Instruction manual for materials testing machines

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Instruction manualfor materials testing machines

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Zwick technical documentation05.04/ldent / V3.0

rnJContents of the sectionMaterials testing machine

Section contents

SectionContents

Safety manual 1

~ Technical manual 2

[Z] Installation manual 3

~ User manual 1

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Reserved for expanded operation tC-OPSTDAL 5l===:J

~ Reserved for retro-fit parts instruction manual ~)

[;i] Reserved for special user programs. , 7

Free............. 8

Free 9

~ Service and maintenance manual 110

~ Circuit diagrams 1 '1~

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ril Reserved for spare parts/wear and tear parts lists .......... ..12

Certificates/Calibration reports 1:3

Free......................... 1.4

m Appendix 15

Zwick technical documentation05.04/ldent / V3.0

rnJUse of the instruction manualMaterials 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 thepossibilities of operation without a PC.

Section 6 "Retrofit parts"is without documents in the initial delivery. You can tiileaway the description(s) of subsequently supplied partsin 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 asstandard.

Section 13 "Certificates ICalibration reports"The declaration of conformity or the manufacturer'sdeclaration, calibration reports, safety data sheets B,ndother certificates are to be found in this section.

Directories

The instruction manual uses contents and hit word indexes.

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To be found on the third page of therespective section.

Lists of contents:

Hit words: To be found at the end of the respective

register.

Zwick technical documentation 505.04/ldent/V3.0

Use of the instruction manualMaterials testing machine

Each page of the instruction manual contains all important information onthe

- Manual- Chapter- Device

as well as for- Date of compilation-Filename- Version of the description.

We'd like to make this clear to you with an example.

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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)

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rnJDescription of the companyMaterials testing machine

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Zwick technical documentation04.03/ Silnhalt / V2.5

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List of contents

List of contents :3

Introduction :5

Supplements 5Transpol1 16

Proper use 7

Improper use 8Remaining risks 9Checks and preventive measures 10

Symbols and signal words 11

Symbols on the test systems 11Signal words in the instruction manual 12

Personnel 13

Operator 13Workplace 15

Safety measures and notes 16

Before switching on , 16At operation 16At Service and maintenance 21When working with electrical equipment 22When working on laser light sources 22When working on hydraulic and pneumatic equipment 23

Cleaning and disposal 24

Index 25

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Zwick technical documentation04.03/ Silnhalt / V2.5 3

~SafetyIntroduction

Introduction

The test system is manufactured to the state of the art technology and torecognised safety requirements. This, however, neither excludes anydanger to life and limb of the operator or third parties which could occurwhen using the test system. Nor can interference nor impairment to theimpact tester be excluded.

The test system may only be used if it is in perfect technical order as longas it is being used properly. At the same time safety and hazard risks aswell as observation of the contents of the instruction manual must betaken into account. The test system must be shut down immediatelyshould any interference occur that impairs safety. The interference or its.cause must then be rectified.

Supplements

Supplement the user manual with instructions from national regulationson 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 usirlg

working means- Instruction manuals

The entire instruction manual must always be available at the installationsite of the test system.~

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Zwick technical documentation10.05/ Sicherheit / V2.9 5

[4JSafetyProper use

Proper use

Our materials testing machines can be used to determine properties ontest pieces such as bars, shaped elements, components and etc. Thetesting machines apply mechanical loading to the test piece in the formof continuous, increasing, pulsating or cyclic tests through an electrical orhydraulic drive system.The test pieces are loaded via the test quantities force, moment ordeformation with defined values, time sequence and frequency.The materials are undergo destructive or non-destructive testsdepending upon the testing machine and test method used.The classical types of test are tensile, compression, flexure and torsiontest on the basis of a variety of test standards.

Please make sure that the specimen and specimen mountings used canneither be propelled away from the testing machine nor can drop to thefloor when under load, or in the case of failure. This could lead to damgeto test equipment and to injury to persons in the vicinity of the machine.

The instruction manual is constructed in modular form. Thus observesection 2 "Technical manual". This section describes the proper use ofeach component.

Inspection and maintenance, transport, installation and operatinginstructions belong to the proper use of the test system.

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Zwick technical documentation10.05/ Sicherheit / V2;9

I4lSafetyRemaining risks

Remaining risks

Remaining risks may be present in, for example, the following cases (F;orexamples 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 energyabsorption and resilience owing to the type of loading and thepropertires of the specimen, i.e.- Springs- Ropes- Belting

Basically we stipulate that the user is well versed in the use of the test

system.

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We offer a range of safety devices that are aimed at providing protectionfor the user and for the vicinity of the test equipment. We stipulate the u:;eof a safety device with electrical interlocking for the test area dependin~~upon the components and applications to be employed by and with thetest system. In this case the maximum drive speed is limited to 600 mrTllmin and the test load is limited to the set preselections in verificationoperation. These limits apply when the safety door is open. Section 4(Operator manual) explains the verification and test operation in moredetail.In addition inching operation has been realised at the testControlelectronics.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 specimenholders is a safety precaution for pneumatic and hydraulic specimenholders.j

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[4lSafetySymbols and hit words

gym bols on the test systems

The following safety remarks can be fixed to the test system. Please payattention to them.

-/tt\~Risk of injury!The crosshead is moving.Caution: Caution, no automatic shutdown if the crossheadis touched.

Risk of trapping parts of the body!Specimen holders can be closed mechanically, manually or

automatically.Caution: Caution, no automatic shutdown if the specimenholder(s) is(are) touched.

1:1Risk of burning or Risk of frostbite!The temperature device can become extremely hot or cold.[ Iii /

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Dangerous electrical voltage!Only qualified electricians are to open the casing.~

Laser beam!Only competent and authorised persons may do any wor1(on Lasers.

System display

Zwick technical documentation10.05/ Sicherheit / V2.9

[4]SafetyInstructions for the operating personnel

Personnel

A differentiation is made in this instruction manual between user and

operating personnel.

User: Responsible personnel with authority for givinginstructions

Operating personnel: Persons who work at or with the test system

Operator

The machine safety can only be implemented in every day use if allnecessary measures are taken.Determine the operating personnel's responsibilities for- Operating- 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).

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The test system may only be used according to its proper use.Only safe tests may be run with the test systemThe test system may only be used if it is in perfect working orderAnything that could impede safety has neither been added norconvertedSafety devices have not been manipulatedCheck 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 ispermitted only following consultation with the responsible safetyofficer (If necessary please ask Zwick)All safety remarks and warning signs attached to the test systemmust not be removed and must be legible.

