documentation 01 04 Tech V2 0 BAN 62088 0 Gg HOU EZ PO L U dO Technical details 13 Zwick Roell Load cell TC LCO200N P01 Technical data Order no BTC LC0200N P01 NMA ET a E 200N Maximum for
5. Zwick Roell er TE Instruction manual for materials testing machines T1 FROOSTN A50 Copyright 2004 Zwick GmbH amp Co D 89079 Ulm Serial number 168336 AB Dossier number 653782 05 04 Ident V3 0 Zwick technical documentation Copyright 2004 Zwick GmbH amp Co D 89079 Uim Contents of the section ZWI C k Roel Materials testing machine Section contents Contents Section sen NL Ea E E S AET 1 Tenne 2 Installation manual seere 3 ag LETE ENE 4 an Reserved for expanded operation tC OPSTDAL 5 vi Reserved for retro fit parts instruction manual 6 Reserved for special user programs ssetnss 7 Pee ENEE 8 Feb 9 Service and maintenance manual rrrnarrrnnernnnrrensnannnsnennnnene 10 Creus ee 11 Reserved for spare parts wear and tear parts lists 12 Certificates Calibration reports r rrrnnrernonnnvrnnvvnnvnnvennnnnnavnnennn 13 Free 14 05 04 Ident V3 0 Zwick technical documentation Copyright 2004 Zwick GmbH amp Co D 89079 Ulm a Use of the instruction manual LWI C k Roel Materials testing machine Reserved These sections could contain the following documents corresponding to your purchased components Section 5 Expanded operation Aimed at the operating personnel and describes the possibilities of operation without a PC Section 6 Retrofit parts is without documents in the initial delivery You can file away the description s o
6. instruction manual Section 2 General In this section you can obtain data important for the materials testing machine and obtain information on our company and its products Document Technical manual Version V3 0 Print date November 2005 All rights reserved Tips remarks and constructive criticism are welcome Please direct these to Zwick GmbH amp Co Technische Dokumentation August Nagel Strake 11 D 89079 Ulm Fax 49 0 7305 200 Zwick technical documentation 05 04 THinhalt V3 0 WIN 62068 0 Gg HAUS PZ POOS N E Zwick Roell mm Proximity switch 13 16 21 W R Warning ans 0000000000n0 13 oo Work Remaining risks c eee 9 On laser light sources N Risk of bumimng 11 Working Risk of frostbite 11 On hydraulic equipment ery A Risk of injury rerrrnrrroorrnorervene 11 On pneumatic equipment G t 0 n ild With electrical equipment 22 Risk of slippage 23 Working area 17 18 Risk of esouashung 18 Workol 45 Risk of trapping parts of the body 11 orkplace Lunde enna Rotating lead screws 17 S Safety Devices rernnnonnnveneevevvnerenesennve 13 16 17 E e EENEG 20 Eege Gees 20 Safety devices E 13 16 Safety measures SE At operation errrrrrrrnnnvrovvevnnne 16 Before switching on 16 Ear protectors rrrorvnnnooooornrr 20 Specimen holders 0000 18
7. Safety notes 16 Safety remarks 0 n aanne0000001n0n0a 13 E PE ET E 21 SBP ee earar N 13 Signal Words sorsooosonnvornnne er 12 Specimen holders 00000010n0000 18 Spring tests eere 19 State of eat ee 29 Supplements A so Symbols Electrical voltage rrinvnnren 11 Laser beam ssrrvrrnnnnnsvrnnvnnenn 11 Risk of buming 0 000aa0000000aaa 11 Risk of frostbite 000 0 1 Risk of injury oreorrrrrvronovvnvnnn 11 Risk of trapping parts of the body n T Tensile tests 18 Transport 6 U Usage Improper use 8 7 Proper use Zwick technical documentation 01 02 Silndex V2 0 iin 62000 0 00 9 HAWS PZ 7002 O Budon Zwick Roell say 24 Cleaning and disposal Please adhere to the legal obligations for avoiding waste as well as disposing and recycling it Water pollutants must not pollute the earth and they must not gain access to the sewer system Examples of water contaminating substances Lubricants and oils Hydraulic oils Coolants Cleansing fluids containing solvents Collect these pollutants in suitable containers Transport dispose of etc pollutants in an environmentally safe manner Please take note of remarks on disposal on all applicable and relevant safety data sheets The enclosed safety data sheets are to be found in section 13 Certificates Calibration reports Dispose of all replacement parts sa
8. Serial number Year of construction Nominal value of the materials testing machine 6 Zwick technical documentation 05 04 THInhalt V3 0 WIN 62000 G OD HAWS OZ PODZ O buido LWI C k Roel sn AA testing machine Your safety This technical manual should make it easier for you to get acquainted with the machine and to use its range of applications This technical manual contains important remarks on transporting the materials testing machine correctly safely and economically and on installing dismantling and storing it Pay attention to these remarks They make it possible to increase the reliability and life span of the machine The instruction manual must be read and used by all persons authorised to work at and with the machine The entire instruction manuals must always be available at the test machine s installation site National regulations Supplement the technical manual with instructions from national regulations on accident prevention and environmental protection Observe and adhere to Valid binding regulations on accident prevention Recognised technical rules for safety and correct working Regulations on safety and health protection when preparing and using working means Instruction manuals Zwick technical documentation 05 04 THinhalt V3 0 WIN 62069 G 0D 8 HOUA PMZ RO O Oudon Document 2 Zwick J Roell Materials testing machine 13 Materials testing machine s
9. Service and maintenance Please note the following points to help avoiding serious injuries or machine damage when carrying out maintenance work on the test system These topics are listed for each component in section 10 Ser vice and maintenance manual Adhere to prescribed Inspection and maintenance intervals Please pay attention to the maintenance and service manuals Only use the indicated operating fuels and lubricants etc Use original Zwick spare parts only Before carrying out any maintenance or repair work pO Switch the mains supply off via the main switch Secure the main o N switch against inadvertant switching on with a padlock Unplug the mains plug or disconnect the mains connection Wait until all parts of the materials testing machine that may perhaps be touched E g motor temperature chamber etc have cooled down to ambient temperature Check the following after maintenance or repair work Have all threaded connections been screwed tight again Have container lids covers sieves or filters that have been removed been replaced again Have all materials tools equipment etc that were required for maintenance and repair work been removed from the materials testing machine s working area Have any liquids that may have leaked been removed Are all safety devices such as limit switches proximity switches and the materials testing machine s EMERGENCY OFF button in perfect working
10. These are amongst others Instructing the employees Proper use of transport means and lifting tackle Personal safety equipment Transport of the test system and accessories is described in chapter Transport in the installation manual Zwick does not accept any liability whatever for the use of any types of transport other than that described in this chapter Zwick technical documentation 10 05 Sicherheit V2 9 WAN 62068 0 Gg HAWES PWZ OO O Kado Zwick Roell Zwick technical documentation 04 03 Silnhalt V2 5 UAN 620860 0 Gg HUD ORAZ E007 O N LAdE Zwick Roell ti EEN Materials testing machine s instruction manual Section 1 General This section contains information that is important for maintenance and service for your materials testing machine and the accessories The safety manual must be read and used by all persons authorised to work at and with the machine Document Safety manual Output V2 9 Print date November 2005 All rights reserved Tips remarks and constructive criticism are welcome Please direct these to Zwick GmbH amp Co Technical documentation August Nagel Stra e 11 D 89079 Ulm Fax 49 0 7305 200 2 Zwick technical documentation 04 03 Silnhalt V2 5 Wf 620060 00 9 HW ENZ 00Z K Product description ZWI ck Roell Materials testing machine Product description Zwick materials testing machines can be
11. air The materials testing machine does not require any compressed air However some of the optional test tools used in conjunction with the machines require compressed air Operating pressure mm nmmsaroroovoosvrveee ee EE 6 to 10 bar with recommend oil to EE EE ISO 3448 VT Leinster Ee 32 mm s filtered dehumidified and oiled Water Gases The materials testing machines require neither water nor gas supplies An exception is hydraulically operated testing machines and some optional auxiliary equipment devices which need water and gas for cooling Please ensure sufficient ventilation for emission of gases Zwick technical documentation 37 Copyright 2002 Zwick GmbH amp Co D 89079 Uim Zwick Roell Index Index Heating up Sci E ee 17 Humidity Fe OO A ET Identification raroorooorrooorooooorosorernvrnvnnnreneneesenere 6 Materials testing machine ccsccscesceeee 19 ke Par 30 29 Ambient temperature rmrrrrrnnnorrevvvasersrrnnenrennnnner 35 Materials testing machine 47 TC MODCSCC module orrrnnvnvoorrerrnnvnvrernvrnn 22 C Installation plan oororrrrrrororrorrorvnnvnvnnevnrvennnnnnnnne 38 Calibration cee 5 Characteristic value ccccccccsccsssessssscssscecsoesseces 2 L Compressed air rrnvnnvovvnnnnnsssvenrersennensnnnnnnnnnnesne 37 Leakage current monitoring rrrnoorrrrnvnorernnunonsvnr 13 Computer Systems EEN S
