What is a strength test bench

Force test bench model ESM301 / ESM301L. Version 2. Operating Instructions

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1 force test bench model ESM301 / ESM301L version 2

2 Thank you Thank you for purchasing the Mark-10 ESM301 / ESM301L programmable force tester. This test stand is designed for compression and tensile tests up to N. The ESM301 is a core component of any force testing system and typically also includes a force gauge and handles. If used properly, this product will provide you with excellent service for many years to come. With their robust construction, Mark 10 test stands are designed for long-term use in laboratory and industrial environments. This contains information on setup, safety and operation as well as dimensions and technical data. If you need more information or have any questions, please do not hesitate to contact us. Our support and technical teams will be happy to assist you. Before using the ESM301 or ESM301L, all operators must be fully trained in its proper operation and the corresponding safety measures. CONTENTS OVERVIEW ... 3 MECHANICAL STRUCTURE AND SAFETY ... 4 BASIC OPERATION ... 6 SETTING UP THE TEST PARAMETERS ... 7 OPERATING MODES DATA EXCHANGE WITH MESUR TM GAUGE SOFTWARE ACTIVATION OF FUNCTIONS TROUBLESHOOTING TECHNICAL DATA MAINTENANCE

3 1 OVERVIEW 1.1 Scope of delivery pc. 1 test stand ESM301 or ESM301L 4 fastening screw for force gauge 2 limit screws (the same as above, are supplied in a separate package) 1 power cable 1 cable between control unit and test frame 12 (longer cables are optional) 1 USB / RJ11 -Cable (for optional integrated travel indicator) 1 ESM X column extension (optional) 1 ESM table mounting set (optional) multifunctional cable (optional) Serial cable (optional) 1 accessory set (small hook, middle hook, 2 pressure plate, 2 extension rod, # 10-32 coupling , Tool set) 1.2 Overview Note: Unless otherwise stated, all information on the ESM301 test bench model also applies to the ESM301L model. The ESM301 has three functional modes: 1. OPERATING MODE In the operating mode, test sequences can be started and stopped. 2. TEST PARAMETER SETUP In this mode, test parameters such as speed and number of cycles, password protection and other test parameters can be configured. 3. FEATURE ACTIVATION In this mode, features that were not originally purchased with the product can be activated through a code activation process. DEMO MODE The ESM301 is delivered in demo mode, during which time all functions are temporarily activated for 160 operating hours. When the power is turned on, a counter shows the number of hours as follows: R E MA I N I NG D E MO T I ME: H O U R S Press the STOP button to continue. After this time, only the purchased functions will be activated. The DEMO MODE can be suspended at any time by holding down the STOP button when switching on the test stand. This mode can be reactivated in the same way and will be active for the rest of the time. For field activation, see the instructions in the Function Activation section. 3

4 2 MECHANICAL STRUCTURE AND SAFETY 2.1 Safety / Suitable test samples Typical materials that can be tested with the ESM301 are, for example, many manufactured products such as springs, electronic components, fastening elements, fasteners, foils and mechanical assemblies. Not to be used with the ESM301 are potentially flammable substances or products, components that can unsafely break, and any other components that could pose an excessive hazard when subjected to force. 1. Using Handles and Brackets with the ESM301 Place the handle or bracket so that the load is applied axially with respect to the load axis of the force gauge. When using a handle, make sure that it holds the test sample securely so that it cannot slip out during the test and pose a potential safety hazard. When using handles or brackets from a third party manufacturer, make sure that they are made of sufficiently robust materials and components. 2. Assembly Place the test stand on a clean, flat and level work surface that is free from vibrations. If necessary, the stand can be fixed to the work surface using ¼-20 screws that are screwed into the underside of the base . If the test stand is improperly installed, there is a risk of tipping over, which can lead to a dangerous situation. IMPORTANT: Do not screw the screws further than 6 mm into the base of the test stand, otherwise internal components could be damaged. The test stand can also be mounted using the ESM mounting set. This set includes screws of different lengths for different table thicknesses. The following figure shows the correct assembly. The ESM301 can generally be mounted at any angle, but particular care must be taken during assembly and operation. Once the test stand is stable and secure, attach a force gauge using four knurled screws (included). All Mark-10 gauges (with the exception of the CG series) are attached directly without an intermediate piece. Handles can be mounted on the measuring device and on the base of the test stand. 3. Installation of the limit switches Upper and lower limit switches are available to stop the travel of the measuring device at any position. Each limit switch consists of an internal block that runs on a rail and an external handle screw. The screws are delivered in an external bag to avoid transport damage. The figure on the right shows the correct installation of the limit switches. 4th