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Workplace

The operator's workplace is in front of the materials testing machine

during operation.

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Materials testing machineWa installed by a wallTable

Stool Workplace

Workplace

Recommended minimum distance to walking lanes

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Materials testing machine setup freein a room~

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Lateral and rear protection

Recommendedminimum distanceto walking lanesWorkplace

Exemplary drawing~


SafetySafety measures and notes

Safety devicePlease use a safety device for any potentially dangerous testrequirements (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 grour1dwith high energy absorption and resilience owing to thetype of loading and the properties of the specimen suc:has- Springs

RopesBelting

Rotating lead screwsBe careful when lead screws, such as those for cross heads orextensometers are rotating.Long hair, jewelry or loose clothing (E.g. sleeves) could getcaught up in rotating lead screws.Please take the following precautions- Wear closely fitting clothing- Do not wear jewelry- Use a haimet if necessary

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Working areaRisk of squashing and/or potential danger through falling

objects.Never place objects in the materials testing machine's testarea nor on the test tools.


(4lSafetySafety measures and notes

Spring testsDanger of trapping parts of the body.Danger of springs, or parts thereof, being propelled awayfrom 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 specimenmounting for tests on compression springs.A safety device is necessary for the test area depending uponthe type oftest(s)!.

Insert the specimenPotential danger through incorrectly clamped or placed

specimen:Parts of the specimen or jaw inserts could be propelled awayfrom the testing system.Check only correctly clamped/insertedspecimen. Off-centretesting may only be carried out with special tools.

Compression test devices may have a centring groove or aguide mandrel. The specimen must then either be seated inthe groove or secured against being propelled away from thetest device by the mandrel.

Flexure test

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Open the gripsPotential danger through incorrectly clamped or placed

specimen:Parts of the specimen or jaw inserts could be propelled awayfrom the testing system.Never ever open specimen holders that are under load.Any load must be removed from the clamped specimenbefore opening the specimen holders.


[4lSafetySafety measures and notes

At Service and maintenance

Please note the following points to help avoiding serious injuries ormachine damage when carrying out maintenance work on the testsystem. 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:- Switch the mains supply off via the main switch. Secure the main

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.) havecooled 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 materialstesting 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 inperfect working order?

All of the above work must be first correctly done free of error before thematerials testing machine is to be used by the operating personnel.:~

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Only use lifting tackle (Such as a fork lift truck, crane, etc.) that is suitab~eand in first class condition when replacing or exchanging heavy machine

parts!


[4lSafetySafety measures and notes

When working on hydraulic and pneumatic equipment

Maintenance and repair work on hydraulic and pneumatic equipmentmust only be performed by competent personnel trained and withexperience in hydraulics/pneumatics!When working with hydraulic oil please observe the correspondingremarks on the safety data sheet (Section 13 "Certificates/Calibration

reports").Hydraulic

Set the materials testing machine to zero pressure when carryingout maintenance and repair work on pneumatic and hydraulic

equipment!These topics are listed for each component in section 1 0 "ServiCE~and maintenance manual"Please check all leads, hoses and threaded connections forleakage 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 hosesevery 6 years (Recommendations to DIN 20066 Fluidics - Hoses)

even if damage to them is not obvious!Hydraulic oil may escape when cleaning the equipment.Please make sure that emergency precautions (Oil sump, oilbinders, etc.) have been taken to make sure that oil cannot intrudeinto the ground and/or the sewer system.Please adhere to the safety data sheets for the hydraulic oil usedand to the necessary rules and regulations.Hydraulic oil and contaminated agents (Oil binders) must always bedisposed of in an environmentally safe way. The safety data sheetsare to be found in section 13 "Certificates/Calibration reports"When replacing hydraulic and compressed air hoses, mount themlin the same manner/direction.

Risk of slippage

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Index

Index Instructing the operating personnelInstructing the transport personnelInstruction manual.........................

13.612

AAuthorised personnelAvoiding waste .........

1324 ............

............

............

13, 16,

LLaser. . . . . . . . . . .

Lasers .........

Lifting tackle

Limit switch.BBefore switching on 16

1321212121

1024202318

CChecks and preventive measuresCleaning recommendations .........Cold ............................................Compressed air hoses ................Compression tests ......................

2223232112

12122424.2

MMachine safety ....................

Mains connection ................Mains plug ..........................Maintenance , ,...

Maintenance intervals ..........

Maintenance workElectrical equipment ......Hydraulicequipment ......Pneumatic equipment .".Switch off ",.

Maintence workEnvironmental protection

Minimum distance ...............

2415

DDefinition .c

CAUTION ,DANGER ~::.:::...WARNING ............................................

Disposal......................................................

Disposal in an environmentally safe mannerDocument .................................................. N

National regulationsNoise level..............

.520E

Ear protectors ..............................

EMERGENCY OFF button ...........

Extensometer TC-EXOWMST. HO1Safe operation .........................

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13, 16, 21 0Oil sumps ......Open the gripsOperate ..........Operation .......

14191613

22

FFlexure tests 18

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211313132310.27

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Hoses ..................

Hydraulic systemsHydraulics ............

pPadlock.............................

Perfect working order ........

Personnel..........................

Personnels responsibilities

Pneumatics .......................

Preventive measures .........

Print date ..........................

Proper use ........................

ProtectionClothing .......................

192113 14

Insert the specimen .................

Inspection intervals ..................

Instructing operating personnel

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Zwick technical documentation05.04/THlnhalt/V3.0

Zwick IRoe11

List of contents

General , 2

Technical details 7

Materials testing machine T1-FROO5TN.A50 9Measurement module TC-MODCSCC " ' """'.' ' '..""'...'.."' 21TC-OP500HZ : 23

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Load cell, function description ~...: 25Load cell TC-LCOO20N.PO1 29Load cell TC-LCO200N.PO1 31VideoextensometerTC-EXVIDEO.OO2 33Environmental conditions and operating conditions 35:8

Index 39

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Zwick technical documentation05.04/THlnhalt/V3.0 3

Test standardsMaterials testing machine

Applied standards

The test standards relevant for materials testing machines are listed inthe

Declaration of conformityor the

Manufacturer's declaration

Remarks on product and manufacturer's liability

The accuracy limits stated in our specification(s) (order confirmation) arenot infinitely valid. Regular checks must be made depending upon themeasurement 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 testingauthorities or by Zwick. The Zwick DKD calibration laboratory isaccredited under registration no. DKD-K-13201.

