Pin on Disk Tribometer Manual

Customer: Date Issued: 6/7/06 Serial Number: Page: 1

INSTRUCTION MANUAL

for the

Falex ISC Pin on Disk Tribometer Data Acquisition System

Falex Corporation 1020 Airpark Drive Sugar Grove, IL 60554 Phone: (630) 556-3669 June 7, 2006


TABLE OF CONTENTS Page 1. Introduction 1.1. Brief Description of Program 3 2. Initial Setup 2.1. Space, Location and Leveling Requirements 4 2.2. Unpacking & Cable Connections 4 3. Description of Equipment 3.1. Principle of Operation 5 3.2. Front Panel Controls 5 3.3. Low Friction Adjustment 7 3.4. softWEAR™ Program Operation 8 4. Calibration 4.1. Tribometer 31 4.2. Software 36 5. Typical Test Procedure 5.1. Mechanical 39 5.2. Software 41 41 6. Options, Accessories and Spare Parts 6.1. Options 42 7. Troubleshooting 7.1 Mechanical 46 7.2. Software 46 7.3. Technical Service Request Form 47 8. Registration, Warranty, Service and Training 8.1. Registration 48 8.2. Warranty 51 8.3. Extended Warranty 52


INTRODUCTION 1.1 BRIEF DESCRIPTION OF PROGRAM

The Falex ISC Pin on Disk Tribometer softWEAR™ Data Acquisition Program is designed to upgrade current Pin on Disk systems using the PC-Stripchart™ program. The program allows the operator to conduct tests under a Windows™ environment making data acquisition and manipulation much easier and intuitive. The softWEAR™ program offers many new features that were not available with the PC-Stripchart program. These include: 1) Data Acquisition of multiple signals The softWEAR™ program captures the coefficient of friction signal from the Tribometer, and also motor speed and cycles. Optionally, humidity and temperature can be captured and displayed. 2) Data Acquisition Rate PC-Stripchart offered 1 data point per second or slower collection rate. The softWEAR™ program allows data acquisition range of 50 points per second (50 Hz) to 1 point per minute (0.017 Hz). 3) Data File type PC-Stripchart saved the raw test data in a proprietary, compressed format which required “uncompressing” to create a file which could be read by a commercial spreadsheet program. Revolutions of the platter (disk) were indicated by a turns pulse. The softWEAR™ program saves the raw test data in a CSV (comma separated value) format which can easily be read by most spreadsheet programs. The data file includes the relative collection time, coefficient of friction, motor speed, cycles, motor speed, humidity level, and temperature. Date and time at start and at end of test are also included in the file. 4) Printing PC-Stripchart supported very few printers. Since the softWEAR™ program operates under a Windows2000 operating environment, any printer identified by the operating system can be used to generate graphs. 5) Test Limit Notification Operators using the PC-Stripchart program could stop a test on coefficient of friction, time, cycles, or total sliding distance. The softWEAR™ program has included these features, but also creates an information box to allow the operator to determine which limit stopped the test.


INITIAL SETUP

2.1. SPACE, LOCATION AND LEVELING REQUIREMENTS

The Pin on Disk test machine requires a bench space of approximately 30 inches by 72 inches to comfortably operate the test machine. The table should be reasonably level (1/32" per foot). This table should be able to support the test equipment while being free of external vibrations. Allow at least four inches behind the machine so there is ample room for wiring hookups. Calibration of the mechanical section requires approximately 12 inches to allow back access panel to open completely.

2.2. UNPACKING AND CABLE CONNECTIONS

Unpack the instrument and computer and inspect for obvious shipping damage. Notify the freight carrier immediately upon discovery of any damage. Unpack the test machine and place it the work area. The test equipment has been calibrated at the factory prior to shipment. Set up the computer to the right of the tribometer. Connect the keyboard, mouse, and monitor to the CPU. The video monitor is plugged into a source of 110VAC and a 9 pin female connector on the rear of the computer. The Pin on Disk machine cable is connected to the data acquisition board in the computer by a 37 pin plug and the 37 pin connector (or 25 pin connector) on the rear of the pin on disk machine. The computer, monitor, and tribometer must be connected to 110 VAC source. (Three 110-120 VAC outlets are required on standard unit). Connect the AC power cable to the right side of the pin on disk machine. Turn on the power switch located near the center front panel of the pin on disk machine (pull out, then up) and the LED displays should light up. At least 15 minutes should be allowed for warm up of the circuits in the unit. The unit is now ready for operation.


DESCRIPTION OF EQUIPMENT 3.1 PRINCIPLE OF OPERATION

The Pin on Disk test machine consists of a spherical end pin (or ball) loaded against the flat surface of a rotating lower horizontal specimen disk. The pin is pressed against the disk at a specified load by means of a lever and attached weights. The maximum dead weight allowed for a test is 2 kgs or 4.41 lbs. (Actual specimen load of 1 kg or 2.2 lbs). The lower specimen has a rotation speed range from ~10-325 rpm.

3.2 FRONT PANEL CONTROLS (See Figure 3a)

a) AC Power Switch

This is a self locking toggle switch. It must be pulled out to flip up. This provides AC power to all circuits except the computer.

b) Motor Control

The multi-turn knob directly above the AC power switch controls the speed of the motor. The on/off switch to the right of this knob turns the motor on. If the motor is turned on, the green light to the left of the motor speed control will be on. Place the data select switch in the RPM position to read the motor speed in revolutions per minute as you rotate the knob. The motor speed is controllable from ~10 RPM to 325 RPM. The motor RPM may not be constant outside of this range. Other speeds may be obtained as an option. The motor control for the oscillation model is found on the touch screen pad on the motor control cabinet. Unidirectional or oscillatory mode is available.

c) Turntable Radius Control

The position of the pin on the test disk is controlled by the knob immediately above the motor speed control. This is a 3 position switch which is normally in the Off (vertical) position. Turning this knob to the right moves the entire motor carriage to the left and thereby increases the radius of the wear track. Moving the knob to the left decreases the radius.