5 2.2 Setting up the control unit The power cord and the control unit cable must be connected to the rear of the control unit as shown in the figure below: 1 1. Fuse socket for control unit cable Insert one end of the cable into this socket and the other end into the socket shown in the figure on the right. If this cable is not connected, the error message ENCODER ERROR is shown on the display and the test stand cannot be operated. 3. PC connection Plug one end of the serial cable into this socket and the other end into the serial port on a computer. 4. Power Jack Connect the power cord here. 5. Connector for travel indicator Connect one end of the USB / RJ11 cable to this socket and the other end to the mini-USB connector on the back of the crosshead. 6. Gauge Cable Connector Connect one end of the cable to this jack and the other end to a Series 5 or Series 4 force gauge. 5

6 2.3 Connecting to the Power Supply Plug one end of the power cord into the appropriate socket on the back of the control unit and the other end into a wall socket. Before switching on the test stand, the following safety checks and precautions must be carried out: 1. Never operate the test stand if the power cord or the test stand itself is visibly damaged. The ESM301 is fed with 220 V. Any contact with this high voltage can lead to serious or even fatal injuries. 2. Always keep the test stand away from water and other electrically conductive liquids. 3. The electrical socket to which the test stand is connected must have a local earth. 4. The test stand may only be serviced and repaired by a trained technician. Before opening the control unit, it must be disconnected from the power supply. After the above-mentioned safety checks and measures have been carried out, the test stand can be switched on and is ready for operation. 3 BASIC OPERATION 3.1 Operational safety Before and during operation, the following safety checks and precautions must be carried out: 1. Always consider the properties of the test sample before starting a test. A risk assessment must be carried out prior to the test to ensure that all necessary safety measures are in place and implemented. 2. Wear eye and face protection when performing tests, especially if the test specimen is brittle and can break under the influence of force. The mechanisms of the ESM301 move relatively slowly, but there is still a risk from the potential energy that can accumulate in the sample during the test. Additional body protection must be worn if there is a possibility of destruction of the test sample. 3. Keep away from moving parts of the test stand. Do not wear loose clothing and cover long hair to prevent it from getting caught in moving parts. A warning sticker about the risk of crushing is attached to the base of the test stand. It looks like this: Meaning: Keep body parts and clothing away from the area between the base of the test stand and the movable crosshead. 4. For certain applications, such as testing brittle test specimens that can break or other applications that could lead to hazardous situations, it is strongly recommended that a machine guard be used to protect the operator and other people in the vicinity from broken pieces. 6th

7 5. When the test stand is not in operation, it must be disconnected from the power supply in order to avoid inadvertent actuation of the controls. 3.2 Position of the operating elements DISPLAY (display) EMERGENCY STOP (emergency stop) UP (up) STOP (stop) / ZERO TRAVEL DISPLAY (zeroing the display) DOWN (down) SOFT KEYS (buttons) SOFT KEYS UP DOWN STOP / ZERO TRAVEL DISPLAY EMERGENCY STOP main function Function depends on the respective text on the display. Starts an upward movement. Starts a downward movement. Stops the movement of the measuring device / sets the travel display to zero (if the travel display is activated). Stops the gauge from moving and disables the test bench until the button is reset. 4 SETTING UP THE TEST PARAMETERS The following section explains the configuration of the individual test parameters: The parameters include: Speed ​​parameter (the same for both directions) Independent up and down speeds Automatic reverse cycle operation with dwell time Programmed travel limits Overload protection Preload Load holding Break detection PC control Communication parameters Selection of the speed unit Programmed key configuration Password protection Standard / Optional Standard Optional Optional Optional Optional Optional Optional Optional Optional Standard Standard Standard Standard All ESM301 test stands are delivered in demo mode, see section 1.2. After the demo mode has expired, only the installed functions are displayed in the test parameter setup. The test parameter setup start screen looks like this: 7