Remarks:We recommend annual calibration with respect to EN ISO 9001

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Technical details

This section contains the description of the materials testing machinewith all accessories.All technical details are contained here. The correct use of the materialstesting machine and all accessories used with it are defined here. Youcan even read about impermissible application and use here.

Do you require the ratings or operating means still to be acquired? You'llfind 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 testmachine with a max. test load of 5 kN. The machine identification (name)contains all characteristical details for this particular materials testingmachine.

.A50 = AC Drive 500 W

N = Normal load frame construction

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T = Table machine

005 = Maximum test load 5 kN

.FR = Materials testing machine

T1 = testControl electronics

Zwick technical documentation04.03 I Tech IV2.7 7

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Moving crosshead -

Fixed crosshead

Overview

Head plate .......

Work area

Technical details

Motor

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cross head

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Main sw

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Measurement and conb'ol electronicsTest data recording rate in the system 500 HzTest data transmission rate to the PC Adjustable from 10 to 100 HzNumber of module slots , 2Zero-drift correction of the entire measurement chain

without sensor Automatic at measurement beginMeasurement signal, runtime correction YesOutput interface .. ... "'."'.'..."'..."'."' ' RS232Required PC connection COM 1Type of protection, casing IP 32

Remarks on the electronics- A maximum of two test data recording p.c.bs can be installed in the electronics,

the module slots are not expandable!

The ventilation slits in the electronics unit must never be covered, not even thoseon the unit's underside. They require a free spacing of at least 100 mm.

The testControl electronics must have a constant temperature for exactmeasurements. Thus switch the materials testing machine on an hour beforethe beginning of test, especially for long term tests.

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Force measurementThe measurement electronics for the force measurement corresponds to ISO 7500/1

Load cell, type IGrade 1 In the range of 0.4 to 100 % of F nom'Grade 0.5 In the range of 2 to 100 % of F nom'

Load cell, type IIGrade 1 At F nom >= 500 N in the range of 0,2 to 100 %,

At F nom <= 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 nom) of the connected load cell.

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Operating data

Rated valuesElectrical connections ........................................Full load current consumption '.'.' '...' "".'"

Power consumption (Full load) ...........................Mains frequency .................................................Mains fusing for the power supply ......................

, 230 V (Ph, N, PE), 9 A

1.9 kVA50160 Hz

, <= 16 A

Mains outputSocket ..............Voltage ........................

Mains drift ....................Maximum loading .........

CEE 7 (Schuko)

230V(1PH, N, PE):f: 15 %

,."""",.""".."",.""",.,...""", 1 kW

Leakage current monitoringThe materials testing machine is works equipped with interferencesuppression filters (EC laws). Interference suppression filters haveleakage current to earth. This current is monitored by your installedleakage current monitoring devices (FI circuit breaker). A singlematerials testing machine doesn't trip a leakage current monitoring with30 mA. Should your power supply be subjected to heavy interference, orif several materials testing machines are operated on one commonFI circuit breaker, the sum of leakage currents could trip the FI circuitbreaker.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 permittedor

If your national laws and regulations, or works regulations allow it thendon't use an FI circuit breaker.

or- Use a DC isolated series transformer such as our BTC-

ACTRAFO.230 for example.

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Zwick technical documentation04.03/230V_Tech/V2.7 13

0Technical detailsMaterials testing machine 5 kN

Function description

The materials testing machine's load frame, and the electronicmeasurement and control unit of the testControl machines constitute thebasic unit for testing a range of materials. The load frame consists asstandard of two guide profiles with integrated, play-free ball lead screwsa 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 andguide even if there is an extremely large amount of fibrous remains,fragments and dust.

The central mounting on the crossheads serves to mount test tools orload cells.

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The materials testing machine's test area can be height adjusted byusing the support profiles.

Proper use

The materials testing machine is concipated for quasi-static loading withincreasing, pulsating or cyclic tests through an electro-mechanical drive

system.It has been designed for tensile, compression and flexure tests (seeunder EEC conformity declaration).

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LimitationThe materials testing machine is not suitable for tests

On elastic specimen such as elastomers, springs or similar materialswhere the actual test load is 50 % greater than the machine's nominalforce

Zwick technical documentation06.02/ Verwend / V2. 1 15

~Technical detailsMaterials testing machine 5 kN

Should one or more of these sources of danger exist owing to the thetesting 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 ofapplications whatsoever that constitute potential sources of danger forpersons and for the environment.

Emissions

Heating upThe motor temperature can reach 80° C when performing cyclic tests

(Continuous testing).

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Free from vibrationsVibrations and jolts at specimen break are dependent upon the materialtested, and on the test arrangement.

Noise levelThe materials testing machine's noise level is listed in the technical dataA loud noise can be generated at specimen failure (specimen break).We recommend the use of ear-protectors for such tests.

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Accessories

The materials testing machine can be used with a wide range ofaccessories. The system elements and accessories listed here are onlya part of the Zwick spectrum of products. You can direct any enquiriesyou may have on the Zwick range of products to your local representativeor direct to Zwick in Ulm-Einsingen, Germany.

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Overview

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The TC-MODCSCC module is the link between a test data recorder witha strain gauge measurement bridge, e.g. a strain gauge load cell, andthe testControl electronics.

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Option TC-OP500HZ

This option enables you to switch the transmission rate from 100 Hz to500 Hz. Switching can be made in a test program at the PC only.

Technical data

Order no. ................... BTC-0P500HZ

Transmission rate.......Software switching

100 Hz or 500 Hz

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~Function description, testControlLoad cell

Load cell, function description

Load cells convert the physical quantity force to an electrical, measurablecurrent. It consists of a mechanical deformation body with bonded strain

gauges (StrG)Strain gauges are strain dependent electrical resistances that areconnected together to a measurement bridge.The value of the measurement voltage at the measuring bridge output isanalogue to the force (F) to be measured; this force acts on thedeformation body and on the entire sensor system.The sign (polarity) for the measuring voltage changes depending uponthe tensile or compression loading of the load cell.

Measuring voltage (-J

;-.;. SupplyYoltage (+)

Measuring voltage (+)

~ Supply voltage (.

ScreenCasing (mass)

A first class, screened data cable with a 25-pin sensor plug establishesthe connection to the measurement technology's measurement amplifier.The sensor plug's p.c.b. has a small data memory IC to which the loadcell's characteristic and calibration data (important for the systemsetting) is saved.

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Definition of the characteristics

The VDINDE guidelines 2638 (April 89) define the followingcharacteristics for load cells:

Nominal force

Fnom

The nominal force for which the load cell has been

designed.