12. com Indentec Hardness Testing Machines Ltd no DKD K 13201 Certified to 180 9001 Zwick projects Leg MA ZwickService Certified to ISO 9001 and EMAS DKD accredited to ISOMEC 17025 DKD accredited to ISO IEC 17025 zno DKD K 23301 Lye Valley Industrial Estate Bromley Street Lye Stourbridge West Midlands DY9 8HX Great Britain TA UKAS accredited to ISO IEC 17025 Tei 44 1384 896949 eMail mail indentec demon co u Internet http weww indentec demon Acmel Labo 10 12 Rue de l Orme Saint Germain F 91160 Champlan Tel 33 1697109595 Fax 33169100186 eMail info acmel fr Intemet http www acmellabo com kino 0232 co uk 16 Fax 44 1568 612626 at I Certified to 150 9001 sl H UKAS accredited to ISO IEC 17025 ER AZLA accredite a no 1897 04 Zwick technical documentation no 01687 05 04 Ident V3 0 WN 620900 OD 9 HERD PZ OS O KAUdo a Use of the instruction manual ZWI ck Roell Materials testing machine The instruction manual is structured to the same repetitive pattern The single chapters are compiled in the sequence Materials testing machine Load cell Extensometer Power pack hydraulic pneumatic Testtools Environmental test device Test accessories Exception is dismantling See the example on this page Some parts of the manual may not be included in your manual as the manuals are supplied for that equipment as per the
13. materials testing machine T1 FROO5TN A50 Serial number 168336 AB Dossier number 653782 Zwick technical documentation Zwick Roell este List of contents General ee NE 2 ER E UE 7 Materials testing machine T1 FROOSTN A50 rrrrnvvrverreerrvrrrnvrvrnnnsnrnnnnennennnnnnenennnenere 9 Measurement module TC MODCSCC nline He 21 EL sc vests EE EEE 23 Load cell function description oornovnrsnnnneer FE EE 25 Load cell TC LCOO20N P01 rrrererorrrrrervnnnansenvennvnnannenen EEE 29 Load cell TC LCO200N P01 rervvrvnnrvrrnnnnnerrvornnvenrnnn EE RE E 31 Video extensometer TC EXVIDEO 002 rrrrrrnnnnnrnvnnvnnnrnnnnnnnnvvnnnnnnnnunennnvnnnnnnenvnnnnnnee 33 Environmental conditions and operating conditions arorrrrorovnnnnnnvnvevenvvernnnenneneeee 35 La ON EEE EE EE N E 39 Copyright 2004 Zwick GmbH amp Co D 89079 Ulm 05 04 THinhalt V3 0 Zwick technical documentation 3 Copyright 2004 Zwick GmbH amp Co D 89079 Ulm 05 04 THinhalt V3 0 x Test standards 2 Zwick Roell Materials testing machine i EE Ce Em Applied standards The test standards relevant for materials testing machines are listed in the Declaration of conformity or the Manufacturer s declaration Remarks on product and manufacturer s liability The accuracy limits stated in our specification s order confirmation are not infinitely valid Regular checks must be made depending upon the mea
14. measurement value Test data recording rate 2 0 0 0 n switchable via software maximal 500 Hz Resolution at 100 nominal measurement value at 500 Hz test data recording rate EE 162000 points at 50 Hz test data recording rate 2 0 0 0 ccc ceecenseeee cea eeeeeenees 297000 points Type of measurement input 0 sersreoronersvevvrnnnerrrrrsrnnneeersrernnnn Differential input Zero point temperature dependent lt 5 104 K of nominal measurement value Maximum linearity error eee 0 01 of measurement end value Temperature range E ee 10 to 45 C Dimensions Height 30 mm Width 108 mm Depth 135 mm Connectable sensors Strain gauge measurement bridges 0 uvsnrernnnnnnsenesene Full bridge Type of connection rrrrrrrrnrrrnvrrnrrennrnnnrn 4 and 6 lead technology Nominal characteristic value sensitivity mssrrnrnesvrnensrvvessene 2 mVIN Maximum characteristic value tolerence e 2 Permissible strain gauge bridge resistance een 100 to 1 200 Q Sensor supply voltage cccc eee tne ne naa eeeentaeeeeens 10 V DC Proper use The TC MODCSCC module is foreseen for connecting strain gauge full bridge sensors This module enables you to operate strain gauge load cells and also other strain gauge measurement bridge sensors in 4 and 6 lead technology Improper use Inductive systems cannot be operated by the TC MODCSCC module Zwick technical documentation 01 02 Tec
15. 7 Limitation oo ec cc ceeescessceeecececesscsesesrseseseees 15 Connection of computer systems 000000000s00s 37 Limitations Video extensometer 000nnnnosnneesoeoeroese000anns 34 D Load Cs EEN 25 K Cable guide rrrrrorrrrnnnnnoronorsnrnsnnvvvnenennereveensne 26 Definition age Characteristic value asnorrnnnvnnnvnvnnnnnvnnnnnnnnnn 28 alaa value En z Force at break rrrroorrnvrvovovonnrnerrnnvnnrnnsssrennnn 27 Data MEMON ene 25 Limit lateral force nnneeneneeeneeneneeenaeosrennna 28 Definiti di PEN haracteristcs 27 Maximum operational force svvonnnnrrnrrrnnnn 27 F a Hae e sd aieeaa 27 Nominal force o on eg 27 iia 35 Operational force cccceccccseccssssesssssosecececeseee 27 unction gestoen En Permissible torque smnornvnvnnnnrr EEE 28 sell era E E ml Static limit lateral force oossssrsrrissrrsvtrssien 28 aaa Temperature influence rornvonnnnns Gs 28 O ne 27 Torque og perationa Cl EEE aS NTT TETT TEEN TETT TETTE SHEERS ECE SERED Permissible torque EE 28 Plug CASING orooonrvrvrvernnveseosonnnnavenevensvnnennsee 25 E Static limit lateral force oosrvrrvrorsororersenennnn 28 Electromagnetic fields 0 36 Temperature influence EA 28 Electronic rating plate an 12 Load cell TC LC0020N P01 n Improper USE rrrrrnennrnnonnovnnvvevernnnenneneenevennn 30 Envir
16. 9 Proper use Our materials testing machines can be used to determine properties on test pieces such as bars shaped elements components and etc The testing machines apply mechanical loading to the test piece in the form of continuous increasing pulsating or cyclic tests through an electrical or hydraulic drive system The test pieces are loaded via the test quantities force moment or deformation with defined values time sequence and frequency The materials are undergo destructive or non destructive tests depending upon the testing machine and test method used The classical types of test are tensile compression flexure and torsion test on the basis of a variety of test standards Please make sure that the specimen and specimen mountings used can neither be propelled away from the testing machine nor can drop to the floor when under load or in the case of failure This could lead to damge to test equipment and to injury to persons in the vicinity of the machine The instruction manual is constructed in modular form Thus observe section 2 Technical manual This section describes the proper use of each component Inspection and maintenance transport installation and operating instructions belong to the proper use of the test system Zwick technical documentation Copyright 2005 Zwick GmbH 2 99079 Uim Zwick J Roel Remeining risks iN 10 05 Sicherheit V2 9 Remaining risks Remaining risks m
17. D 89079 Uim 10 05 Sicherheit V2 9 Safety AN Safety measures and notes Spring tests Danger of trapping parts of the body Danger of springs or parts thereof being propelled away from the test equipment Springs or spring components must neither move crosswise with respect to the test axis nor may they slip sideways Use an anti buckle device and a shape fitting specimen mounting for tests on compression springs A safety device is necessary for the test area depending upon the type of test s Insert the specimen Potential danger through incorrectly clamped or placed specimen Parts of the specimen or jaw inserts could be propelled away from the testing system Check only correctly clamped insertedspecimen Off centre testing may only be carried out with special tools Compression test devices may have a centring groove or a guide mandrel The specimen must then either be seated in the groove or secured against being propelled away from the test device by the mandrel Open the grips Potential danger through incorrectly clamped or placed specimen Parts of the specimen or jaw inserts could be propelled away from the testing system Never ever open specimen holders that are under load Any load must be removed from the clamped specimen before opening the specimen holders Zwick technical documentation 1 9 Copyright 2005 Zwick GmbH amp Co D 89079 Ulm LWI ck Roell E measures and notes AN At
18. If potential sources of danger exist as for example defined by DIN 51233 Danger Caused by Risk of injury by specimen Them being propelled away from the machine or their constituent parts or falling to the floor Danger of squashing by specimen holders Specimen holders that are not manually operated e g hydraulic pneumatic electrical with closing speeds higher than 10 mm s Risk of injury through jaw inserts Those made of hardened steel or other brittle materials e g glass ceramic etc Danger of squashing parts ofthe body At speeds above 10 mm s around the crosshead When using temperature chambers Risk of injury by very hot or very cold parts and surfaces ms e Zwick technical documentation 06 02 Verwend V2 1 d H EK 7 HUS NOMA Z007 O M UAdO Zwick Roell Technical details 1 Materials testing machine 5 kN 14 Zwick technical documentation 04 03 230V Tech V2 7 UN 62088 C OD 8 HAWS OZ CO O udon Zwick Roell eme Electronic rating plate a All of a materials testing machine e important data such as the nominal Tam force of the load application device is saved to an electronic rating plate DYP This materials testing machine is thus capable of determining its own configuration Zwick technical documentation 04 03 Tech V2 7 WIN 82000 0 09 9 HAUO PZ E007 O Zwick Roell eme z Technical data Type Order no BT1 FROOSTN A50 Load fram