8 S P E E D: E S C <> E N T R Closes the test parameter setup and switches back Scrolls to the next parameter. Selects the parameter so that it can be changed. When the parameters have been configured as desired and are ready to be saved, press to exit the test parameters setup. The message SAVE CHANGES? (Save changes?) Is displayed. YES will save the changes and return the display to its current state. With NO, the changes will not be saved and the test parameter setup menu will reappear. Note: Any number of settings can be changed before they are saved. The flowchart below shows the menu structure. OPERATING MODE SAVE CHANGES MENU UP SP. + (inc) - (dec) PRELOAD OFF STOP DOWN SP. + (inc) - (dec) STOP, ZERO ZERO, GO AUTO RETURN + (on) - (off) LOAD HOLDING + (on) - (off) CYCLES HI + (inc) - (dec) BREAK DETECT + (on) - (off) DWELL LO + (inc) - (dec) CONTROL BAUD + (PC) - (CONSOLE) DWELL HI + (inc) - (dec) RATE STOP & + (inc) - (dec) LIMIT + (inc) - (dec) PAR + (inc) - (dec) LO LIMIT + (inc) - (dec) UNITS + (in) - (mm) OVERLD OFF MARK-10 OTHER 2V OTHER 4V KEYS MAINTAINED MOMENTARY AUTO COMP OVERLD + (inc ) - (dec) DEFAULT SETTINGS + (inc) - (dec) TEN OVERLD + (inc) - (dec) NEW PASSWORD + (inc) - (dec) 8

9 4.1 Speed, upward speed, downward speed (SPEED, UP SPEED, DOWN SP) If the option for different upward and downward speeds is not activated, the speed is the same in both directions and can be programmed using the SPEED parameter. If the different upward and downward speeds are activated, the parameters UP SPEED (upward speed) and DN SPEED (downward speed) are displayed. These can be set individually. Standard setting: 254 mm / min Possible settings: mm / min U P S P E E D: Increases the speed setting by 0.5 mm. Holding + will change the value faster and faster. Decreases the speed setting by 0.5 mm each. Holding down changes the value faster and faster. Opens the menu for the test parameter setup again. Closes the parameters without saving the changes. 4.2 Automatic return (AUTO RETURN) With this function, the crosshead moves to a limit switch, a force setpoint or the end of the maximum travel distance, whichever occurs first, and stops. Then the crosshead moves back to the other governor and stops. The test speed is determined by the SPEED setting or the UP SPEED and DOWN SPEED settings. The return speed is always the maximum speed. Default setting: off Possible settings: off, on A U T O R E T U R N o f f + or cycles through the available settings Opens the menu of the test parameter setup again Closes the parameters without saving the changes. Note: If the AUTO RETURN function is activated (on), the CYCLING function is automatically deactivated (off) and the KEYS parameters (buttons) are automatically set to MAINTAINED mode. Details on the parameters CYCLING (cycle operation) and KEYS (keys) can be found on the following pages. 9

10 4.3 Cycle operation (CYCLES) This setting can be used to define the number of upward and downward cycles that the crosshead runs through. A cycle comprises the following steps: The crosshead moves to a limit switch, a force setpoint or the end of the maximum travel distance, whichever occurs first, stops there for the specified dwell time and moves back at the set speed to the limiter on the other side . If the option for different upward and downward speeds is not activated, the speed is the same in both directions. Standard setting: (off) Possible settings: C Y C L E S: Press and hold + and Simultaneously Increases the number of cycles in steps of 1. Holding down + changes the value faster and faster. When the value is reached, it starts again at. Decreases the number of cycles in steps of 1. Holding down changes the value faster and faster. When the value is reached, it starts again at. If the buttons are held down simultaneously for two seconds or longer, the number of cycles changes to 0. Re-opens the parameter setup menu. Closes the parameter without saving the changes. 4.4 Dwell time for upper limiter and dwell time for lower limiter (HI DWELL and LO DWELL) This setting defines how long (in seconds) the crosshead stops at the limiter during a cycle sequence. Note: The dwell time setting is not available for a sequence with automatic reversing. Standard setting: (no dwell time) Possible settings: H I DWE L L: Increases the dwell time in steps of 0.1 s.Keeping + pressed changes the value faster and faster. When the value is reached, it starts again at. Decreases the dwell time in steps of 0.1. Holding down changes the value faster and faster. When the value is reached, it starts again at. Opens the menu for parameter setup again. Closes the parameter without saving the changes. 10