The radius is displayed in the DATA display when the data select switch is in the Radius position. The units of the radius are in millimeters.

d) Preset Rotations

The turntable can be set to automatically stop when a preset number of rotations has been reached. The number is set with the thumb switches to the left of the "motor on" indicator. The turntable will only respond to the preset count if the toggle switch on the right of the thumb switches is up (on). The rotation count LED (above the preset rotations) will always increment as the turntable rotates regardless of the preset switch being on or off. The rotation count LED can be reset to zero at any time by depressing the clear button to the left of the preset rotations thumb switches.


In oscillation mode, the rotation count is displayed on the touch screen. A cycle limit field is also available on the touch screen.

e) Data Select Switch

A five position rotary switch is on the right-center of the front panel.

i) Calibrate Used when calibrating the force gauge. ii) Radius (mm) Displays the radius set in millimeters. iii) RPM Displays the disk rotations per minute. iv) Force (gm) Displays the friction reaction force on the pin. v) Friction Displays the friction coefficient (unitless).

f) Zero Force

This is a 10 turn control which is used to set zero on the force gauge when there is no load. Put the data select switch in the Force position while adjusting zero.

g) Weight (gm) Setting

The weight thumbwheel switch is an input device, which tells the tribometer what weight is hanging from the lever arm. Note that this is not the pin load value, which is one half the value of the hanging weight.

h) Friction Limit

When running a wear test, the rotation will automatically stop when the friction coefficient exceeds the value input on the push button switches. This friction limit function is only activated if the toggle switch on the right of the thumb switch is up (on). When the limit is reached, the red indicator comes on and stays on until it is cleared by lowering the toggle switch to the down (off) position.

Please be aware that there is a load limit for the force transducers. The following chart will enable you to select a friction limit setting on the front panel that will prevent damage to the force transducer.

454g 113g Hanging Weight Friction Limit Friction Limit

4000 gm .15 0.038 2000 gm .30 0.075 1000 gm .61 0.151 500 gm 1.22 0.301 200 gm 3.04 0.753 100 gm 6.08 1.506 50 gm 12.12 3.012


Figure 3a Front Panel Controls

3.3. LOW FRICTION ADJUSTMENT

NOTE: Optional feature. For location, see Figure 4a.

When the coefficient of friction is less than 0.02, the individual increments in the analog-to-digital conversion process cause the value to jump in visible steps. At such low friction values, the resolution can be improved by increasing the friction signal amplification with this special option. The standard setting allows coefficient of friction values of 0 to 5. This provides a resolution of 0.0024. With the amplifier on, the friction values can be 0 to 1. This gives a resolution of 0.00049. NOTE: This option should only be used when friction values are low. If a large force is applied on the force sensor, the signal will jump to a high value and also distort other signals being captured by the data acquisition system. Turning On the Low Friction Option:

a) Open the rear door panel by unscrewing the 2 screws at the top corners of the rear

metal cover panel. The panel hinges at the bottom and opens outward.

b) A toggle switch is located on the main board, which is the largest board on the rear door panel. When the switch is toggled down toward the bottom of the rear door panel, it is in the normal position. When the switch is up toward the top of the rear door panel, it is in the low friction position.


c) Close the rear door and secure.

d) Start the softWEAR™ program. Open DAQ calibration.

e) Calibrate friction signal with a light mass (i.e. 20 grams) as detailed in calibration section. (Remember that hanging weight setting on front of Tribometer to be 33% higher than actual weight used.)

f) Close calibration panel. Conduct test.

3.4 softWEARTM PROGRAM OPERATION

softWEARTM 2002 by Falex Corporation. All rights reserved. No part of this publication may be stored in retrieval systems, transmitted, or reproduced in any way, including but not limited to photocopy, photography, magnetism or other recording technique without the express written permission of Falex Corporation. Information in this document is subject to change. The software described in this document is furnished under a license agreement. The software may be used or copied only in accordance with the terms of that agreement. It is against the law to copy this software on magnetic tape, disk, or other medium for any purposes other than the purchaser's personal use, except as specifically described in the license agreement.

The Falex softWEAR™ program has been designed to complement the Pin on Disk machine, and many of the options are specific for the needs of friction measurement. The Falex ISC Pin on Disk Tribometer is an independent instrument and can produce data without being connected to the softWEAR program. Similarly, a knowledgeable user can connect the computer to other signal sources than the pin on disk machine and use the software as a data acquisition program.

The softWEAR™ program analyzes data on the following variables from the pin on disk system:

i) Coefficient of Friction ii) Test Radius iii) Rotation speed iv) State of the motor (On or Off) v) Humidity (option) vi) Temperature (option)

The friction, motor speed and optionally, humidity and/or temperature can be plotted during testing. Since both the pin on disk machine and softWEAR™ program can independently zero the turns count, the two values may not agree. Resetting the turns counter on the pin on disk machine before starting the program will ensure correct cycle counts between the program and the equipment.


Various derived parameters are also displayed by the softWEAR™ program. These include:

i) Linear speed of the pin relative to the disk (cm/s) ii) Accumulated wear track distance (cm) iii) Time elapsed (hours:minutes:seconds) iv) Date of test v) Frictional Force (grams)

The linear speed is an important parameter when duplicating test conditions. Distance worn is the total distance the pin has rubbed on the disk and is related to elapsed time, radius, and rotation speed.

Other parameters are available for the user to document the test. These include the following:

i) Test name (Run Title description) ii) Pin material iii) Disk material iv) Lubricant v) Environment vi) Test Load (on the pin)

These parameters are included in the data file as a header prior to the test data. This allows the user to save test conditions with the resultant test data. Generally, the softWEAR™ program is supplied with the computer hardware as part of the Pin on Disk Tribometer system. If it is ever used on other equipment, the following hardware is required:

i) Windows 2000™ operating system ii) PC compatible computer. (1.0 GHz microprocessor, or faster) iii) 256 MB RAM, or more iv) A video monitor v) Keyboard, mouse vi) 20 GB hard drive, or larger vii) floppy disk drive viii) CD-ROM ix) Backup storage device (CD-R or Iomega ZIP drive) To facilitate archiving

of test data. x) Spreadsheet program (If plotting of saved data is desired) xi) One PCI expansion slot, for data acquisition card

Starting the Program Falex softWEAR™ is provided already installed on the computer. To start the program, follow these steps:

a) Turn on computer and monitor. b) Double-click Falex softWEAR™ icon on the desktop c) The copyright display should result after a few seconds. (See Front Page photo) d) The operating screen will display (Shown in Figure 3c) will be produced. The

program is ready to operate.