19. Static limit lateral force Fain N Permissible torque torque M in Nm Characteristic value C in mV V Temperature influence to the characteristic value per 10 K TK Temperature influence to the zero signal per 10 K 0 Function description testControl Load cell Greatest force that may be applied at the load cell s force introduction point vertical to the measurement axis without any significant changes to the load cell s measurement properties being detectable when using the load cell again up to its nominal force This is also valid at simultaneous loading of the load cell to nominal force Permissible torque about the load cell s measurement axis without any significant changes to the load cell s measurement properties being detectable when using the load cell again up to its nominal force This is also valid at simultaneous loadingof the load cell to nominal force The output signal at nominal force is diminished by the pre load signal Relative change to the characteristic value of the load cell owing to a change in the temperature by 10 k within a defined temperature range after setting the stationary states Changes to the load cell s zero signal related to the characteristic value due to a temperature drift by 10 K within a defined temperature range after setting the stationary states WIN 82060 0 OD 9 HUE OZ OO O K Zwick technical documentation 04 02 Ffunk V2 1 Function description t
20. TION SE e 12 SWitCh off meme 21 DANGER rirrrrrrvronervrrnervnrsvnsesvenn RNA 12 Maintence work WARNING rrirvrrrrrrrvrvrreserernrorseveseesenenn 12 Environmental protection 24 Disposal r ssvrornornnnovnvernvnrnvenennnnnnrrenrveenne 24 Minimum distance 15 Disposal in an environmentally safe manner 24 Document rrororvovervrnnnorensorsvnnnnvennvevenneene 2 N National regulations 5 E Noise level 20 Ear protectors eege sea evans 20 EMERGENCY OFF button 13 16 21 H Extensometer TC EXOWMST H01 Oil sumps 14 Safe operation orrnuvrennvner 22 Open the grips 19 Operate 16 F Operation 13 Flexure tests 18 P H Padock 21 Heat eeornorrnrr 20 Perfect working order 13 HOSES 2 0 0 eee 23 Personne 13 Hydraulic systems 14 Personnels responsibilities 13 Hydraulics 23 Pneumatics 00 0000 23 Preventive measures 10 Print date 0 00 sd Insert the specimen 19 Properuse 0 000 00000000n 7 Inspection intervals 21 Protection Instructing operating personnel 13 Clothing 00068 14 01 02 Silndex V2 0 Zwick technical documentation gl 5 Copyright 2004 Zwick GmbH amp Co D 89079 Ulm Dossier Wi ck Roell Materials testing machine Section 2 05 04 THinhalt V3 0 Instruction manual Technical manual for the
21. achines Materials testing Physical measurement units foe machine connection via PC Load cell ch HEN R M a ea testControl Vernier gauge electronics Extensometer fe md Micrometer Testtool REN 4 H Thickness E measurement EIS H DES device N L pg T Cross a sectional area monitor Safety device ay Scales Temperature chamber wt i p Printer Network LAN Laboratory file server HEN lener NE l Zwick technical documentation 19 lmetsi star Fa eanan ien Copyright 2002 Zwick GmbH amp Co D 89079 Uim Zwick Roell To Monee eee 3 Measurement module TC MODCSCC Overview T Screw fixing ax i Sensor or test data recorder 25 pin _ sub D pin plug I Screw fixing f 96 Pin module bus plug The TC MODCSCC module is the link between a test data recorder with a strain gauge measurement bridge e g a strain gauge load cell and the testControl electronics 01 02 Tech V2 0 Zwick technical documentation 21 Copyright 2002 Zwick GmbH amp Co D 09079 Uim Zwick Roel mar TC OP500HZ Option TC OP500HZ This option enables you to switch the transmission rate from 100 Hz to 500 Hz Switching can be made in a test program at the PC only Technical data Order no BTC OP500HZ Transmission rate 100 Hz or 500 Hz Software switching 01 02 Tech V2 0 Zwick technical docu
22. achines constitute the basic unit for testing a range of materials The load frame consists as standard of two guide profiles with integrated play free ball lead screws a fixed lower and a moveable central crosshead as well as a head plate The mechanical drive system is to be found in the base A bellows cover integrated in the guide profile protects lead screws and guide even if there is an extremely large amount of fibrous remains fragments and dust T meer er et mm rm mm rm ee uL The central mounting on the crossheads serves to mount test tools or load cells The materials testing machine s test area can be height adjusted by using the support profiles recen ad t Proper use The materials testing machine is concipated for quasi static loading with increasing pulsating or cyclic tests through an electro mechanical drive system It has been designed for tensile compression and flexure tests see under EEC conformity declaration Limitation The materials testing machine is not suitable for tests On elastic specimen such as elastomers springs or similar materials where the actual test load is 50 greater than the machine s nominal force 06 02 Verwend V2 1 Zwick technical documentation 4 5 Copyright 2002 Zwick GmbH amp Co D 89079 Uim Technical details LWI ck Roell Materials testing machine 5 kN 06 02 Verwend V2 1 Should one or more of these sources of dang
23. ation should you have any enquiries 05 04 Ident V3 0 Zwick technical documentation Copyright 2004 Zwick GmbH amp Co D 89079 Utm Zwick Roell Zwick Series Electro mechanical materials testing machines and accessories Test software Macro hardness tester Plastics testers Melt index measurement devices Pendulum impact testers up to 750 J Toni Technik Baustoffprilfsysteme GmbH Servo hydraulic testing machines Automated specimen preparation devices Chronometers Devices for determining hydration heat Complete laboratories Service and refurbishment of test machines 05 04 Ident V3 0 Description of the company Materials testing machine Manufacturing companies Zwick Roell AG Zwick GmbH amp Co Zwick projects Automated test systems magnet test devices Materials testing machines for loads greater than 250 kN Customised testing systems High velocity testing machines Servo hydraulic testing machines Indentec Hardness Testing Machines Ltd Rockwell hardness testers Vickers hardness testers Brinell hardness testers Zwick technical documentation ZwickService Installation Maintenance Accredited calibration Spare parts supply Retrofits Refurbishment Used machines Tuition Tests ordered bya customer Acmel Labo Building materials test equipment Devices for testing cement and mortar Copyright 2003 Zwick Gm
24. ay be present in for example the following cases For examples also see DIN 51233 Using hardened or ceramic jaw inserts without protection against shattered parts Danger of trapping fingers etc when opening and closing specimen holders which are electrically hydraulically or pneumatically operated Specimen or parts of specimen that are or can be propelled away from the test system or fall to the ground with high energy absorption and resilience owing to the type of loading and the propertires of the specimen i e Springs Ropes Belting Basically we stipulate that the user is well versed in the use of the test system We offer a range of safety devices that are aimed at providing protection for the user and for the vicinity of the test equipment We stipulate the use of a safety device with electrical interlocking for the test area depending upon the components and applications to be employed by and with the test system In this case the maximum drive speed is limited to 600 mm min and the test load is limited to the set preselections in verification operation These limits apply when the safety door is open Section 4 Operator manual explains the verification and test operation in more detail In addition inching operation has been realised at the testControl electronics The test itself is run only if the safety door is closed and interlocked The speed limit of 600 mm min for opening and closing specimen h
25. bH amp Co D 89079 Uim Zwick J Roell seer testing machine Instruction manual Section 1 Safety manual for the materials testing machine T1 FROO5TN A50 Serial number 168336 AB Dossier number 653782 04 03 Silnhalt V2 5 Zwick technical documentation Copyright 2003 Zwick GmbH amp Co D 80079 Uim Zwick Roell erd beg List of contents LUTT NNN se 3 Fa ek UE Le EE NE SE NE eai 5 USI geet A TAS gt eg EEE cee 5 POT 7 MGE LEG 8 RENSKE LJ 9 Checks and preventive measures NENNEN NR ENNER ENNER Ne 10 Symbols and signal words s ssseessoosssosesoesssonesssssesssssssoesreoosessesocssseoessssesenseseesesesssss 11 Symbols on the test systems rrrrrrnnnnrrnnennrrnnnernnnnnnnnnnrnvennnnnrnenvnrnnnannnennennuennannnnneeee 11 Signal words in the instruction manual 12 ELELLA EEE E S E 13 Ge Le TE 13 WEE 15 Safety measures and notes ivi cesisissesecevsiessevesonsccnsssisisssasivienssevscssciencscceusseusssassscnssenessaents 16 PENE MINN 16 Me 16 At Service and maintenance rrarnnnnnnnvrnnernunennnennnrvnnnnnnnnnennnnnnnnnnnennsvnesnnnsennnennnen 21 When working with electrical equipment EE 22 When working on laser light sources rrrrrrrnrnrrorranrrnanernnvnnnnvrnnavnnennnsanevennvennesennneee 22 When working on hydraulic and pneumatic equipment 0000000000nnna0n0000raeessenessnenns 23 ean and CASO NEE 24 Il ie 25 04 03 Silnhalt V2 5 Zwick technical documentati