Maximum operational forceFGin N

Greatest force in the direction of the load cell'smeasurement axis up to which a defined and repeatablerelationship between the force and the output signal exists,however an eventually existing protection againstoverloading won't be tripped at this point.

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Force at breakFBin N

Force in the direction of the load cell's measurement axisabove which mechanical destruction must be reckonedwith.

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Load cells convert the physical quantity force to an electrical, measurablecurrent.


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Load cells convert the physical quantity force to an electrical, measurablecurrent.


Technical detailsTc-EXVIDEO.OO2

Overview

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Function description

The surface of the specimen is digitised by the video extensometer.An analog measurement signal is generated depending upon thebrightness of the captured surface area. This is then converted to adigital signal by the related measurement electronics and is thenevaluated by a picture processing program on the PC.


GJEnvironmental and operating conditions

Environmental conditions and operating condition~.

Our materials testing machines and testers are designed for use inatmospheres that are not an explosion risk. Please note that the useraccepts liability to choose a safe installation site. Explosion protectionguidelines also require that the explosion hazard and thus the resultingzoning must be taken into consideration.

The following conditions must exist at the site of installation to enablereproducible and exact results to be obtained. Otherwise themeasurement results could be negatively influenced.

MainsVoltage fluctuations ~.t; 10 % related to the

nominal voltage connection as offered

~ 20 ms

.t; 1 % related to the nominal frequency as per our offer

Earth resistance ~ 5,Q

Short term interference

Frequency ...................

Protective earthing ......

Suitable voltage stabilisators are required if strongly fluctuating mainsvoltages are to be reckoned with.

TemperaturePermissible range for Ambient temperature +10 °C to + 35 °C

Permissible ambient temperature driftduring a test :t 1K

Humidity, non-dewing '."".".".."..."' '."' "...' 20 % to 90 %Transport and storage temperature - 25 °C to + 55 °C

Please make sure of sufficient ventilation. You must place a de-humidifying agentto the materials testing machine if it's to be stored for a lengthy period of time.

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System operation emits heat depending upon the performance. Pleasetake measures to ensure sufficient heat dissipation.

Type of protectionCorresponds 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 documentation05.04/ TUmgeb / V3. 0

Zwick IRoe11.Connection of computer systems/Peripherals

Devices connected to the materials testing machine must be within theradio interference limits.

Interference free operation is only possible if these devices are pluggedinto the materials testing machine's mains output sockets, or connectedto the same phase plug as that for the materials testing machine.Whereby all cables should be as short as possible.

Compressed air

The materials testing machine does not require any compressed air.However, some of the optional test tools used in conjunction with themachines require compressed air.

6 to 10 barISO 344832 mm2/s

filtered, dehumidified and oiled

Operating pressure ..................................................with recommend oil to .........................................

Viscosityt...........................................................

'8Water, Gases

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The materials testing machines require neither water nor gas supplies.An exception is hydraulically operated testing machines and someoptional auxiliary equipment/devices which need water and gas forcooling.Please ensure sufficient ventilation for emission of gases.

,.Zwick technical documentation05.04/TUmgeb/V3.0 37

Zwick I Roell

~

Index Heating upHumidity ..

:;.:~.J: 17,..'::...:.:: 35

Identification 6Improper use

Load cell 30, 32Materials testing machine """""""""""""""'" 17TC-MODCSCC module 22

Installation plan 38

AAccessories

Materials testing machine ..............

Ambient temperature ...........................1935

CCalibration 5Characteristic value 28Compressed air 37

Computer systems 37Connection of computer systems 37

LLeakage current monitoring """"",."" "" 13Limitation 15Limitations

Video extenso meter 34Load cell 25

Cable guide 26Characteristic value 28Data cable 25Data memory 25Definition of the characteristics 27Force at .break 27Function description 25Maximum loading range 27Measurement range """"""""""""",."""", 27Nominal force 27Operational range ,."",..""""", ,."" 27Permissible torque 28Plug casing 25Static limit lateral force 28Temperature influence 28

Load cell TC-LCOO20N.PO1Improper use ' ".."'.'.""""."".."."""..' 30Overview 29Proper use 30Technical data 30

Load cell TC-lCO200N.PO1Improper use 32Overview 31Proper use 32Technical data 32

Load cell's cable guide 26

DDefinition

Characteristic value 28Force at break 27Limit lateral force 28Maximum operational force 27Nominal force , 27Operational force "",..,."", , 27Permissible torque ,..",.",.., 28Static limit lateral force " ,.., ,.., 28Temperature influence " ",.,.,.., , 28Torque ",.,.",..., " 28

EElectromagnetic fields ............Electronic rating plate ............Environmental conditions ........

~1235

13182717

!

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.. 15

..33

FFI Circuit breaker """""'."".'."".'.""Fire fighting equipment .....................Force at break ..................................Free from vibrations ,Function description

Materials testing machine ...........Video extensometer ....................

361335

GGases....

MMagnetic fields ....................

Mains output .......................

Mains requirements.............

Materials testing machineAccessories ...................Electronic rating plate ....Emissions ......................

37

HHazardous use . 16

Zwick technical documentation01.02/THlndex/V2.0 39

191217

Index

111516171013.91510.7272525

Video extensometer 34

2222212222

Force measurement .....Function description .....Hazardous use ' '.Improper use .................Load frame ....................Operating data ,0/er.fIeIN ,Proper use " ' '.."Technical data ...............Technical details ...........

Maximum operational forceMeasurement amplifier .......Measurement bridge...........

23

30,......""".....................................

NNoise level.....Nominal force

~~27

TTC-MODCSCC module

Connectable sensors .......Improper use ....................0tIerview ...........................Proper use .......................Technical data ..................

TCOPSOOHZTechnical data ..................

Technical dataLoad cell ..........................Materials testing machineTC-MODCSCC module. . .. .TC-OP500HZ....................Video extensometer .........

Technical details ...................Temperature influence ...........Temperature requirements .....Type of protection ..................

35

13

0Operating conditions .............Operating data

Materials testing machine0Jerview

Load cell ..........................Materials testing machineTC-MODCSCC module .....Video extensometer .........

333433343434

p

VVideo extensometer TC-EXVIDEO.OO2

Function description .......................Limitations .....................................0Ierview "'.""""""""""""'.".'.."...Proper use .....................................System description ........................Technical data ................................

2813 W

Water 37......30,..................

Permissible torque ................

Power consumption ...............

Proper useLimitations .......................Load cell ..........................Materials testing machineTC-MODCSCC module. . . ..Videoextensometer .........