Ending the Program

The best way to exit the softWEAR™ program is to press the “exit” button at the bottom right corner of the operating screen. To stop a test before a limit is reached, press the “Motor” button at the bottom of the screen. The Tribometer motor will stop and the data acquisition system will stop collecting data.

Figure 3b Desktop screen


License Banner

When the softWEAR program is opened, the license banner is displayed. This information is also displayed when the “Help” tab is selected at the operating screen. If the system is configured to allow internet access, the Falex website can be accessed by selecting the blue hyperlink on the banner. The banner displays the software version number and shows the data acquisition card used with the program.


Figure 3c softWEAR™ Operating Screen

Through the use of custom settings, the operator can select how many signals to display during testing. Informational fields (to the left of the graphical display) can also be configured by the operator. Prior to starting a test, the fields to be displayed are selected. All information displayed in the fields is saved with the test data. Prior to starting a test, the operator must input test values and information required for calculated values. To access these “preferences” fields, the operator must select the “Tools” option located at the top of the screen. When the Tools menu is opened, select the “preferences” option. The following pages describe the options available.


Figure 3d General softWEAR settings

The general settings tab allows the operator to add a comment to the saved data file under “Run title”. The data acquisition (scan) rate allows from 20 mSecs (500 data points/ sec) to 6000 Sec (1 data/ minute). The hanging weight field is used to calculate friction force. The input value is the actual hanging weight to be used during the test. For those units which include a temperature option, temperature can be displayed in Fahrenheit or centigrade scale. (Note that saved file will always save in centigrade scale.) The operator can choose a delimiter for the saved data file which is most appropriate for the user’s data program. If a check is made in the “Delete all saved settings on exit” option, all changes made will be discarded after the test. The “Reset Opt-Out Dialogs” button is used to turn on the warning boxes. For example, when attempting to start a test, a dialog box will remind the operator to create a recording file. If the operator chooses, this dialog box reminder can be deactivated. To reactivate, press this button. If any changes to the fields are made, the “Apply” button must be depressed before moving to the next tab.


Figure 3e Control Preferences Tab

For humidity-controlled equipment, a control tab is used to allow the operator to set a controlled environment during testing. During the test, the operator can change these limits by selecting tools at the upper left screen menu. A “humidistat” control window will open, which will allow the operator to change the humidity level. Closing the “humidistat” window will allow the program to use these preprogrammed values.


Figure 3f Limits Preferences Tab

If the operator wishes to stop a test based on a limit, this tab allows the user to input a value. Tests can be stopped on time, friction limit, turns (or cycles) and/or distance. Limits entered in the softWEAR™ program or the Tribometer can be used to stop a test. For example, if the cycle counter on the Tribometer stops the test, the softWEAR™ program will stop and close the data file. If the humidity option is enabled, the software will also allow the operator to stop the humidity control unit when the test is stopped.


Figure 3g Graphing Preferences

The user can select which signals to graph during testing using the “Graph” preference setting screen. To select a signal, place a check in the box beside the signal to be graphed. To select a color for the graph, press the box to the left of the checkbox. Equipment which includes the optional humidity or temperature control allows the choice to display these signals. This setting does not change the saved data settings. The graphs can automatically scale or open to user-defined settings. After the test has started, these settings cannot be changed until the test is stopped. The operator can input the range for the displayed signals. The time window can be set to display a minimum and maximum range. The displayed data (time window) can be changed during testing with the “turn” of a button on the screen. The maximum size of this window is set by the value placed in the maximum graph time field. A cursor can be used to review values during testing. By synchronizing the cursor, multiple values are displayed on the screen.


Figure 3h Display Preferences

The operator can select those fields which appear on the screen during testing. Information entered for each filed is also stored in the data file with the raw test data. Displayed values can be selected and adjusted to the required precision using the bottom half of the display preference screen.


Figure 3i Hardware Preference Screen

The hardware preference screen has been adjusted to the particular pin on disk system for which it was installed. The channels used for signals coming from the Tribometer should not be changed. The screen displays the data acquisition board used with the software. If no board is displayed, the hardware must be reconfigured.


If test data will be saved, the user is prompted to create a recording file. Pressing “Yes” will allow the operator to create the file. Pressing ”No” will allow a test to begin without test data being saved. Pressing “Cancel” will stop the process.

Figure 3j Warning screen created at start up of test

After pressing “Yes” the operator

can create a recording file. A

folder called “data” has been created on the C drive. The user may select this

file, or other folders for the data file. The

program will open the path to the

previously opened file.

Figure 3k Data output file screen


Figure 3l Test Operating Screen

After creating a save file name, the “record” button on the bottom of the screen will turn green. The DAQ status button at the upper right of the screen will also show an active status. To begin a test, the operator can now press the “Motor” button on the bottom of the screen.


Figure 3m Operating screen

During the test, those signals selected for display are shown on the screen. The informational fields to the right of the graph show current test data. The number of data scans and the test time are shown in blue in the bottom right portion of the screen. The display window can be compressed and re-zeroed by turning the “Time Window” button. Pressing the “Zero” button will allow the starting data to be displayed. Pressing “Normal” button will open the window to the time indicated in the preferences setting.


Figure 3n Operating Screen showing magnifying windows.

Magnification windows can be used to view the values for each signal. The windows can be moved on the screen and opened and closed during the test. To open a window for a signal, using the mouse input device, double click on the appropriate signal on the right side of the operating screen. For example to open the coefficient of friction window, double-click on the coefficient of friction value displayed on the right side of the screen. The magnified signal is opened. The size and position will be the same as the previous opened window.


Figure 3o Stop Test Notification

The test can be stopped at any time by pressing the “Motor” button. This closes the data file and stops the Tribometer. Current values are displayed, and the operator must press the “close” button on the pop-up screen to clear the screen.