26. ce to be used Fg ERT 120 of From ltr e E ER pas 150 of F rom Force at break Ee ER EEE gt 300 of From Static permissible limit and transverse force sorte CE 10 OF Fire Nominal measurement path 0 1 mm Maximum temperature influence on the zero signal TK t 0 05 F 10 K sl SEH Maximum temperature influence on the characteristic value TK t 0 05 F 10 K fn ME Measurement range initial value nea grade 1 0 4 of nominal value 0 8 N TI grade 0 5 2 0 of nominal value 4N Lo Temperature range 20 60 C ae Type of protection 1P42 Model KAP Z Dimensions E Height aaeeea 86 mm WIO rn 42 mm Ee 14 mm Mounting studs O 8 mm Weight 0 3 kg Proper use This load cell is designed for measuring static and dynamic tensile and compression forces It must be operated in the direction of the test axis and to its nominal force whilst adhering to the conditions as contained under the technical data Improper use Load cells are precision measurement devices and as such should be treated with the utmost care during transport and at assembly They could become irreparably damaged if subjected to shocks and or knocks 32 Zwick technical documentation 01 02 Tech V2 0 un 62068 0 09 T HERDO HPMZ 2002 O KUA Zwick Roell Technical details Load cell TC LCO020N P01 Technical data Order no Nominal force F pom ssmiosovmssmmss
27. configuration of your materials testing machine Some chapters don t require a detailed description for certain parts The next diagram shows how a section in the instruction manual is compiled using the installation manual for a materials testing machine with hydraulic power pack test tools extensometer and temperature chamber as an example Installation manual Safety Sequence of the chapter Installation Erection Materials testing machine Load cell Extensometer Hydraulic power pack Installa Hydraulic grips Ce SE Environmental test device Transport Test accessories Initial commissioning Sequence of the chapter Dismantling Environmental test device Hydraulic power pack Extensometer Storage Load cell Materials testing machine Dismantling 6 Zwick technical documentation 05 04 Ident V3 0 UN 62088 0 og HAUD PMZ KO O M UAdOI e Use of the instruction manual Zwi ck Roel l Materials testing machine Should you resell your materials testing machine you must also provide your customer with the instruction manual The complete instruction manual is an integral part of the materials testing machine Instruction manual s structure Read through this short introduction and you ll be able to find the theme that interests you more quickly as this introduction informs you where and how you can find your way The instruction manual is split into different categories Important for e
28. converted to a digital signal by the related measurement electronics and is then evaluated by a picture processing program on the PC 01 04 Tech V2 0 Zwick technical documentation 33 Copyright 2004 Zwick GmbH amp Co D 89079 Uim Zwick Roell a 0 05 04 TUmgeb V3 0 Environmental and operating conditions Environmental conditions and operating conditions Our materials testing machines and testers are designed for use in atmospheres that are not an explosion risk Please note that the user accepts liability to choose a safe installation site Explosion protection guidelines also require that the explosion hazard and thus the resulting zoning must be taken into consideration The following conditions must exist at the site of installation to enable reproducible and exact results to be obtained Otherwise the measurement results could be negatively influenced Mains Voltage fluctuations EEE NN lt 10 related to the nominal voltage connection as offered Short term interference mmmmmrrnnnnnnnennrrenrnnerrnnnnvnnnsnereennrssennnnnvvnnnnsnnnnneeeree lt 20 ms Frequency 1 related to the nominal frequency as per our offer Protective earthing smmmmmrrernnrnrnsnnoerrrssersrnnnnnvnnnneneesn Earth resistance lt Q Suitable voltage stabilisators are required if strongly fluctuating mains voltages are to be reckoned with Temperature Permissible range for Ambient temp
29. e Test load intensile compression mssrvererrrrssserseer 5 KN Load frame heat 1 299 mm Overall height 0 0 1 545 to 2 114 mm Load frame width eerrrrrrrrrnnvren eee aeetnsteees 680 mm Overall wd 856 mm Load frame depth cc0c000 avvvvvvvevvveen 256 mm Overall dentin 650 mm Weight With electronics console 150 kg With typical accessories approx 180 kg Space requirements Pure contact area 106 cm Load frame area 000 aanai0a00an0 5 564 cm Specific floor loading Related to the typical accessories 1 70 kg cm With 50 safety 0 0 i 2 55 kg cm Floor loading Related to the typical accessories 0 03 kg cm With 50 safety 0 0 0 0 0 05 kg cm Testarea wd 440 mm Height of the lower test area WO ACCESSONIES rnrrrrrrrrrrrrrrvrnsvorssnrnrnnnnvenvrseenne 1 058 mm Height of the upper test area w o accessories Crosshead is required 1 034mm PUST EE RAL 7011 and RAL 7038 Ambient temperature rrrnnnonnrrrnrvrrvsnnrnvennr 10 to 35 C Humidity non dewing 00000enesnoneeoeernnrsereeoeen 20 to 90 Ge Noise level rrrrrvrrrrrrerrnovnvrresnvsverevsvvnsesnennevernnen 67 dB A Drive system Crosshead speed 0 0005 to 3 000 mm min Accuracy of the set SPR vane 0 03 of Von Drive system s travel resolution umn 0 041 um Positioning repetition accuracy lw lt 1 0 um Operator s workp
30. er exist owing to the the testing machine s equipment or setup a suitable safety device e g safety door shield etc must be installed The safety device is used to protect the operator and the vicinity Therefore the function of the safety device must never be deactivated Improper use Materials testing machines must not be put to use for any kind of applications whatsoever that constitute potential sources of danger for persons and for the environment Emissions Heating up The motor temperature can reach 80 C when performing cyclic tests Continuous testing Free from vibrations Vibrations and jolts at specimen break are dependent upon the material tested and on the test arrangement Noise level The materials testing machine s noise level is listed in the technical data A loud noise can be generated at specimen failure specimen break We recommend the use of ear protectors for such tests Zwick technical documentation 4 7 Copyright E 2002 Zweck GmbH amp Co D 29079 Lim 7 Technical details 2 LWI ck Roell Materials testing machine 5 kN 3 i Accessories The materials testing machine can be used with a wide range of accessories The system elements and accessories listed here are only a part of the Zwick spectrum of products You can direct any enquiries you may have on the Zwick range of products to your local representative or direct to Zwick in Ulm Einsingen Germany Accessories for Zwick test m
31. er for a device with the signal words as indicated below These functions may only by carried out by trained operating personnel with due care and diligence DANGER Indicates an imminently hazardous situation Which if not avoided could result in serious injury Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury Possible hazardous situations at which the test system or an object in the vicinity could become damaged Safety remarks with the signal word DANGER or WARNING may also contain hazards for test systems accessories and the environment Zwick technical documentation 10 05 Sicherheit V2 9 6068 0 OD 8 HAWO MZ GO Q 1BUAdoD Zwick Roell eie Furthermore each of our materials testing machines is equipped with an EMERGENCY OFF button The safety device is used to protect the operator and the vicinity Never ever shut down or override the functions of safety devices Checks and preventive measures The following checks and preventive measures must be carried out inde pendent of your running checks for any evident deficiencies Electrical equipment and systems should be checked regularly at least every 4 years for proper functioning BGV A3 by qualified and competent electricians Please make regular visual checks of all hydraulic hoses They must be replaced immediately if any damage is detected According to DIN 20066 fluid technology h
32. er supply E lt 16A Mains output AR Se GS CEE 7 Schuko lo ol Voltage asnaesaecneesnecanecs 230 V 1PH N PE Bas Mains dr 15 Maximum loading ee 1 kW Leakage current monitoring The materials testing machine is works equipped with interference suppression filters EC laws Interference suppression filters have leakage current to earth This current is monitored by your installed leakage current monitoring devices FI circuit breaker A single materials testing machine doesn t trip a leakage current monitoring with 30 mA Should your power supply be subjected to heavy interference or if several materials testing machines are operated on one common FI circuit breaker the sum of leakage currents could trip the FI circuit breaker You can help yourself by Running one materials testing machine on one FI circuit breaker or Use an earth leakage circuit breaker with a higher response threshold if this is permitted or If your national laws and regulations or works regulations allow it then don t use an FI circuit breaker or Use a DC isolated series transformer such as our BTC ACTRAFO 230 for example 04 03 230V_Tech V2 7 Zwick technical documentation 13 Copyright 2002 Zwick GmbH amp Co D 89079 Ulm m Technical details z ZWI ck Roell Materials testing machine 5 KN Function description The materials testing machine s load frame and the electronic measurement and control unit of the testControl m