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13

38

RRated values ...............Requirements for fixing

.628352538

SSerial number plate .....

Static limit lateral force

Storage temperature .....

Strain gauges ...............

Structural requirements

System description

Zwick technical documentation 01.02/THlndex/V2.0

3210222334,. 7283535

29, 319

2133

1532152234

~Environmental and operating conditions

Installation plan

The space requirements are listed in the Technical manualunderparagraph Technical data.

Storing accessories

Depending upon the accessories to be stored, you should have alockable storage place (Cabinet or similar). This furniture hasn't beentaken into consideration for the installation plan.Why a cabinet that can be locked-up? Extensometers, load cells andphysical 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 listedin the technical data. Please note that the height of the room must beapprox. 20 cm higher than the test machine's maximum height (see therespective technical data).

Requirements for fixing

The materials testing machine is normally free standing, however, somehydraulic testing machines are fixed to the floor.Align the machine and pay attention that it stands safely on its own on alevel floor.

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Zwick technical documentation38 05.04/ TUmgeb / V3.0

~Environmental and operating conditions

External influencesMaterials testing machines and testers are highly sensitive measurementsystems. Thus the following must be avoided at the installation site:. Jolts and vibrations. Oscillations. Vibrations. Schock. Conducting air. Corrosive contamination

RecommendationInstalling shock absorbers, air filters or signal filters.

We would be only too pleased to be of assistance to you should you beconfronted with these problems.

Electrical, magnetic and electromagnetic fields

Our materials testing machines and testers are laid out to the now validEMC guidelines.The following measures have already been taken against the namedinterferences in the construction of materials testing machines withelectronics consoles:. Enclosed metallic casing.. Screened leads.. Connection of all devices and screens to the protective earthing.. Star shaped reference conductor system.

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You must take the following measures if the above ones are insufficient:. 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

~Technical detailsTC-EXVIDEO.OO2

Technical data

Order no. BTC-EXVIDEO.OO2

This order no. for the video extensometer includes a video camera, a pictureprocessing software and a PC hardware dongle.

The technical data for the video camera can be taken from the separate videocamera instruction manual.

System description

The measurement system is a digital video camera with a pictureprocessing system. The resolution and measurement range can beadapted to the properties of the materials to be tested by a suitableselection of camera lenses.The picture of the specimen digitised by the video camera is processedin a PC supported video processor in real time.

Proper use

The video extensometer makes non-contact and high resolution tensileand compressive deformation measurements on all types of plastics,metals, rubber, laminates, wafers and foils.

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Limitations

There is a risk of fogging in a temperature chamber when thisextensometer is used in conjunction with Co2 or LN2 cooled temperaturechamber. It may eventually be necessary to wait several minutes beforeproceeding 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

Technical data

Order no. BTC-LC0200N. PO1

200 N120 % of F nom

150 % of F nom

>300 % of F nom<= 10 % ofF nom

0,1 mm

i: 0,05 % FN/10 K

i: 0,05 % FJ10K

Nominal force F nom , "' "'."..'..'..".'-'f-"'~""~".

Maximum force to be used FG :............................................................;;L. . & F >:,

Imrt ,orce L ~.............................

~Force at break Fe ';,.....................--.

Static permissible limit and transverse force F Q ~

Nominal measurement path ........................................................Maximum temperature influence on the zero-signal TKo ...................

Maximum temperature influence on the characteristic value TKc

O,8N.. 4 N

Measurement range, initial value:grade 1 0,4% of nominal valuegrade 0,5 2,0% of nominal value

Temperature rangeType of protection. .

Model....................

-20 +60 DC

IP42

. KAP-Z

..86

..42

..14

08

Dimensions:Height ......................Width .......................Depth .......................Mounting studs ........

Weight 0,3 kg

Proper use

This load cell is designed for measuring static and dynamic tensile andcompression forces. It must be operated in the direction of the test axisand to its nominal force whilst adhering to the conditions as containedunder the technical data.

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Improper use

Load cells are precision measurement devices and, as such, should betreated with the utmost care during transport and at assembly. They couldbecome irreparably damaged if subjected to shocks and/or knocks.

Zwick technical documentation 01.02/Tech /V2.032

mmmmmmmm

~Technical detailsLoad cell TC-LCOO20N.PO1

Technical data

Order no. BTC-LC0020N.PO1

20 N110 % of F nom

150 % of F oom

..>500 % ofFnom<= 10 % of Fnom

0,4 mm.:t 0,1 % FJ10K.:t 0,1 % FJ10K

'A

Nominal force F nom ,.,.~~~.~

Maximum force to be used FG ~ ~..

Limit force FL '.."""""""""""""""".""...""".' ¥............................

Force at break F B ;.~..............................Static permissible limit and transverse force F Q .....................................

Nominal measurement path ,

Maximum temperature influence on the zero-signal TKo ...................

Maximum temperature influence on the characteristic value TKc

u Measurement range, initial value:

grade 1 0,4% of nominal value

grade 0,5 2,0% of nominal valueO,08N. O,4N

Temperature rangeType of protection..Model....................

-20 +60 °CIP42

. KAP-Z

..81 mm

..60mm

..13mm08mm

Dimensions:Height ..............Width ...............Depth ...............Mounting studs

Weight 0,3 kg

Proper use

This load cell is designed for measuring static and dynamic tensile andcompression forces. It must be operated in the direction of the test axisand to its nominal force whilst adhering to the conditions as containedunder the technical data.

Improper use

Load cells are precision measurement devices and, as such, should betreated with the utmost care during transport and at assembly. They couldbecome irreparably damaged if subjected to shocks and/or knocks.

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~Function description, testControlLoad cell

Static limit lateral forceFain N

Greatest force that may be applied at the load cell's forceintroduction point vertical to the measurement axis withoutany significant changes to the load cell's measurementproperties being detectable when using the load cell againup to its nominal force.This is also valid at simultaneous loading of the load cell tonominal force.

Permissible torque torqueMG in Nm

Permissible torque about the load cell's measurement axiswithout any significant changes to the load cell'smeasurement properties being detectable when using theload cell again up to its nominal force.This is also valid at simultaneous loadingof the load cell tonominal force.

Characteristic valueC in mVN

The output signal at nominal force is diminished by the pre-load signal.

Temperature influence to thecharacteristic value per 10 KTKc

Relative change to the characteristic value of the load cellowing to a change in the temperature by 10 k within adefined temperature range after setting the stationarystates.

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Temperature influence to thezero-signal per 10 KTKo

Changes to the load cell's zero-signal related to thecharacteristic value due to a temperature drift by 10 Kwithin a defined temperature range after setting thestationary states.