Figure 3p Limit Notification Screen

When a test limit is reached the Tribometer will stop and the data file will close. The user must press the “close” button on the screen to clear the screen. All values at the end of the test are kept on the screen until the user clears the screen. This feature allows the operator to quickly see the final test data and the limit which caused the test to stop.


Figure 3q Graph Tool Screen

Pressing the “Graph Tools” button during the test (or after opening a test file) will allow the operator to control the display of the data. Both X and Y-axis can be changed for each signal. Two lines of commands appear at the top of each graph, which contain the tools available for use in each graph. Plot This is the normal, default mode. In this mode, real time data is being plotted on each graph as it is being collected. In playback mode, the data is simply displayed statically according to the settings of the time window control knob. Scroll-X Select this mode to move the time window forward or backward. Click and drag the mouse over the graph to change the time (X-axis) of the data being displayed.


Zoom-X To view an event in closer detail, select this mode then click and drag the mouse to the right to zoom in on the time displayed, or left to zoom out. This tool is frequently used with the Scroll-X tool to scrutinize details of a graph. Scroll-Y All data points are usually located within the entire range of the Y-axis. When setting specific axis limits under preferences, some data may plot outside of the visible window. Use this tool to drag that data back into the visible window space without altering the scale of the graph. Zoom-Y Often used with the Scroll-Y tool, this tool is used to zoom in or out on specific pieces of data in the graph. As with all the other tools, click on the graph and drag the mouse to zoom. Drag upward to zoom in and downward to zoom out. Scroll-XY This graph tool combines the effects of Scroll-X and Scroll-Y described above. When in this mode, moving the mouse left and right performs the Scroll-X function, while moving it up and down performs the Scroll-Y function. Zoom-XY Like Scroll-XY, this tool combines the operation of both the Zoom-X and Zoom-Y tools, depending on the direction in which the mouse is moved. Cursor In this mode, a vertical cursor (line) is placed on each graph at the same position on the X-axis (time). Clicking on any graph will cause the cursor to move to the time position on all graphs where a data point has been collected, and each graph will display the coordinates of that point next to the Cursor tool at the top of the graph. The user may also click and drag the mouse left or right to move among the data points collected. The cursor will not interpolate; that is, it will only position where there is a true collected data point. Usually, the cursor of all graphs will be visually aligned at the same point on the screen. However, if any graphs are in a scroll or zoom mode, that visual alignment may be skewed. Cursors are always positioned at the same absolute time on the X-axis of each graph. Cursor synchronization among the graphs is the default case. On the Graph tab of the Preferences dialog, the operator may clear the “Synchronize cursor” checkbox so that the cursor of each graph operates independently. Zoom-Box A special case of Zoom-XY, this plot tool allows the operator to draw a box around the data to be analyzed. When the mouse button is released, the graph zooms into the area drawn. Note: The graphs continue to collect data in real time, regardless of which tool is selected. However, to see the data being plotted in real time, the Plot tool must be selected.


Figure 3r Print Screen Menu

The displayed signals can be printed directly from the program by selecting the print command under the “File” menu. The user can select any (or all) signals to be printed by checking the appropriate box on the “Print Charts” window. Each printed page will include the signal graph and the data from the informational fields on the screen.


Figure 3s Test Data File (beginning)

After a test the data file can be opened with a spreadsheet program. Each data file will include the data in the informational fields and the data captured at the user selected interval. Elapsed time, turns, coefficient of friction, speed, humidity and temperature are saved for each test. The second column of data (marker) is used the program during testing.


Figure 3t Test Data File (end)

At the bottom of each test file, a description of the stop test condition, data, time, total cycles and number of data points are given. This feature allows the user to verify the actual time of the test and provides other valuable data so repeat tests can easily be conducted.


Figure 3u Operating Screen showing Humidistat Control

During a test, the operator can change the humidity level by opening the Humidistat control and turning the knobs. The yellow indicating pointer will indicate the actual humidity level of the tribometer. The Humidistat control can be moved to any part of the operating screen. Closing the Humidistat will deactivate the new humidity level.


CALIBRATION

Calibration of the test equipment includes calibrating the pin on disk tribometer unit and then calibrating the software to match the new settings.

Please Note: Calibration steps for ISC-200PC and ISC-450PC (high temperature version) differ for force gauge calibration due to location of force transducer.

4.1 TRIBOMETER CALIBRATION

Calibrating the electronic circuits of the tribometer is performed by adjusting potentiometers which are located on two printed circuit boards mounted on the inside of the rear panel. To access, remove the two screws on the upper corners of the rear panel, and pull the panel outward. It is hinged at the bottom. Figures 4a and 4b show the locations of the potentiometers. A small screwdriver or similar adjustment tool is required. The items to be adjusted are the motor speed, force readout, and radius setting. These should be checked monthly and adjusted as necessary. If the unit cannot be adjusted to the values described herein, please contact Falex Corporation.

RPM Adjustment for Zero Value

a) Set the Data Select switch to RPM. b) Turn the motor off. c) Adjust R28 until the RPM value on the Data Display reads zero. d) Turn the motor on and turn the RPM knob all the way to the CCW end. e) The motor should stop completely and the Data Display should read zero.

Adjustment for Gain

Method 1: a) Get a stopwatch that is calibrated in seconds. b) The Data Select switch should remain at RPM. c) Turn on the motor and adjust its speed to 60 RPM. d) Place the stopwatch directly below the Rotation Count display. e) Press Stop and Reset on the stopwatch. f) Observe the Rotation Count display. g) At an instant when the rotation count is changing units digits, simultaneously start

the stopwatch and press the Clear Rotations Count button. h) Observe both counters and adjust the motor speed control to keep them tracking

one another for a period of 2 minutes. i) Repeat steps 5-8 as necessary. j) When the counters are tracking, adjust R34B until the RPM readout on the Data

Display reads 60.0. Note: ± 4 rpm is acceptable according to the ASTM G 99 standard.


Method 2: a) Set the Data Select switch to RPM. b) Turn on the motor and adjust the speed to 300 (or near maximum range for unit)

rpm. c) Use a handheld digital tachometer to verify the motor speed. This may be

accomplished by placing the tachometer in the center of the calibration disk or using an optical sensing tachometer.

d) Adjust the speed until 300 rpm is read on the tachometer. e) Adjust R34B until the rpm readout on the Data Display reads 300.