33. erature rrrrrnnnoorororrnnvennnre 10 C to 35 C Permissible ambient temperature drift GUNNO ERT EE IK Humidity non dewing rrrrrrnnnrrrrrnnnnrrrnrrnnnerennvvnnvrrnnennsrrrenennnnenerenvnne 20 to 90 Transport and storage temperature rrrrrnrrrrrrrnrnnrnrrrvrvrvnnnnsnrerene 25 C to 55 C Please make sure of sufficient ventilation You must place a de humidifying agent to the materials testing machine if it s to be stored for a lengthy period of time System operation emits heat depending upon the performance Please take measures to ensure sufficient heat dissipation Type of protection Corresponds to IP32 To EN 60529 The electronics is protected against Solid foreign bodies with a diameter greater than 2 5 mm Dripping water if the casing is inclined up to 15 Zwick technical documentation SECH a Environmental and operating conditions e Zwick Roell Copyright 2004 Zwick GmbH amp Co D 89079 Utm Ly Li y ra 277 05 04 TUmgeb V3 0 Connection of computer systems Peripherals Devices connected to the materials testing machine must be within the radio interference limits Interference free operation is only possible if these devices are plugged into the materials testing machine s mains output sockets or connected to the same phase plug as that for the materials testing machine Whereby all cables should be as short as possible Compressed
34. esssissese essensen ee Maximum force to be used Fg visiirien jaa Limit force F svss1visiri1riissritsoesressresrssrserenriisnrineraeens nr Force at break Fp mmsmmmmummemuises EE Static permissible limit and transverse force Nominal measurement path Maximum temperature influence on the zero signal TK Maximum temperature influence on the characteristic value TK Measurement range initial value grade 1 0 4 of nominal value grade 0 5 2 0 of nominal value Temperature range Type of protection Dimensions Height Width Mounting studs Weight Proper use BTC LC0020N P01 110 of F rom Ss 150 of From 2500 of F rom lt 10 of From ERE 0 4 mm 0 1 Fy10K 0 1 F 10K 0 08 N 0 4N 20 60 C P42 KAP Z 81 mm 60 mm 13 mm O 8 mm 0 3 kg This load cell is designed for measuring static and dynamic tensile and compression forces It must be operated in the direction of the test axis and to its nominal force whilst adhering to the conditions as contained under the technical data Improper use Load cells are precision measurement devices and as such should be treated with the utmost care during transport and at assembly They could become irreparably damaged if subjected to shocks and or knocks Zwick technical documentation 01 02 Tech V2 0 UN 620890 OD 3 HAUD PZ 7007 O K Zwick Roell
35. estControl Zwick f Roell Load cell Cable guide As the respective test requirements are so different the followingrequested recommendations are to be observed and the corresponding measures are to be taken 1 The load cell s measurement cable must not be subjected to any mechanical stressingor stretching at all over the entire crosshead travel gt Feed the cable so that there is always sufficient available to avoid the above 2 The load cell data cable must not be fed together with the motor s connection leads nor direct on the motor gt Feed the load cell data cable out of the cable duct above the motor 3 Specimen remains must not damage any part of the load cell measuring cable at specimen break gt Place the cable so that it is correspondingly protected AS Cable clamp Moving crosshead Load cell H l Gable loop gt Reserve for the crosshead s entire travel Ap CT Feed the cable from the side testControl electronics System overview rear view 26 Zwick technical documentation 04 02 Ffunk V2 1 WIN BZ06E O CD 9 HAWES PWZ TODT O Wudoo Zwick Roell Technical details TC OP500HZ Zwick technical documentation 01 02 Tech V2 0 UM 620800 OD THRO MONAT ZOOZ N Mdor Zwick Roell emm 22 Technical data Order no BTC MODCSCC Measurement range 0000000000 0 2 to 165 of the nominal
36. f subsequently supplied parts in this section Section 7 Special user programs Contains an introduction to the purchsed PC software Section 12 Spare parts Wear and tear parts are not contained in the instruction manual as standard Section 13 Certificates Calibration reports The declaration of conformity or the manufacturer s declaration calibration reports safety data sheets and other certificates are to be found in this section Directories The instruction manual uses contents and hit word indexes Lists of contents To be found on the third page of the respective section Hit words To be found at the end of the respective register 05 04 ident V3 0 Zwick technical documentation 5 Copyright 2004 Zwick GmbH amp Co D 89079 Uim a E g Hr Each page of the instruction manual contains all important information on a Use of the instruction manual LWI ck Roell Materials testing machine Manual Chapter Device as well as for Date of compilation File name Version of the description We d like to make this clear to you with an example Zwick Roell ad ce 06020620 Device with order no Electronics or type of drive system could be contained here Chapter These can be found in the respective list of contents Pictogram of the manual Navigation help File s date of compilation File name File s version no Please provide us with this inform
37. fely and in an environmentally safe manner Zwick technical documentation 10 05 Sicherheit V2 9 UN 6060 0 OD HE YOUNZ SOOZ O W lo Zwick Roel Eger mon A When working with electrical equipment The leads from the mains cable s and mains input filters up to the input of the main switch are under current even when the materials testing machine is switched off Maintenance and corrective maintenance work on electrical equipment must be carried out by competent and qualified electricians only Electrical equipment and systems should be checked regularly at least every 4 years for proper functioning BGV A3 by qualified and competent electricians Please keep the switch console closed at all times Access is only permitted for electricians with keys tools Switch consoles Housing for electrical equipment Such as electronic housing motors should never come into contact with water nor steam l e steam jet cleaners When working on laser light sources Only trained competent and authorised personnel are to be allowed to work on laser equipment 22 Zwick technical documentation 10 05 Sicherheit V2 9 UAN 62089 0 Gg HAWS ee 0 O M 20 Zwick Roell Safety cer AN Safety measures and notes A Safety goggles safety gloves Risk of injury Example Tests on specimen that shatter Tests with jaw inserts that might shatter Component testing Everybody even observers mu
38. h V2 0 WN 62000 0 0D HAUD JPIMZ 71007 O R MO Zwick Roell Technical details Materials testing machine 5 kN Zwick technical documentation 06 02 Verwend V2 1 Wel 820900 09 F HOWE YYZ OC O Edon Zwick Roel Technical details Materials testing machine 5 KN Fire fighting equipment Fire extinguishers to DIN EN 2 combustion classes A and B may be used for combatting fire smouldering and similar These are Combustion class A Burning of solid materials Combustion class B Burning of liquid or liquefying materials Support profile 061110 02 The support profiles for the materials testing machines are optional 18 Zwick technical documentation parts To enable truely ergonomical operation for seated or standing operation reference to the optional support profiles will be made quite often in this instruction manual 06 02 Verwend V2 1 UNT 61000 0 05 9 HUD ez 2007 K EN 7 Technical details ZWI ck Roell Materials testing machine 5 kN No risk use Specimen and jaw inserts may be used that will neither be propelled away from the test machine at specimen failure break nor will fall from the grips Hazardous use A safety device must be used for all other test requirements This is especially true for Specimen with high potential energy and resilience properties such as springs ropes belts and similar Use of hardened or ceramic jaw inserts
39. he appendix Document Instruction manual Materials testing machine is split into Safety manual Technical manual Installation manual User manual Service and maintenance manual Version See the respective manual Print date November 2005 Copyright c 2005 by Zwick GmbH amp Co August Nagel Str 11 D 89079 Ulm Einsingen All rights reserved We ve done our best to make sure that this instruction manual is complete and free of errors Should you notice anything that is unclear in spite of this please inform us Our products are being continuously improved upon Thus it may happen that some statements in this manual don t always correspond to the latest state Exact info can be obtained by calling Zwick in Ulm if you re not entirely sure Ut 620868 0 OH HIWO PWZ VYOOZ O buldog 2 Zwick technical documentation 05 04 Ident V3 0