Zwick technical documentation 04.02 I Ffunk I V2. 1

iii:i!(,~""' ","'C

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Cable guide

As the respective test requirements are so different, thefollowingrequested recommendations are to be observed and thecorresponding measures are to be taken:

1) The load cell's measurement cable must not be subjected to anymechanical stressingor stretching at all over the entire crossheadtravel.=> 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'sconnection leads nor direct on the motor.=> 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 cellmeasuring cable at specimen break.=>Place the cable so that it is correspondingly protected.

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Zwick technical documentation26 04.02 I Ffunk I V2. 1

Technical detailsTC-OPSOOHZZwick I Roell

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~Technical detailsTC-MODCSCC module

Technical data

Order no. BTC-MODCSCC

Measurement range 0,2 to 165 % of the nominal measurement valueTest data recording rate switchable via software, maximal 500 HzResolution at 100% nominal measurement value:

at 500 Hz test data recording rate 162000 pointsat 50 Hz test data recording rate 297000 points

Differential input< 5* 1 Q-4 %/K of nominal measurement value

+1- 0,01 % of measurement end value+10 to +45 °c

Type of measurement input ...........

Zero-point, temperature dependentMaximum linearity error .................

Temperature range ........................

Dimensions:Height ...Width....Depth. . . .

.30mm108mm135mm

Connectable sensors

Full bridge

4 and 6 lead technology

2 mVN+/- 2 %

100 to 1 200 0.

10 V DC

Strain gauge measurement bridges ............Type of connection .....................................

Nominal characteristic value, sensitivity.....

Maximum characteristic value tolerence .....Permissible strain gauge bridge resistance

Sensor supply voltage ................................

Proper use

The TC-MODCSCC module is foreseen for connecting strain gauge full-bridge sensors. This module enables you to operate strain gauge loadcells and also other strain gauge measurement bridge sensors in 4 and6 lead technology. .I.

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Improper use

Inductive systems cannot be operated by the TC-MODCSCC module.


Technical detailsMaterials testing machine 5 kN

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Zwick technical documentation 06.02/ Verwend / V2. 1


Fire fighting equipment

Fire extinguishers to DIN EN 2 combustion classes A and B may beused for combatting fire, smouldering and similar.These are:

Combustion class A Burning of solid materialsCombustion class B Burning of liquid or liquefying materials

Support profile 061110.02

The support profiles for the materials testing machines are optionalparts. To enable truely ergonomical operation for seated or standingoperation, reference to the optional support profiles will be made quiteoften in this instruction manual.

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Zwick technical documentation18 06.02 I Verwend I V2. 1

~Technical detailsMaterials testing machine 5 kN

No risk use

Specimen and jaw inserts may be used that will neither be propelledaway from the test machine at specimen failure (break), nor will fall fromthe grips.

Hazardous use

A safety device must be used for all other test requirements. This isespecially true for:- Specimen with high potential energy and resilience properties, such

as springs, ropes, belts and similar- Use of hardened or ceramic jaw inserts

If potential sources of danger exist as, for example, defined by DIN51233:

Danger: Caused by

Risk of injury by specimen(or their constituent parts)

Them being propelled away from the machine,or falling to the floor

- Danger of squashing by specimenholders Specimen holders that are not manually

operated(e.g. hydraulic, pneumatic, electrical) withclosing speeds higher than 10 mm/s

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Risk of injury through jaw inserts Those made of hardened steel or other brittlematerials (e.g. glass. ceramic, etc.)

Danger of squashing pans of the bodyaround the crosshead

At speeds above 10 mm/s

When using temperature chambersRisk of injury by very hot or very coldparts and surfaces

Zwick technical documentation 06.02/Verwend /V2.1


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Zwick technical documentation14 04.03/230V- Tech /V2. 7

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Technicar detailsMTM T1-FROO5TN.A50

Electronic rating plate

All of a materials testing machine's important data, such as the nominalforce of the load application device, is saved to an electronic rating plateThis materials testing machine is thus capable of determining its own

configuration.

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Technical detailsMTM T1-FROO5TN.A50

Technical data

Type/Order no. BT 1-FROOSTN.A50

5 kN

1,299mm1.545to2.114mm

680 mm856 mm256 mm650 mm

680~ ~

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Load frameTest load in tensile/compression

Load frame height.......................

Overall height .............................

Load frame width ........................

Overall width ...............................

Load frame depth .......................

Overall depth ..............................

~~ 150 kg180 kg

..,.~~

NI

It)

.'1;~

...106cm25,564cm2

1.70 kg/cm22.55 kg/cm2

,

WeightWith electronics console ..............With typical accessories, approx.

Space requirements:Pure contact area ........................Load frame, area '.' "" "."'"

Specific floor loading:Related to the typical accessoriesWith 50% safety ...........................

Floor loading:Related to the typical accessoriesWith 50% safety "' ".."' '.'

0.03 kg/cm20.05 kg/cm2

1Test area width 440 mmHeight of the lower test areaw.o. accessories 1,058 mmHeight of the upper test area

w.o. accessories (Crosshead is required) 1,034 mmFinish """"""""""""""""""""""'" RAL 7011 and RAL 7038Ambient temperature +10 to +35 °C

Humidity, non-dewing 20 to 90 %Noise level 67 dB(A)

0,0005 to 3,000 mm/min

0,03 % ofV~0.041 ~m< 1.0 ~m

Drive systemCrosshead speed .....................Accuracy of the setspeed .. .....................................Drive system's travel resolution

Positioning, repetition accuracy(W.o. reverse of direction)Maximum test frequency..........Operator's workplace

~

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Zwick technical documentation10 04.03 I Tech IV2.7

Technical detailsMTM T1-FROO5TN.A50

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IdentificationMaterials testing machine

Identification

Each materials testing machine has two serial number plates asstandard. A large serial number plate is on the electronics console andsa small one is on the rear of the machine base. An exception is thesingle screw materials testing machines, each of these has only oneserial number plate.

Large serial number plate

Here is the CE sign for those materials testingmachines that have a declaration of conformity.

Manufacturer with address

Nominal value of the materials testing machine

Small serial number plate

Manufacturer with address /' Here is the CE sign for those materials testingmachines that have a declaration of conformity.

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- Order number = Machine type

Serial number/Year of construction

Nominal value of the materials testing machine

~SafetyMaterials testing machine

Your safety

This technical manual should make it easier for you to get acquaintedwith the machine and to use its range of applications.