Note: ± 4 rpm is acceptable according to the ASTM G 99 standard.

Force Gauge Calibration for Falex ISC-200PC Adjustment for Zero Value

a) Allow the tribometer to warm up for at least 15 minutes. b) Lift the pin off the disk. Place the arm in its holder. (Nothing should be touching the

force gauge at this time.) c) Set the weight thumbwheel switches to 134. d) Turn the Zero Force knob counterclockwise until it stops. Then turn it 5 turns

clockwise. (It is now at midrange.) e) Set the Data Select switch to Friction. Adjust R84 on the Force Gauge board until

the Friction value on the Data Display reads zero. f) Set the Data Select switch to Force. Adjust R23 on the Main board until the Force

value on the Data Display reads zero.

Adjustment for Gain for Falex ISC-200PC

Note: The values in the following procedure are for the standard Falex ISC-200PC tribometer with the standard 454 gram and the optional 113 gram force transducers. The adjustment for gain procedure applies to all Falex ISC tribometers except the high temperature options (250ºC or greater). The correct adjustment for gain for these units will be provided in the following paragraph.

a) Remove the 2 screws that hold the force gauge to the top deck. Carefully lift the

gauge until it is 3 inches above the deck. b) Set the force gauge on its "face" at the back edge of the deck so that the hook

hangs down below the edge. Carefully place the 500 gram weight on the back of the gauge's "foot".

c) Set the Data Select switch to Friction. Observe the weight thumbwheel switches. They should be set to 134.

d) Turn the Zero Force knob until the friction value on the Data Display reads zero. (The weight of the hook has caused the change.)

e) Hang the 100 gram weight on the hook. It must hang freely and should not swing. f) Set the Data Select switch to Calibrate. g) Adjust R24 on the Main board until the Calibrate value on the Data Display reads

100. h) Set the Data Select switch to Force. i) Adjust R32 on the Main board until the Force value on the Data Display reads 67. j) Set the Data Select switch to Friction.


k) Adjust R91 on the Force Gauge board until the Friction value on the Data Display reads 1.000.

l) Repeat steps 6 through 11 to verify that the correct values are displayed. m) Carefully remove the weights and replace the force gauge on the top deck. Do not

tighten the 2 screws. n) To remount force gauge, use the vertical pin on the side puller arm to make sure

force gauge is positioned correctly. Keep the readout knob on Friction and make sure it is reading 0.00. The vertical pin should not be in contact with either side of the hook. Tighten force gauge screws when gauge is positioned correctly.

o) Calibration of the force gauge is now complete; continue to Radius calibration section.

Force Gauge Calibration for Falex ISC-450PC Adjustment for Zero Value

a) Allow the tribometer to warm up for at least 15 minutes. b) Lift the pin off the disk. Place the arm in its holder. (Nothing should be touching the

force gauge at this time.) c) Set the weight thumbwheel switches to 100. d) Turn the Zero Force knob counterclockwise until it stops. Then turn it 5 turns

clockwise. (It is now at midrange.) e) Set the Data Select switch to Friction. Adjust R84 on the Force Gauge board until

the Friction value on the Data Display reads zero. f) Set the Data Select switch to Force. Adjust R23 on the Main board until the force

value on the Data Display reads zero. Adjustment for Gain for Falex ISC-450PC

a) Unscrew the force gauge from its mount next to the pin arm. b) Set the force gauge on its "face" at the back edge of the deck so that the hook

hangs down below the edge. Carefully place the 500 gram weight on the back of the gauge's "foot".

c) Set the Data Select Switch to Friction. Observe the thumbwheel switches. They should be set to 100.

d) Turn the Zero Force knob until the friction value on the Data Display reads zero. (The weight of the hook has caused the change.)

e) Hang one (1) 100g weight on the force gauge hook. It must hang freely and should not swing.

f) Change Data Select Switch to Calibrate. Adjust R24 until readout is 100. g) Change Data Select Switch to Force. Readout with 100g weight should be 50g.

Adjust R32 if reading is not 50. h) Change Data Select Switch to Friction. The readout should be 1.00. If it is not,

adjust R91. i) Repeat steps f - h. j) Remount force gauge on its mount. Use the vertical pin on the pin-arm to make

sure force gauge is positioned correctly. Keep the readout knob on Friction and make sure it is reading 0.00. The vertical pin should not be in contact with either side of the hook. Tighten force gauge screws when gauge is positioned correctly.

Radius


Adjustment for Zero Value

a) Mount the cone shaped pin to the ball holder and insert the holder on the arm. Adjust the holder to the 90° position (Cone is vertical to disk.)

b) Mount the calibration disk into the cup assembly. c) The calibration disk has a hole at the zero radius position and a groove at the 25

mm radius position. d) Decrease the radius by turning the Radius Adjust switch to Dec(rease). Turn the

Data Select switch to Radius. Observe that the display will read 0.0 when the cone is at the zero position. (If the cone does not fit into the zero position hole, remount the force gauge assembly for proper alignment.)

e) Adjust R10 until the Radius value on the Data Display reads zero. f) Proceed to the next section, Adjustment for Gain.

Adjustment for Gain

a) Increase the radius to 25 mm. Note that the cone should be located in the groove of

the calibration disk. b) Adjust R22 until the Radius value on the Data Display matches the 25 mm radius

value. c) Repeat steps a & b to verify zero and 25 mm setting.

Note: To maintain proper calibration do not use the cone tipped pin or calibration disk for testing. Contact Falex if new calibration cone or disk is needed.