40. ical documentation 7 Sopyright 2003 Zwick GmbH amp Co D 89079 Uim Zwick Roel tiie 1 Materials testing machine T1 FROO5TN A50 Overview Head plate Position pointer Load frame crosshead pointer em e Moving crosshead d ul Work area Fixed crosshead Main switch Ir EMERGENCY OFF k button Secure 1 Support profiles 8 Wes le testControl electronics Contact area to the floor lt 04 03 Tech V2 7 Zwick technical documentation 9 Copyright 2003 Zwick GmbH amp Co D 89079 Uim LWI ck Roell MTM T1 FROOSTN ASO H aa gw O 04 03 Tech V2 7 Technical details F fz Measurement and control electronics Test data recording rate in the system mrrrrrrnnnnrrrnnrrrrnnnnnnnrnnnrrrnrrrrvrrrnene 500 Hz Test data transmission rate to ebe Adjustable from 10 to 100 Hz Number of module slots 0 0 00 ceeccssssecesceveececusvesceeecceusesesuusseeuesesenteeseeees 2 Zero drift correction of the entire measurement chain without Sensor Automatic at measurement begin Measurement signal runtime correction rrrrrrnrrrernrrrnnrrnnrrnrnrrnrrnnnrrnnnrrnnernne Yes UNE rn RS232 Required PC connection aorrioennnvrvsrrnnvrnnensrnraversnuersnevsrenensnnessnvesenenersenueeen COM 1 Type of protection casing EE IP 32 Remarks on the electronics A maximum of two test data recording p c bs can be in
41. lace W o reverse of direction Maximum test frequency 0 5 Hz 10 Zwick technical documentation 04 03 Tech V2 7 UNN 62080 0 00 HAWES PWZ E007 R G Zwick Roel eme 22 8 Zwick technical documentation 04 03 Tech V2 7 WIN 62086 0 OD 7 HAUD PMZ GO M M Identification 2 ZWICK Roell Materials testing machine 13 Identification Each materials testing machine has two serial number plates as standard A large serial number plate is on the electronics console ands a small one is on the rear of the machine base An exception is the single screw materials testing machines each of these has only one serial number plate Large serial number plate Here is the CE sign for those materials testing machines that have a declaration of conformity Manufacturer with address Zwick Roell C E August Nagelstr 11 D 89079 Ulm type BXX XXXXXXX serial no 000000 0000 order no 000000 Power 000 000V 00 00Hz 00A Order number Machine type Serial number Year of construction Order confirmation number Dossier number Fnom Mains connection Nominal value of the materials testing machine Small serial number plate Manufacturer with address Here is the CE sign for those materials testing machines that have a declaration of conformity Zwick Roell August Nagelstr 11 D 89079 Ulm BXX OOOO f sl 000000 0000 Order number Machine type Fram OOOkN
42. mentation 23 Zopyright 2002 Zwick GmbH amp Co D 88079 Uin D Function description testControl Zwick Roell Load cell Load cell function description Load cells convert the physical quantity force to an electrical measurable current It consists of a mechanical deformation body with bonded strain gauges StrG Strain gauges are strain dependent electrical resistances that are connected together to a measurement bridge The value of the measurement voltage at the measuring bridge output is analogue to the force F to be measured this force acts on the deformation body and on the entire sensor system The sign polarity for the measuring voltage changes depending upon the tensile or compression loading of the load cell Measuring voltage A Supply voltage Measuring voltage w Supply voltage Screen Casing mass A first class screened data cable with a 25 pin sensor plug establishes the connection to the measurement technology s measurement amplifier The sensor plug s p c b has a small data memory IC to which the load cell s characteristic and calibration data important for the system setting is saved Plug casing Connecting cable 04 02 Ffunk V2 1 Zwick technical documentation 25 e Function description testControl 1 e Zwick Roell Load cel Definition of the characteristics The VDI VDE guidelines 2638 April 89 define the following characteristics for load cells N
43. n cleaning the equipment Please make sure that emergency precautions Oil sump oil binders etc have been taken to make sure that oil cannot intrude into the ground and or the sewer system Please adhere to the safety data sheets for the hydraulic oil used d and to the necessary rules and regulations Risk of slippage Hydraulic oil and contaminated agents Oil binders must always be disposed of in an environmentally safe way The safety data sheets are to be found in section 13 Certificates Calibration reports When replacing hydraulic and compressed air hoses mount them in the same manner direction 10 05 Sicherheit V2 9 Zwick technical documentation 23 opyright 2002 Zwick GmbH amp Co D 89079 Uim Zwick Roel rm Index Instructing the operating personnel 13 Instructing the transport personnel 6 Instruction manual 12 A L Authorised personnel 13 Avoiding ete 24 EE deeteebdevers 22 Lasers 00000 4sssenssess 20 B Lifting tackle messen 21 o Limit switch 13 16 21 Before switching on 16 C Machine safety 13 Checks and preventive measures 1 Mains connection 21 Cleaning recommendations 24 MAINS plug seire 21 CO sine en 20 Maintenance Ls 24 Compressed air hoses 23 Maintenance hienat 24 Compression tests 18 Maneten Electrical equipment 22 D Sisal tellende aie ok i neumatic equipment Pe CAU
44. ng conditions Zwick Roell External influences Materials testing machines and testers are highly sensitive measurement systems Thus the following must be avoided at the installation site Jolts and vibrations e Oscillations e Vibrations s Schock e Conducting air e Corrosive contamination Recommendation Installing shock absorbers air filters or signal filters We would be only too pleased to be of assistance to you should you be confronted with these problems Electrical magnetic and electromagnetic fields Our materials testing machines and testers are laid out to the now valid EMC guidelines The following measures have already been taken against the named interferences in the construction of materials testing machines with electronics consoles s Enclosed metallic casing e Screened leads e Connection of all devices and screens to the protective earthing e Star shaped reference conductor system You must take the following measures if the above ones are insufficient e Place power cables spacially separate to measurement leads Use twisted wire pairs for self made measurement leads each wire pair should be separately screened Screen mesh Screen the materials testing machine from any nearby Substations Busbars HF generators Such as induction oven welding gear etc Zwick technical documentation 05 04 TUmgeb V3 0 UA 62060 C GHG HOWE OMZ YOOZ O Zwick Roell Temes
45. ntual alterations amendments to the test system however at least Annually The operating personnel must know the safety remarks contained in the instruction manual and adhere to them The operating personnel wears suitable protective clothing Safety goggles face shield safety shoes protectice gloves tightly fitting clothing hairnets for long hair Please pay attention to the following as a user of hydraulic test systems Loss of oil could possibly occur during both operation or when the system is idle due to leakage It could even occur during maintenance work Loss of oil could cause environmental pollution Ground water pollution and could also be the cause of accidents Please pay attention that hydraulic components are situated where it would cause no problems at all to accommodate the maximum quantity of oil which could be lost due to leakage Oil sumps or similar k nnen or specially built hydraulics cellars can be used Please make sure that hydraulic oil cannot penetrate into the ground Please make sure that all valid rules and reugallations as well as laws and guidelines on the handling and disposal of Hydraulic oil s are strictly adhered to Zwick technical documentation 10 05 Sicherheit V2 9 WAN 62060 0 00 3 HAD PMZ SO O HOOD ZW ck Roell i and hit words Signal words in the instruction manual The instruction manual marks functions which may contain risks of injury for the operating personnel or dang
46. olders is a safety precaution for pneumatic and hydraulic specimen holders Zwick technical documentation 9 Copyright 2005 Zwick GmbH amp Co D 89079 Ulm System display 10 05 Sicherheit V2 9 Symbols and signal words Symbols on the test systems The following safety remarks can be fixed to the test system Please pay attention to them Risk of injury The crosshead is moving Caution Caution no automatic shutdown if the crosshead is touched Risk of trapping parts of the body Specimen holders can be closed mechanically manually or automatically Caution Caution no automatic shutdown if the specimen holder s is are touched Risk of burning or Risk of frostbite The temperature device can become extremely hot or cold Dangerous electrical voltage Only qualified electricians are to open the casing Laser beam Only competent and authorised persons may do any work on Lasers Zwick technical documentation Copyright 2005 Zwick GmbH amp Co D 89079 Uim Personnel differentiation is made in this instruction manual between user and operating personnel User Responsible personnel with authority for giving instructions Operating personnel Persons who work at or with the test system Operator The machine safety can only be implemented in every day use ff all necessary measures are taken Determine the operating personnel s responsibilities for Operating