11 4.5 Upper and lower travel limiters (UPPER LM and LOWER LM) This setting defines the travel that the crosshead covers before it stops or moves in the other direction. The upper and lower limiter are programmed independently of each other. The programmed distances are based on the zero position of the crosshead. The travel distance display can be set to zero by holding down the STOP button for 3 seconds. Standard setting: mm, mm Possible settings: from mm to mm H I L I M I T: Increases the travel limiter by 02 mm. Holding + will change the value faster and faster. Decreases the travel limiter by 02 mm. Holding down changes the value faster and faster.Opens the menu for setting parameters again Closes the parameter without saving the changes Overload protection (OVERLD) This setting defines the maximum analog voltage output in relation to the end value of the measuring range of the force measuring device. The ESM301 protects the force gauge from overload by measuring the analog input voltage and stopping the crosshead movement when it reaches the programmed percentage of the final value (see section 4.7). The value for Mark-10 meters is ± 1 V, the setting can be adjusted to ± 2 V or ± 4 V. The adjustable tension ensures compatibility with other force gauges. Standard setting: OFF Possible settings: MARK-10, OTHER 2V, OTHER 4V, OFF OVERLD: MA ​​RK Pressure and tension overload (COMP OVERLD and TEN OVERLD) This setting defines the percentage of the full scale value of the force measuring device at which the movement of the crosshead is stopped becomes. A setting of 80% for a force measuring device with a measuring range of 222 N, for example, would result in the movement of the crosshead being stopped when it reaches 177 N. Note: When the crosshead moves up, only the tension overload setting applies. When the crosshead moves down, only the pressure overload setting applies. Standard setting: 100% Possible settings: 20% - 100% (10% steps COMP O V E R L D:% 11

12 + or Runs through the available settings Opens the menu for the test parameter setup again Closes the parameter without saving the change Preload (PRELOAD) This setting corresponds to the approach dynamics of the test bench with an initial load, which is referred to as PRELOAD (preload). When the preload is reached, the crosshead will stop or zero. This function is useful for testing springs, stretching, and measuring tension and compression on various materials. Details on setting the preload value can be found in the section Default setting: OFF Possible settings: STOP, STOP / ZERO, ZERO / GO, OFF PRELOAD: ZE RO, GO + or runs through the available settings STOP crosshead stops as soon as the preload has been reached STOP, ZERO crosshead stops as soon as the preload has been reached, the display is zeroed ZERO, GO The display is zeroed when the preload has been reached, crosshead does not stop Opens the menu for setting the parameters again Closes the parameter without saving the change Preload value (PRELD% FS) This setting corresponds to the preload value, which is defined as a percentage of the end value of the force measuring device in N units. When this value is reached, the test bench reacts as described in the previous section. Note: In the case of low force applications, please consider test stand vibrations and cross-head accelerations if they are noticeable enough to achieve a force that exceeds the preloaded value. Default setting: 1% Possible settings: 0 100% P R E L D% F S: or Scrolls through the available settings Opens the menu for setting parameters again Closes the parameter without saving the change 12

13 4.8 Load hold This setting instructs the test bench to dynamically adjust the crosshead position in order to obtain a programmed force. The force is programmed as a setting in a Series 5 force gauge (see user manual for more information). If the CYCLING option has been activated, the cycles run for the time set for the dwell time for the upper limiter and the lower limiter. If CYCLING is not activated, the load holding is continued indefinitely. Default setting: OFF Possible settings: ON, OFF LOAD HO LDI NG: ON + or Scrolls through the available settings Opens the menu for parameter setup again Closes the parameter without saving the change Breakage detection This setting stops the test bench if the test sample is broken or was demolished. The test stand is triggered when the force has decreased by a certain percentage of the peak. For details on programming the percentage of peak, see section Default setting: OFF Possible settings: ON, OFF BREAKDETECT: ON + or Scrolls through the available settings Re-opens the parameter setup menu Closes the parameter without saving the change Break detection with percentage Decline This setting corresponds to the force trigger for breakage detection, defined as a percentage of the peak force. For example: a specimen is pulled to 50 N and then breaks. The setting for breakage detection with a percentage decrease is 50%. After the specimen is broken, the force drops rapidly to 25 N (50% of the peak value), then the test stand stops. Standard setting: 80% Possible settings: 10% - 90% (10% classifications) B R E A K D E T E C T: ON + or Scrolls through the available settings Opens the menu for setting parameters again Closes the parameter without saving the change 13