This technical manual contains important remarks on transporting thematerials testing machine correctly, safely and economically and oninstalling, dismantling and storing it. Pay attention to these remarks. Theymake it possible to increase the reliability and life span of the machine.

The instruction manual must be read and used by all persons authorisedto work at and with the machine.

The entire instruction manuals must always be available at the testmachine's installation site.

National regulations

Supplement the technical manual with instructions from nationalregulations on accident prevention and environmental protection

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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/THlnhalt/V3.0

DocumentMaterials testing machine

General

In this section you can obtain data important for the materials testingmachine and obtain information on our company and its products.

Document: Technical manual

Version:Print date:

V3.0November 2005

All rights reservedI0~ri~~

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Tips, remarks and constructive criticism are welcome. Please directthese to:

Zwick GmbH & CoTechnische OokumentationAugust-Nagel-StraBe 110-89079 Ulm

Fax: +49 - (0) 7305 - 200

Zwick technical documentation 05.04/ THlnhalt / V3.0

Index

Proximity switch 13, 16, 21

13

.911111123181117

22

WWarning signs ......................Work

On laser light sources .....

WorkingOn hydraulic equipment ..On pneumatic equipmentWith electrical equipment

Working area ........................Workplace ............................

.,":if

......

......17,

RRemaining risks ..........................Risk ofbuming ............................Risk of frostbite ...........................Risk of injury ...............................Risk of slippage ..........................

Riskofsquashing........................Risk of trapping parts of the bodyRotating lead screws ...................

13, 16, 172020

13, 16

16162018

16

13

21

13

12

18

19

.5

.5

111111111111 I

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SSafety

Devices """"" '..".' '

Gloves .........................................Goggles ,

Safety devices :',.,

Safety measuresAtoperation ................................Before switching on .....................Ear protectors .............................Specimen holders " '.."""

Safety notes.....................................Safety remarks.................................Serv'K:e "" """" ""..."".

Setup ...............................................Signal words ....................................Specimen holders.............................Spring tests ......................................State of the art '.."..."'..."..."' '.'.Supplements ....................................

SymbolsElectrical voltage .........................Laser beam .................................Risk ofbuming ............................Risk of frostbite ...........................Risk of injury ...............................Risk of trapping parts of the body

18.6

TTensile tests

Transport.....

UUsage

Improper useProper use ...

87

Zwick technical documentation 01.02/ Silndex / V2.0

2323221815

[4]".SafetyCleaning

Please adhere to the legal obligations for avoiding waste as well asdisposing and recycling it.

Water pollutants must not pollute the earth, and they must not gain accessto the sewer system IExamples 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 relevantsafety data sheets. The enclosed safety data sheets are to be found insection 13 "Certificates/Calibration reports"Dispose of all replacement parts safely and in an environmentally safemanner.

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Zwick technical documentation 10.05/ Sicherheit / V2.924

[4JSafetySafety measures and notes.

When working with electrical equipment

The leads from the mains cable(s) and mains input filters up to the inputof the main switch are under current even when the materials testingmachine is switched off.

Maintenance and corrective maintenance work on electrical equipmentmust be carried out by competent and qualified electricians only!

Electrical equipment and systems should be checked regularly, atleast every 4 years, for proper functioning (BGV A3)by qualified and competent electricians.Please keep the switch console closed at all times! Access is onlypermitted for electricians with keysltools!Switch consoles/Housing for electrical equipment (Such aselectronic housing, motors) should never come into contact withwater nor steam (I.e. steam jet cleaners)!

When working on laser light sources

Only trained, competent and authorised personnel are to be allowed towork on laser equipment.

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Zwick technical documentation22 10.05/ Sicherheit / V2.9

[4]SafetySafety measures and notes

Safety goggles, safety glovesRisk of injury!

Example:- Tests on specimen that shatter- Tests with jaw inserts that might shatter- Component testing

Everybody, even observers, must wear safety goggles ifpotentially dangerous tests are being run (EN 166) and/or

protective gloves.

TemperatureDanger 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 atemperature chamber.Never ever leave hot/cold specimen lying around unprotected.Only work with heat resistant protective gloves.

NoiseLoud 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 thatcould damage your hearing. The noise levels for therespective materials testing machines and their componentsare to be found in section 2 "Technical manual"

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Laser extensometerSafety goggles aren't necessary. Avoid looking into a laserlight source and never use optical instruments to look into

laser beams.

Working on laser equipment should only be done bycorrespondingly trained service personnel.


~SafetySafety measures and notes

Working in the working areaDanger of trapping parts of the body.Keep your hands away from the test area when the materialstesting machine is running.

Specimen holders, hydraulic/pneumaticDanger of trapping parts of the body.Keep your fingers away from between the gripping jaws.Use a tool, e.g. tongs, for inserting specimen!Tongs are available for hydraulic grips.

Please make sure that any pneumatic and/or hydraulicequipment of, or for use with, the materials testing machine isat zero pressure before you start to work with it.

..I Tensile tests: Risk of squashingDanger of trapping parts of the body.There's a danger of trapping parts of the body after test duringreturn to der initial position. There's a danger of squashingparts of the body especially between specimen holders thatare close to one another, i.e. the free grip to grip separation isvery small.You must wait until the test is ended and the crosshead hasstopped moving before attempting to access the workingarea.

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Compression and flexure tests: Risk of squashingDanger of trapping parts of the body.There's a danger of squashing parts of the body during thesetests whilst the compression platens or flexure test elementsare in motion. Never ever attempt to access the spacebetween compression platens or flexure test elements withparts of your body whilst a test is running.

Zwick technical documentation V2.910.05/ Sicherheit

~SafetySafety measures and notes

Before switching on

Please observe the following before switching the materials testingmachine on:- Only authorised persons may be allowed into the working area of

the materials testing machine- Check the all safety devices (Safety devices, limit switches,

proximity switches and EMERGENCY OFF button) for evidentmalfunctions.

- 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 machineinto operation.

At operation

Gather information on how to react in case of defects or damage beforeswitching the materials testing machine on.Non-observance could lead to injury.

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EMERGENCY OFF buttonIn case of danger any movement of the materials testing machine mustbe stopped immediately by hitting or pressing the red EMERGENCYOFF button.


SafetyInstructions 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 worksafety and environmental protection as follows:- Before the beginning of their work- After any eventual alterations/amendments to the test system

however, at least- Annually

The operating personnel must know the safety remarks contained inthe instruction manual and adhere to themThe operating personnel wears suitable protective clothing (Safetygoggles/face shield, safety shoes, protectice gloves, tightly fittingclothing, haimets for long hair).