47. ole for a IOCk pIn Sie Mounting studs ER Load cells convert the physical quantity force to an electrical measurable current Copyright 2002 Zwick GmbH amp Co D 80079 Uim 01 02 Tech V2 0 Zwick technical documentation 29 Copyright 2002 Zwick GmbH amp Co D 89079 Uim Load cell TC LCO200N P01 01 02 Tech V2 0 Zwick Roell Load celTC LCO20ON PO1 K EH del DE A Overview Mounting studs e R lt r Slotted nut alll Load cell Hole for a lock pin Mounting studs Load cells convert the physical quantity force to an electrical measurable current Zwick technical documentation ch Copyright 2004 Zwick GmbH amp Co D 89079 Uim Zwick Roell mess Video extensometer TC EXVIDEO 002 Overview 7 si d i a ee d ender Ap rn Edhi EE Aidi Kee kane E ech r Wy EN eg ai ERT age de r d Get fr en s d US PC D Mi GAN pg de iy PEREA tS mr in sa ii TW VW kz f JE Sr nity Ki mee ili ru ES pan CS zb A W L Mer Che E t e p i EEE Le Ri y D Fiesta a Ft d CCRA G t eet E ve HA ke Way tr kL is EA telt ke Peri i r S T i SE Function description The surface of the specimen is digitised by the video extensometer An analog measurement signal is generated depending upon the brightness of the captured surface area This is then
48. ominal force f Measurement range The accuracy limits as stated in the technical data are upheld Operational force V Operational range The accuracy limits as stated in the technical data can be exceeded Limit force Force at break 7 y Destructive range Remaining deformation to the load cell Maximum loading range The accuracy limits contained in the technical data are not upheld no measurement capability above the operational force no damage to the load cell Nominal force The nominal force for which the load cell has been SN designed Maximum operational force Greatest force in the direction of the load cell s Fin N measurement axis up to which a defined and repeatable relationship between the force and the output signal exists however an eventually existing protection against overloading won t be tripped at this point Copyright 2002 Zwick GmbH amp Co D 89079 Ulm Force at break Force in the direction of the load cell s measurement axis F inN above which mechanical destruction must be reckoned with 04 02 Ffunk V2 1 Zwick technical documentation 27 Technical details ZN I CK Roel l Load cell TC LCO020N P01 Load cell TC LC0020N P01 pt ep XX K ae Herd ga DXO May E Si lie E 2540 pen wt ISS SE Kit A Slotted nut Load cell Pre stress nut XXXXXX me M44 SS Ki D cn Hole for a lock e
49. on 3 Copyright 2005 Zwick GmbH amp Co D 89079 Ulm Zwick Roell sn D 10 05 Sicherheit V2 9 Introduction The test system is manufactured to the state of the art technology and to recognised safety requirements This however neither excludes any danger to life and limb of the operator or third parties which could occur when using the test system Nor can interference nor impairment to the impact tester be excluded The test system may only be used if it is in perfect technical order as long as it is being used properly At the same time safety and hazard risks as well as observation of the contents of the instruction manual must be taken into account The test system must be shut down immediately should any interference occur that impairs safety The interference or its cause must then be rectified Supplements Supplement the user manual with instructions from national regulations on accident prevention and environmental protection Please observe and adhere to Valid binding regulations on accident prevention Recognised technical rules for safety and correct working Regulations on safety and health protection when preparing and using working means Instruction manuals The entire instruction manual must always be available at the installation site of the test system Zwick technical documentation 5 Copyright 2005 Zwick GmbH amp Co D 89079 Ulm Zwick Roell en AN 10 05 Sicherheit V2
50. onmentalconditions messen 35 OVEIVIEW 0 00 ccccccccccsescccscessensssscssssecessessccasenanes 29 Proper use he 30 F Technical data 30 FI Circuit breaker 13 Load cell TC LCO200N P01 FP Improper USE ssrnnnnnrrravorornoennnvrneneererennvnvvssn 32 Fire fighting equipment osssossoss 18 EE 31 Force at break snneeeseeessersses 27 Proper USE ooo eecccceeeceeseescstecesesseeeseesseeees 32 Free from vibrations 6 17 Technical data 32 Function description Load cell s cable guide orrrrnrevnrrorrnonoorvssnnvvnvnenn 26 Materials testing machine 15 Video extensometer 0 0 3 M G Magnetic fields rrrrrrvre vorornnnnonnorrroernnrvevnnnnnnnnn 36 Mains output roroorooooronre sossererssssnesenrsnnnnsenssesnnnr 13 Gases ST Mains requirements m sist 35 Materials testing machine H Accessories EE RRE ssvdceseoconscsssecceessecarcsesss 19 Hazardous use 46 Electronic rating plate EE 12 EMISSIONS EE 17 01 02 THIndex V2 0 Zwick technical documentation 39 Zwick Roell no Force measurement 11 Video extensometer 34 Function description 15 Hazardous use 16 T Improper use 17 Load frame 00000aan 10 TC MODCSCC module Operating data 13 Connectable sensors 22 OVEIVIEW o oo ee H Improper use 0 22 Proper use
51. order All of the above work must be first correctly done free of error before the materials testing machine is to be used by the operating personnel Only use lifting tackle Such as a fork lift truck crane etc that is suitable and in first class condition when replacing or exchanging heavy machine parts 10 05 Sicherheit V2 9 Zwick technical documentation 2 Copyright 2005 Zwick GmbH amp Co D 89079 Uim ZWI ck Roell Dee measures and notes A When working on hydraulic and pneumatic equipment Maintenance and repair work on hydraulic and pneumatic equipment must only be performed by competent personnel trained and with experience in hydraulics pneumatics When working with hydraulic oil please observe the corresponding remarks on the safety data sheet Section 13 Certificates Calibration reports Hydraulic Set the materials testing machine to zero pressure when carrying out maintenance and repair work on pneumatic and hydraulic equipment These topics are listed for each component in section 10 Service and maintenance manual Please check all leads hoses and threaded connections for leakage and for visible damage Replace any damaged hoses pipes immediately Spraying oil could lead to injuries and fires As a precautionary measure please replace all hydraulic hoses every 6 years Recommendations to DIN 20066 Fluidics Hoses even if damage to them is not obvious Hydraulic oil may escape whe
52. oses hydraulic hoses should be replaced every six years at the latest as a precautionary measure Recommendation All safety devices E g EMERGENCY OFF button limit switches safety door etc should be checked and maintained by an authorised person Immediately upon detection of damage Following maintenance work Atleast once a year 1 0 Zwick technical documentation 10 05 Sicherheit V2 9 UN 61000 0 9 HAWS ET GO N AdO ZWI ck Roel se AP use Improper use Any usage listed or exceeding the proper use is recognised as being improper use Zwick does not accept any liability whatever for damge resulting from any application or use not included under proper use Liability is the sole responsibility of the user The gurantee for the test system expires Examples of impermissible use Amendments to the test system not agreed upon by Zwick Use of the testing system in the sense of a production machine if not agreed upon by Zwick Overriding safety systems Zwick does not accept any liability for tools appliances or devices integrated by the user Any necessary safety measures are then the sole responsibility of the operator user Zwick technical documentation 10 05 Sicherheit V2 9 WN 62088 0 95 F HAO PMZ GO O N DD Zwick Roell 9 AN Transport Adhere to the regulations governing safety and health protection at work Liability of the system supervisor when making work means available
53. pping jaws Use a tool e g tongs for inserting specimen Tongs are available for hydraulic grips Please make sure that any pneumatic and or hydraulic equipment of or for use with the materials testing machine is at zero pressure before you start to work with it Tensile tests Risk of squashing Danger of trapping parts of the body There s a danger of trapping parts of the body after test during return to der initial position There s a danger of squashing parts of the body especially between specimen holders that are close to one another i e the free grip to grip separation is very small You must wait until the test is ended and the crosshead has stopped moving before attempting to access the working area Compression and flexure tests Risk of squashing Danger of trapping parts of the body There s a danger of squashing parts of the body during these tests whilst the compression platens or flexure test elements are in motion Never ever attempt to access the space between compression platens or flexure test elements with parts of your body whilst a test is running Zwick technical documentation 10 05 Sicherheit V2 9 UE EW 9007 K Zwick Roell re a pee Safety measures and notes Before switching on Please observe the following before switching the materials testing machine on Only authorised persons may be allowed into the working area of the materials testing machine Check the all safety de