14 4.10 Control type (CONTROL) This setting defines the type of control of the test bench. With the default setting CONSOLE, the test bench is configured to only receive commands from the console (control unit on the front). External commands received via the serial interface are ignored. PC refers to the external control via serial data transfer. If a parameter is changed on the control unit, this setting is ignored, with the exception of the Auto Return or Cycling parameters. If one of these parameters is activated, the PC control is deactivated. Default setting: CONSOLE Possible settings: CONSOLE, PC CO NT RO L: CO NSOLE + or Scrolls through the available settings Opens the menu for setting parameters again Closes the parameter without saving the change 4.11 Baud rate (BAUD RATE) This setting defines the baud rate of the computer program with which the test stand is controlled. Standard setting: Possible settings: 1200, 2400, 4800, 9600, 19200, 38400, 57600, B A U D R A T E: Stop bits and parity (STOP & PAR) This setting defines the stop bits and parity setting of the computer program with which the test stand is controlled. Default setting: 8-1n Possible settings: 8-1E 8 stop bits, 1 stop bit, even parity 8-1o 8 stop bits, 1 stop bit, odd parity 8-1n 8 data bits, 1 stop bit, no parity 8-2n 8 data bits, 2 stop bits, no parity 7-1E 7 data bits, 1 stop bit, even parity 7-1o 7 data bits, 1 stop bit, odd parity 7-2E 7 data bits, 2 stop bits, even parity 7-2o 7 data bits, 2 stop bits, odd parity 7-2n 7 Data bits, 2 stop bits, no parity STOP & PAR: 8-1 n + or Scrolls through the available settings Opens the menu for setting parameters again Closes the parameter without saving the change 14

15 4.13 Speed ​​units (UNITS) This setting defines the unit for the speed measurement. Default setting: in / min Possible setting: in / min, mm / min UNITS: in / min + or Scrolls through the available settings Opens the menu for setting parameters again Closes the parameter without saving the change 4.14 Programmable key functions (KEYS) The Buttons can be configured with three possible function modes: 1. Maintained The crosshead moves continuously as soon as the button is pressed. Then press the UP, DOWN, or STOP button during a test to stop the movement of the crosshead. 2. Momentary (non-latching) The crosshead only moves as long as the button is held down. As soon as the button is released, the movement is stopped immediately. 3. Auto If the button is held down for longer than 0.5 seconds, the system switches to non-latching operation. A signal tone sounds and the LED display on the pressed button lights up. Briefly pressing the button switches the test stand to self-holding mode. Pressing the UP, DOWN, or STOP button during latching operation will stop the crosshead from moving. Standard setting: maintained (latching) Possible settings: maintained (latching), momentary (non-latching), auto KEYS: MAINTAINED + or Scrolls through the available settings Opens the menu for setting parameters again Closes the parameter without saving the change 4.15 Resetting the standard settings ( DEFAULT SETTINGS) With this setting, a quick reset to the factory settings is possible. These are as follows: SPEED: 10 in / min UP SPEED: 10 in / min DOWN SP: 10 in / min AUTO RETURN: off CYCLING: (off) HI LIMIT: LO LIMIT: OVERLD: off 15

16 PRELOAD: off LOAD HOLDING: off BREAK DETECT: off CONTROL: CONSOLE BAUD RATE: STOP & PAR: 8-1n UNITS: in / min KEYS: maintained PASSWORD: 0000 (off) Standard setting: off Possible settings: off, on D E F A U L T? : NO + or Scrolls through the available settings Opens the menu for setting parameters again Closes the parameter without saving the change 4.16 Password (NEW PWORD) If necessary, a password can be set up to prevent unauthorized changes to the test parameters. The password can be any number between 0000 and 9999. In the standard setting 0000, the password is deactivated and the user can call up the menu for setting up the test parameters at will. If the password is misplaced or forgotten, it can be reset using a code activation process. Details can be found in section 9. Default setting: 0000 (off) Possible settings: NEWP WO RD or Scrolls through the available settings Opens the menu for setting parameters again Closes the parameter without saving the change 5 OPERATING MODES 5.1 Overview of the operating modes Das ESM301 can operate in several modes, including a combination of these modes: 1. Basic Operation The movement of the crosshead is controlled manually. 2. Auto Return Mode The crosshead moves to a limit switch, a force setpoint or the end of the maximum travel distance, whichever occurs first, and then moves at maximum speed in the opposite direction to the limiter there. 16