Figure 4a Calibration potentiometer locations on circuit board


Figure 4b Calibration potentiometer locations on force gauge board


4.2 softWEAR™ PROGRAM CALIBRATION

To calibrate the softWEAR™ program the operator must open the calibration screen, select a signal, then press the “calibrate” button when a known low and high value are sent to the DAQ card. The following step-by-step procedure must be done for each signal being acquired by the acquisition program. Open calibration screen: 1. Start softWEAR™ program. 2. On the “TOOLS” menu, select “Calibrate DAQ” (See Figure 4c) 3. The calibration program will open. (See Figure 4d)

Figure 4c Tools Menu


Figure 4d Data Acquisition calibration screen

Friction: 1. With no force on the friction sensor, turn the “Data Select Switch” on front of the

Tribometer to “Friction”. Move thumb-wheel setting (hanging weight) to 134g. 2, Verify that the value 0.000 is showing. If slight value is displayed, use Zero Force

Knob to bring to 0.000. 3. Select “Coeff of Friction” signal on calibration screen. 4. Press ”Calibrate to low value” button on screen. The program will sample and

average the input signal. 5. Hang 100 gram weight on force sensor with same method used when calibrating the

signal on the Tribometer. 6. Verify that value displayed on Tribometer is 1.000. Enter 1.000 in “Friction is set to a

high point” field. Press “Calibrate to high value” button on calibration screen. Program now has identified low and high values for input signals. Calibration of coefficient of friction is complete.


Speed: 1. With motor off, turn “Data Select Switch” on Tribometer to “RPM”. Verify that 000 is

displayed on Tribometer. 2. On calibration screen, select speed signal from drop down list. 3. Press ”Calibrate to low value” button on screen. The program will sample and

average the input signal. 4. Turn on motor. Adjust to high speed. (For this example assume 300 rpm). Verify 300

on display on the Tribometer. 5. Enter 300 in “Speed is set to a high point” field. Press “Calibrate to high value” button

on calibration screen. 6. Program now has identified low and high values for input signals. Calibration of

speed is complete. Radius: 1. Turn “Data Select Switch” to “Radius”. Turn radius knob to decrease setting, and

bring radius to 00.0 on display. 2. On calibration screen, select radius from drop down list. 3. Press ”Calibrate to low value” button on screen. The program will sample and

average the input signal. 4. Use radius adjust knob to move disk to 25.0 mm. 5. Enter 25.0 in “Radius is set to a high point” field. Press “Calibrate to high value”

button on calibration screen. 6. Program now has identified low and high values for input signals. Calibration of

radius is complete. If optional humidity and temperature signals will be captured by the acquisition program, continue with calibration procedure for each of these signals using the same procedure as detailed for the signals above. After calibration, save the calibration file by selecting “File” button located at upper left corner of Data Acquisition Calibration window. The data of the calibration is automatically inserted for the file name. Select save. The calibration file is saved in the Calibration folder in the softWEAR program directory.


TYPICAL TEST PROCEDURE 5.1 MECHANICAL

Before running a pin-on-disk wear test, one should know what Hertzian contact pressure is desired so that the pin (ball) diameter and the load can be determined.

A linear sliding velocity should also be chosen so that the RPM and track radius can be selected. This must depend on the available test specimen diameter and the range of rotation speeds available on the Falex ISC Tribometer.

After one has finalized the pin diameter, pin material, disk diameter, disk material, disk RPM and the load, the following test procedure should be followed.

Mount Test Pin (ball):

Mount the selected test ball 1/8", 1/4", or 1/2" diameter in the appropriate holder by epoxy or “super” glue. (These can be removed after testing by soaking in acetone) Screw the pin holder to the pin mount and insert the assembly in the arm elbow at the end of the lever arm as shown in Figure 5a.

Figure 5a Sketch of Pin Tilt Assembly


Set the pin holder at the #1 position and tighten knurled screw A. Set the angle between the pin holder and the vertical (approx. 30o) and tighten knurled screw B. The 30o angle of the pin permits the user to use the same ball for 6 different tests. Make sure that there is no clearance between the arm elbow and the side puller. The arm elbow must be slid all the way in to hit the side puller before tightening the knurled screw B.

Balance Lever Arm

With the pin in place, rotate the 2 counter weights so that the arm stays horizontal (balanced). Tighten the two weights against each other to lock them in place. Move tone arm into its holding place while mounting the disk in place.

Mount Test Disk

A 2-jaw chuck is supplied for clamping the sample disk. Use the provided allen wrench to tighten the jaws against the disk. The chuck is capable of holding samples with random shapes. It is not essential for the sample to be exactly centered in the chuck. However, if you plan on doing many tests on one sample, then to fit many concentric wear tracks, it is necessary to be able to exactly reproduce the mounting of the disk.

Adjust radius to an unused track area. Hold the pin over the disk to determine the proper test track. (Prevent the ball from contacting the surface of the disk while setting up the test.)

Adjust RPM to get the desired linear speed. To view the linear speed on the softWEAR™ screen, press the “motor” button at the bottom of the screen and observe the value for linear speed on the right side of the display. Matching linear speed is important for duplicating test conditions.

Stop platter rotation and clear turns count.

Set desired limits (turns and/or friction).

Put pin on disk in starting position.

Notes on the chuck (cup) assembly:

The chuck is not intended to be dismantled. The two jaws must be carefully aligned to ensure that a cylindrical disk is exactly centered. Incorrect assembly will cause the axis of the disk to differ from the axis of the chuck, and wobble will occur. A special tool is needed to get accurate centering.

Lubricating fluids may be used in the standard cup. At speeds over 100 RPM centrifugal force can cause fluid to escape over the walls of the cup. Also, at high speed the impact of rotating fluid can affect the measured force on the pin if the cup is filled deeply with liquid. When using fluids, only add enough liquid to just cover the disk where it contacts the pin. Set this liquid level when the cup is rotating at the desired speed. High speed models, which are capable of rotation speed up to 1,500 RPM, use a special light weight disk chuck which cannot contain fluids. The high speed would cause liquids to rapidly escape the surface.


Lower Tone Arm onto Disk

Hang the test weight from the hook located on the tone arm and gently lower the pin to the disk. The side arm will fit into the hole of the force gauge.

Falex ISC models 320 (Humidity Control ) and 450 (High Temperature) also include a tone arm lift/ lower mechanism to allow the test environment to stabilize before beginning a test. The control switch is located on the right side panel of the tribometer. After lowering the pin onto the disk, use the lift mechanism to lift the pin from the disk before heating or controlling humidity. After the controller has stabilized the environment, lower the tone arm before beginning the test. The lift mechanism operates slowly and the operator should become familiar with its use before beginning testing.