54. put to universal use They are concipated for almost all test requirements for nationalen and internatio nal standards as well as for a large part of the requirements as described by a wide range of in house standards Thesematerials testing machines are not only for use in quality assurance for rotine investigation but also for research whereby test programs must first be defined Overview Load cell MCE Unit Extensometer Materials testing machine wn Test tools Safety device Measurement Control Electronics Communication Environmental interface r simulation Physical measurement unit The modular construction enables supplementary retrofits to be made very easily 1 0 Zwick technical documentation 05 04 Ident V3 0 UN 62008 0 OD HAUS ENT VOOZ O N UAdO Zwick Roell Description of the company Materials testing machine Zwick Roell AG Zwick Roell AG August Nagel Strabe 11 Zwick D 89079 Ulm Einsingen GmbH amp Co KG Tel 497305 100 August Nagel Strafie 11 Zwick Series Fax 49 7305 10200 D 89079 Ulm Einsingen eMail info zwickroell com Tel 497305 100 Internet http www zwickroell com Fax 497305 10200 eMail info zwick de Internet http iwww zwick de Toni Technik Baustoffpriifsysteme GmbH Gustav Meyer Allee 25 D 13355 Berlin Tel 49 30 64403921 23 Fax 493064403922 eMail infotonitechnik com Intemet http wwww tonitechnik
55. r ET minimum distance Workplace t to walking lanes Exemplary drawing po 10 05 Sicherheit V2 9 Zwick technical documentation i 1 5 Copyright 2005 Zwick GmbH amp Co D 89079 Ulm Zwick Roell 10 05 Sicherheit V2 9 Safety Safety measures and notes Safety device Please use a safety device for any potentially dangerous test requirements Safety door with electrical interlock Examples of potentially dangerous test conditions Using hardened or ceramic jaw inserts without protection against shattered parts Specimen or parts of specimen that are or can be propelled away from the test system or fall to the ground with high energy absorption and resilience owing to the type of loading and the properties of the specimen such as Springs Ropes Belting Rotating lead screws Be careful when lead screws such as those for crossheads or extensometers are rotating Long hair jewelry or loose clothing E g sleeves could get caught up in rotating lead screws Please take the following precautions Wear closely fitting clothing Do not wear jewelry Use a hairnet if necessary Working area Risk of squashing and or potential danger through falling objects Never place objects in the materials testing machine s test area nor on the test tools Zwick technical documentation 17 Zwick Roell Copyright 2006 Zwick GmbH amp Co
56. st wear safety goggles if potentially dangerous tests are being run EN 166 and or protective gloves Temperature Danger of burning or freezing Parts of the machine such as the motor can become very hot The outer parts of temperature chambers and other parts e g connectors may become very hot or cold when testing with a temperature chamber Never ever leave hot cold specimen lying around unprotected Only work with heat resistant protective gloves Noise Loud specimen break can lead to damage to your hearing Please use ear protectors in such cases The materials testing machine doesn t emit any noise that could damage your hearing The noise levels for the respective materials testing machines and their components are to be found in section 2 Technical manual Laser extensometer Safety goggles aren t necessary Avoid looking into a laser light source and never use optical instruments to look into laser beams Working on laser equipment should only be done by correspondingly trained service personnel Zwick technical documentation 10 05 Sicherheit V2 9 AA 82000 G Gg HAWS HZ o O M M Zwick Roell Safety Safety measures and notes Working in the working area Danger of trapping parts of the body Keep your hands away from the test area when the materials testing machine is running Specimen holders hydraulic pneumatic Danger of trapping parts of the body Keep your fingers away from between the gri
57. stalled in the electronics the module slots are not expandable The ventilation slits in the electronics unit must never be covered not even those on the unit s underside They require a free spacing of at least 100 mm The testControl electronics must have a constant temperature for exact measurements Thus switch the materials testing machine on an hour before the beginning of test especially for long term tests Force measurement The measurement electronics for the force measurement corresponds to ISO 7500 1 Load cell type I Grade 1 In the range of 0 4 to 100 of F som Grade 0 5 In the range of 2 to 100 of F om Load cell type Il Grade 1 At From 7 500 N in the range of 0 2 to 100 At From lt 200 N in the range of 0 4 to 100 Grade 0 5 In the range of 1 to 100 The percentage values refer to the nominal force F om of the connected load cell Zwick technical documentation 1 1 Copyright 2003 Zwick GmbH amp Co D 89079 Uim Technical details 1 E ZWI ck Roel Materials testing machine 5 kN W s Operating data Rated values Electrical connections rrrvrrrrrrsraransnnnvnnvavserr saveveeeeeeseeee 230 V Ph N PE Full load current consumption e 9A Power consumption Full load cccc2ccccccce seeenseseeeeesesessersessssenes 1 9 KVA Mains frequency 0 sccscccsccccosnneossvevscesuceces innnsvessepsnsvvpsnnseneseseee 50 60 Hz Mains fusing for the pow
58. surement accuracy You can do this yourself if you have the necessary measurement means If not it can be done by accredited centres such as materials testing authorities or by Zwick The Zwick DKD calibration laboratory is accredited under registration no DKD K 13201 Remarks We recommend annual calibration with respect to EN ISO 9001 Zwick technical documentation 5 Copyright 2003 Zwick GmbH amp Co D 89079 Uim Technical details SCH Zwick Roell MTMT EROOSTN ASO 13 Technical details This section contains the description of the materials testing machine with all accessories All technical details are contained here The correct use of the materials testing machine and all accessories used with it are defined here You can even read about impermissible application and use here Do you require the ratings or operating means still to be acquired You ll find all values necessary for the materials testing machine here Materials testing machine T1 FROO5TN A50 The materials testing machine MTM described here is a table top test machine with a max test load of 5 KN The machine identification name contains all characteristical details for this particular materials testing machine T1 FR 005 T N A50 L A50 AC Drive 500 W N Normal load frame construction T Table machine 005 Maximum test load 5 kN FR Materials testing machine T1 testControl electronics 04 03 Tech V2 7 Zwick techn
59. verybody Section 1 Safety manual The contents must be known to everyone For the technicians Section 3 Installation manual Aimed at personnel responsible for transport installation dismantling packing and storage Section4 User manual Aimed at operating personnel and describes the operation operating elements of purchased components Section 10 Service and maintenance manual Aimed at maintenance personnel with maintenance intervals as well as error rectification Section 11 Circuit diagrams Aimed at maintenance and service personnel What everybody needs Section2 Technical manual Contains the technical data Section 15 Appendix Contains addresses and a maintenance order form Zwick technical documentation 05 04 Ident V3 0 WIN 62009 0 05 HAUS OWT KO O wOUAdo x Document ZWI ck J Roel Materials testing machine Materials testing machine T1 FROOSTN A50 Serial number 168336 Order confirmation Dossier number 653782 Model 2005 Manufacturer Customer service Zwick GmbH amp Co ZwickService August Nagel Strae 11 August Nagel Strafe 11 D 89079 Ulm D 89079 Ulm Germany Telephone 07305 10 0 Hotline 07305 10225 Help for malfunctioning Supportline 0190881988 Support for operation and application Fax 0730510200 eMail info zwick de Internet http www zwick de http www zwick com Further addresses from service and sales companies are listed in t
60. vices Safety devices limit switches proximity switches and EMERGENCY OFF button for evident malfunctions Check the materials testing machine for visible damage Report any determined damage immediately The materials testing machine must not be used at all if the following Exemplary defects are detected Defects or damaged separating safety devices Defects or damaged pneumatic leads Defects or damaged hydraulic leads Defects must be rectified before putting the materials testing machine into operation At operation Gather information on how to react in case of defects or damage before switching the materials testing machine on Non observance could lead to injury EMERGENCY OFF button In case of danger any movement of the materials testing machine must be stopped immediately by hitting or pressing the red EMERGENCY OFF button 1 6 Zwick technical documentation 10 05 Sicherheit V2 9 WN 620800 9D 3 HAWD eu SOO O Klo m Safety ZWI ck Roel Instructions for the operating personnel The test system must be operated by qualified and authorised operating personnel only The operating personnel must have some knowledge of Safe operation Suitable safety clothing Any potential risks emanating from the test system The operating personnel must be instructed with respect to work safety and environmental protection as follows Before the beginning of their work After any eve
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