Please pay attention to the following as a user of hydraulic testsystems:

Loss of oil could possibly occur during both operation or when the systemis idle due to leakage. It could even occur during maintenance work. Lossof oil could cause environmental pollution (Ground water pollution) andcould also be the cause of accidents.

Please pay attention that hydraulic components are situated where itwould cause no problems at all to accommodate the maximum quantityof oil which could be lost due to leakage. Oil sumps or similar konnen orspecially built hydraulics-cellars can be used. Please make sure thathydraulic oil cannot penetrate into the ground.

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Please make sure that all valid rules and reugallations as well as lawsand guidelines on the handling and disposal of (Hydraulic) oil(s) arestrictly adhered to.

Zwick technical documentation 10.05/Sicherheit /V2.9

14]SafetySymbols and hit words

Signal words in the instruction manual

The instruction manual marks functions which may contain risks of injuryfor the operating personnel or danger for a device with the signal wordsas indicated below. These functions may only by carried out by trainedoperating personnel with due care and diligence.

Indicates a potentially hazardous situationwhich, if not avoided, may result in minor or moderate injury.

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iSafety remarks with the signal word "DANGER" or "WARNING" may alsocontain hazards for test systems, accessories and the environment.


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Safe~Preventive measures

Furthermore, each of our materials testing machines is equipped with anEMERGENCY 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, atleast every 4 years, for proper functioning (BGV A3)by qualified and competent electricians.Please make regular visual checks of all hydraulic hoses. They mustbe replaced immediately if any damage is detected. According toDIN 20066 fluid technology, hoses hydraulic hoses should bereplaced every six years at the latest as a precautionary measure.

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RecommendationAll safety devices (E.g. EMERGENCY OFF button, limit switches,safety door, etc.) should be checked and maintained by anauthorised person:- Immediately upon detection of damage- Following maintenance work- At least once a year


~SafetyImpermissible use

Improper use

Any usage listed or exceeding the proper use is recognised as beingimproper use. Zwick does not accept any liability whatever for damgeresulting 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 devicesintegrated by the user. Any necessary safety measures are then the soleresponsibility of the operator/user.

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Zwick technical documentation 10.05/ Sicherheit V2.9

[4JSafetyTransport

Transport

Adhere to the regulations governing safety and health protection at work(Liability of the system supervisor) when making work means available.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 liabilitywhatever for the use of any types of transport other than that described inthis chapter.

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Zwick technical documentation6 10.05/ Sicherheit V2.9

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Zwick technical documentation4 04.03/ Silnhalt / V2.5

~DocumentMaterials testing machine

General

This section contains information that is important for maintenance andservice for your materials testing machine and the accessories.

The safety manual must be read and used by all persons authorised towork at and with the machine.

Document: Safety manual

Output:Print date:

V2.9November 2005

All rights reserved

Tips, remarks and constructive criticism are welcome. Please directthese to:

Zwick GmbH & CoTechnical documentationAugust-Nagel-StraBe 110-89079 Ulm

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Fax: +49 - (0) 7305 - 200

Zwick technical documentation2 04.03/ Silnhalt / V2.5

[VJProduct descriptionMaterials testing machine

Zwick materials testing machines can be put to universal use. They areconcipated for almost all test requirements for nationalen and internatio-nal standards, as well as for a large part of the requirements asdescribed by a wide range of "in-house standards".Thesematerials testing machines are not only for use in quality assurancefor rotine investigation, but also for research whereby test programs mustfirst be defined.

Overview:

ExtensometerMCEUnit

{MeasurementControl

Electronics}Materials testing machine

Communicationinterface

Environmentalsimulation

PC.,

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Safety device

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The modular construction enables supplementary retrofits to be made

very easily.

Zwick technical documentation10 05.04 Iident I V3.(J

Description of the companyMaterials testing machine

~

Zwick Roell AG

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Zwick technical documentation8 05.04/ldent / V3.0

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Use of the instruction manualMaterials testing machine

The instruction manual is structured to the same repetitive patternThe single chapters are compiled in the sequence:- Materials testing machine

- Load cell- Extensometer

- Power pack (hydraulic/pneumatic)- Test tools

- 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 themanuals are supplied for that equipment as per the configuration of yourmaterials testing machine. Some chapters don't require a detaileddescription for certain parts.

The next diagram shows how a section in the instruction manual iscompiled, using the installation manual for a materials testing machinewith hydraulic power pack, test tools, extensometer and temperaturechamber as an example:

[Z]Installation manual

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Zwick technical documentation6 05.04/ldent/V3.0

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Use of the instruction manualMaterials testing mach,ne

Should you resell your materials testing machine, you must also provideyou r customer with the instruction manual. The complete instructionmanual 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 themethat interests you more quickly as this introduction informs you where andhow you can find your way.The instruction manual is split into different categories:

Important for everybody

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,

Section 4: "User manual".Aimed at operating personnel and describes theoperation/operating elements of purchased

components.

Section 10 "Service and maintenance manual".Aimed at maintenance personnel with maintenanceintervals as well as error rectification.

Section 11 "Circuit diagrams"Aimed at maintenance and service personnel.

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What everybody needs

Section 2: "Technical manual".Contains the technical data,

Section 15 "Appendix".Contains addresses and a maintenance order form.

Zwick technical documentation 05.04/ldent I V3.0

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Manufacturer:Zwick GmbH & CoAugust-Nagel-StraBe 110-89079 UlmGenTlany

Customer service:ZwickServiceAugust-Nagel-StraBe 110-89079 Ulm

Telephone:07305 102250190881988

Help for malfunctioningSupport for operation andapplication

Fax: 0730510200eMail: [email protected]

Internet: http:\\www.zwick.dehttp:\\www.zwick.com

Further addresses from service and sales companies are listed in the appendix.

Document: Instruction manual "Materials testing machine"is split into:- Safety manual- Technical manual- Installation manual- User manual- Service and maintenance manual

Version:Print date:

See the respective manualNovember 2005

Copyright (c) 2005 by Zwick GmbH & Co.August-Nagel-Str. 110-89079 Ulm-Einsingen

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All rights reserved

We've done our best to make sure that this instruction manual is complete and free oferrors. Should you notice anything that is unclear in spite of this please inform us. Ourproducts are being continuously improved upon. Thus it may happen that somestatements in this manual don't always correspond to the latest state. Exact info canbe obtained by calling Zwick in Ulm if you're not entirely sure.


0730510-0Hotline:

Supportline:

Documents

Instruction manual for materials testing machines