5.2 SOFTWARE

Setting Up a Test Open softWEAR™ program Open “TOOLS” menu. Select “preferences”. (Alternatively, pressing F5 key will open

preference menus.) Complete all tabs with proper test information, settings, limits and graphing preferences. Close Preference screens.

5.3 STARTING THE TEST

If data is to be saved, press “Acquire” button on bottom of operating screen. Enter filename for test data file. “Record” button indicator will turn green. Press “Motor” button on bottom of screen to start test. Data acquisition starts when motor starts. Data acquisitions will stop when motor stops. NOTE: If optional humidity control is needed, press humidity button prior to starting the motor. The humidity controller will start and control the humidity level to the input range. Start motor when humidity level becomes stable.


OPTIONS, ACCESSORIES AND SPARE PARTS 6.1 OPTIONS A. Humidity Control System

Falex Corporation Humidity Control System (HCS) Model 320 is a stand alone assembly and only needs proper electrical connections. It has been designed to run either manually or by computer. In manual mode the humidity can be changed by means of the front panel switches. When connected to the computer, the softWEAR™ program regulates the humidity automatically.

The Humidity Control System has the capability to control the relative humidity in a closed 3 cubic foot or 85 liter container anywhere in the range from 5% to 95% and within ±3 RH units. (Improved accuracy can be obtained with specified equipment. Check specifications with factory.)

Figure 6a

Front Panel of Humidity Control System


Humidity is regulated automatically by the softWEAR™ computer program. The value of humidity is shown on the display during testing. The humidity is sampled to the user-defined setting. The range of display values is 0.0% to 99.9%.

Operating Screen showing Humidistat control window The humidity level can be adjusted after the test is started by using the humidistat control. To open this feature, select “Tools” and “Humidistat”. Or, press ALT-H. By rotating the control knobs, the level can be increased or decreased. The Humidity Control System uses anhydrous calcium sulfate (desiccant) which is blue when dry and turns pink when saturated with moisture. The system has two independent drying columns to reduce moisture in the circulating system. Two valves are used to switch between drying column #1 or #2. Both valves should be pointing toward either position 1 or position 2.

To increase humidity, the Humidity Control System uses an ultrasonic humidifier to increase the moisture in the circulating system. The humidifier is set on its lowest setting for mist to reduce overshoot during testing. Do not change this setting on the humidifier base (located inside the black cabinet).


Computer Controlled Operation (wet, and dry switches down)

a) Turn power switch ON (located at bottom of HCS front panel)

b) Wipe dry the container cover of the tribometer if it is wet from a previous run.

c) Set up the tribometer for a test as described in Section 5.1. Replace the plastic cover.

d) Enter the required humidity (the setpoint) in the softWEAR™ program on the

computer.

e) Turn on humidity control in the softWEAR™ program. One may see a fluctuation around the setpoint for 2 minutes until the system converges on the set humidity, especially if a large change in humidity was required.

f) Once the humidity is stable, lower the tone arm with the lower mechanism . Be sure

to lower the lift arm sufficiently so the tone arm does not contact the lift arm as wear takes place during testing.

Desiccant Regeneration

The desiccant can be removed by taking off the console's top cover (4 screws).

a) Unscrew top of desiccant column (75mm diameter). Remove spring, metal

perforated disc, and felt pad.

b) Pull out sack of desiccant.

c) Heat desiccant at 200ºC for 1 hour to renew desiccant. If you use a vacuum oven, you must remove the desiccant from the sack first. Cool desiccant in a sealed container to avoid air humidity. Dry the felt filter at 100ºC.

d) Replace the dry desiccant in each column.

Ultrasonic Humidifier

Refill the water tank of the humidifier with particle-free water, preferably distilled water. The water tank can be reached through the top cover of the HCS 320. Remove the hose from the top of the tank and use the built in handle to remove the tank from the base. Wipe the inside of the humidifier base with a clean, damp cloth at each tank refill. The tank is refilled by removing the cap on the bottom of the tank.

Computer Control

Humidity is regulated automatically by the computer program. The humidity level is shown on the chart. The range of display values is 0.0% to 100% RH.

Turn on the AC power switch for the humidity control module if it is not already on.


B. High Temperature System

The High Temperature Option (Model Falex ISC-450PC) provides the following modifications to the standard Falex ISC-200 Tribometer.

a) Pin and disk region inside 600ºC furnace.

b) Pin and disk mounting components fabricated from Nickel-based alloys

c) Separate temperature regulator module

d) Temperature readout in the softWEAR™ program.

e) Plumbing for gas flow inside selected portions of the furnace.

Operation - Heat Control

A Honeywell temperature control unit is provided to regulate temperature based on the reading of the thermocouple. Refer to the instruction manual for the Honeywell unit for instructions on entering a setpoint for regulation.

There are two switches on the High Temperature Module. The lower switch turns on the Honeywell controller and the upper switch connects power to the heater. Both must be up to operate the heater. The heater cannot be operated manually.

Temperature Readout

A type K Chromel Alumel thermocouple is positioned inside the heated volume. The temperature is displayed on the Honeywell Control Unit and a copy is displayed in the softWEAR™ program. Temperature Restriction

The High Temperature Option is designed for a maximum working temperature of 600°C. No guarantee can be placed on the performance if the user operates the unit beyond the allowed range. In particular, it is expected that corrosion discoloring and increased heating of the outside stainless steel (SS) jacket will occur. Unless sufficient auxiliary gas flow is provided, the sealed platter shaft bearing may also overheat.

The SS jacket becomes hottest when auxiliary gas flow is being provided at a high flow rate. This occurs because the flow goes directly to the heated zone and then exhausts through the various apertures in the shield.


TROUBLESHOOTING

7.1 MECHANICAL

Motor Does Not Stay On

If the disk does not rotate when the motor is switched on either manually or by the computer, check the preset rotation and friction limit cut-off switches (If the friction limit is exceeded the red light will turn on.) and the radius adjust knob. The cycles may be reset by pressing the button to the left of the display. The friction limit switch can be reset by the toggle switch to the right of the thumbwheel switches. The radius adjust knob must be in the off position in order for the disk motor to operate.

7.2 SOFTWARE Cannot Collect Data

If the softWEAR™ program is not registered or does not acknowledge the presence of the data acquisition card, the program will operate in “analysis” mode only. Data can be opened and reviewed, but new data cannot be captured. Call Falex for troubleshooting assistance.


Customer: Machine Number: Customer Address: Serial Number: Customer Contact: Date: Machine Description: Phone: Customer Problem: Field Engineer’s Comments: Date: Initial Service Engineer’s Comments: Date: Initial Corrective Action: Date: Initial Conclusion at Completion: Date: Initial Work Order Number:

TECHNICAL SERVICE REQUEST


REGISTRATION, WARRANTY, SERVICE, AND TRAINING 8.1 REGISTRATION When you purchase a Falex test machine, we ask that you register. You may do by completing the following page in this section. In addition to the registration form, we have included a Registration Change Form. Please use this form to update us of any changes in the original information provided. Your registration will ensure that you are informed of any new items or changes involving this machine.


IMPORTANT

OWNER REGISTRATION FORM In order to properly register, please fill out and return the card below. This will allow us to keep you informed on equipment up-dates and new products related to this apparatus. Please contact us with any questions. If technical assistance in needed, contact the Technical Service Manager. Thank you for your help in allowing us to serve you better. Primary User: Multiple User: Name: Name: Title: Title: Company: Company: Address: Address: Telephone: Telephone: Fax: Fax: Email: Email:


IMPORTANT

REGISTRATION CHANGE FORM Please complete this form if there have been any changes to your original registration. Your assistance in this matter will help us to keep the proper persons apprised of all matters related to your machine. Thank you. Primary User: Multiple User: Name: Name: Title: Title: Company: Company: Address: Address: Telephone: Telephone: Fax: Fax: Email: Email:


8.2 WARRANTY

STANDARD WARRANTY AND SERVICE POLICY

Falex test machines DO NOT include field service or field installation at the customer’s location. If a technical service representative is requested, a quotation will be generated on a per diem basis plus air fare and all expenses. Alternatively, various Service Programs are available. Prior to shipping, a one day training on equipment can be provided at Falex Corporation, free of charge. This includes operational and maintenance training only. Cost of transportation and other expenses while receiving training are paid by customer. Any product* manufactured by Falex Corporation (hereinafter referred to as the company) is sold on the following basis and none other. ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND OF FITNESS FOR A PARTICULAR PURPOSE ARE HEREBY EXPRESSLY EXCLUDED. The following warranty shall apply, and no other warranty, express or implied, shall apply: If within one year from date of shipment the product fails because of defective material or poor workmanship, the company will repair or replace without charge, any product that has failed, provided:

a) The product has been properly installed, operated and maintained. b) The company is advised in writing of the malfunction and authorizes the return of

the product to the factory. c) All transportation charges for the return to the factory are prepaid. (Products will

be returned freight collect.) d) A complete description of the reason for return must accompany the unit.

NOTE: A nominal handling charge for inspection will be made on units for which a claimed defect cannot be confirmed.

THE COMPANY’S SOLE LIABILITY HEREUNDER SHALL BE TO REPAIR OR REPLACE ANY PRODUCT UNDER THIS WARRANTY. In no event shall the company be liable for:

a) Prospective profits or special, indirect or consequential damages caused by

failure of its product. b) Any charges for labor or materials for work done on its product by others.

*Wherever used in this Warranty Policy the term “product” shall mean any items manufactured (only) by Falex Corporation. Any “product” or sub-component sold by Falex Corporation but manufactured by others carries original manufacturer warranty only.


8.3 EXTENDED WARRANTY

a) F-1500-10 No Charge Factory Training

With purchase of any Falex equipment, one pre-scheduled day of operational and maintenance training is provided at Falex Corporation free of charge. This training includes operation and maintenance of equipment ordered. Cost of transportation and other expenses while receiving training are paid by customer. Factory training should be scheduled at time of order.

b) F-1500-10A Start Up Assistance for New Machines

Falex Corporation will provide, at reasonable cost, a service technician to field train personnel on operation and recommended maintenance at customer's location. This one day service will also include calibration procedure training.

Available only at time of equipment purchase, training must take place within 45 days of receipt of test equipment. Falex is not responsible for installation of test equipment, electrical power, pneumatics or water supply hookup when required. All required utilities must be in place and operational prior to Falex representative's arrival. Customer should indicate at time of order interest in this service to allow proper scheduling.

c) F-1500-10B Extended Warranty Service Agreement

Falex Extended Warranty Service Agreement is available on all new Falex equipment. Two service calls are included: one within 45 days of receipt of test equipment and one again 12 months later. A technical service representative will return for one day at each time interval to field calibrate, inspect and perform required preventative maintenance. If this agreement is purchased, the basic mechanical test machine warranty policy will also be extended from 12 months to 18 months. All materials and parts used for repairs will be billed at a discount of 15% off manufacturers' list price unless warranty replacement. Available only at time of equipment purchase and initial service must take place within 45 days of receipt of test equipment. All travel and living expenses will be billed at cost. Further details and copy of service agreement are available for review upon request. Price for this service agreement varies with type of test machine.

d) F-1500-10C Field Service Agreement

This Service Agreement is available on all Falex, and certain Dow Corning, Timken, Roxana, Strama and Plint and Partners equipment, and others at the customer's request.

Two service calls are included: one within 45 days after purchase of agreement and one again 6 months later. A technical service representative will return for one day at each time interval to field calibrate, inspect and perform required preventative maintenance. Electronic components are subject to calibration only. Accessory items can also be added within this agreement. All materials and


parts used for repairs will be billed at a discount of 15% off manufacturer's list price unless warranty replacement.

Available at any time during ownership of equipment. All travel and living expenses will be billed at cost. Further details and copy of service agreement are available for review upon request.

e) F-1500-10D Instruction Manuals in Languages other than English

Text portion of instruction manuals are available in languages other than English. Cost for this service is available upon request. Please specify desired language. Brochures describing component parts not manufactured by Falex but used in the design are only available in English.

Documents

Pin on Disk Tribometer Manual