17 3. Cycle operation The crosshead moves in cycles at the specified speed between the limiters or setpoint for a specified period of time. 4. Preload mode The crosshead moves until the preload is reached and executes the programmed setting. An autom. Return, cycle / dwell time or break detection sequence can follow. 5. Load Hold Mode The crosshead will move up to a force set point, stop and receive the programmed force. An autom. Return or cycle / dwell time sequence can follow. 6. Break detection The crosshead stops when the sample is broken. An autom. Return or cycle / dwell time sequence can follow. 7. PC operation The test stand is controlled via a serial connection with a computer. The operating screen looks like this: S P E E D: m e n u m i n ma x S E T If the travel path display is activated, the screen looks like this: Travel path speed m e n u m i n ma x S E T The selected component is highlighted in capital letters (see figure above). The set speed can be changed in the test parameter setup. When activated, the up and down speeds (UP SPEED and DN SPEED) can be configured independently of each other. Otherwise, the SPEED setting determines the crosshead speed in both directions. 5.2 Menu navigation When switching on, the display shows the screen for the operating mode that was last used. The display shows one of the following screens: 1. Basic & Auto Return Modes (travel display not activated): S P E E D: m e n u m i n ma x S E T 2. Basic & Auto Return Modes (travel display activated): Travel speed m e n u m i n ma x S E T 17

18 3. Cycling mode (travel display not activated): travel remaining cycles C Y C L E S: me n u m i n ma x S E T Note: The min and max keys are not displayed if a password has been set. 4. PC mode Same screen as in basic and automatic reversing mode menu min max set Opens the menu for setting up the test parameters. Sets the speed to minimum. Does not appear if a password has been set. Sets the speed to maximum. Does not appear if a password has been set. Sets the speed to the programmed SPEED, UP SPEED, or DN SPEED setting. Pressing menu opens the test parameter setup menu. If a password has been configured, the display shows the following screen: P A S SWOR D The password is a four-digit number. The first digit of the password will flash, meaning it is selected and can be increased by pressing +. To go to the next digit, press>. Change the following digits in the same way. After you have completely entered the password, press. If the password is correct, the display shows the parameter setup menu. If the password is incorrect, the message INCORRECT PASSWORD is shown in flashing letters and the display returns to the operating screen. 5.3 Basic Operation The crosshead moves up when UP is pressed and down when DOWN is pressed. While the crosshead is moving, an LED indicator lights up on the key that is pressed. The KEYS setting defines how the crosshead movement changes when the UP and DOWN buttons are pressed. There are three settings: 1. Maintained (default setting) The crosshead moves continuously as soon as the button is pressed. By then pressing the STOP button during a test, the movement of the crosshead is stopped. 2. Momentary (non-latching) The crosshead only moves as long as the button is held down. As soon as the button is released, the movement is stopped immediately. 3. Auto If the button is held down for longer than 0.5 seconds, the system switches to momentary (non-latching) operation. A signal tone sounds and the LED display on the pressed button lights up. Briefly pressing the button changes the 18th

19 test bench in the maintained (self-sustaining) operation. Pressing the STOP button during maintained operation stops the crosshead from moving. To continue testing, press UP or DOWN again. By pressing the EMERGENCY STOP (emergency stop) button, the movement of the crosshead is stopped immediately in any operating mode. To release, turn the button counterclockwise until it has returned to its original position. To continue testing, press UP or DOWN. The crosshead moves until it reaches a limit switch, a force setpoint or the end of the maximum travel distance. If the crosshead has stopped at a force set point or at the end of the maximum travel, this condition can be overridden by holding the UP or DOWN button for two seconds. Travel indicator When activated, the travel indicator is shown in the upper left corner of the display. The units displayed correspond to the units set in the UNITS parameter. The specified travel distance is a relative value. To zero the travel, make sure the crosshead is not moving, then press and hold the STOP button for three seconds. If the cable with the crosshead is connected to the back of the controller, the position value will not change when the crosshead moves.Operation with limit switches Limit switches allow the operator to set a point along the column at which the movement of the crosshead will stop. Limit switches are located on the rear of the test stand column. To adjust the position of the switches, loosen the knurled screws, reposition the switch and retighten the screws. Overload protection The cable is required for overload protection of a Mark 10 force gauge. If the overload protection is activated, the crosshead stops as soon as the programmed percentage of the full scale value of the force measuring device is reached. If the overload protection is activated and the cable is not connected and / or the force measuring device is switched off, an error message is displayed. To clear the message, connect the cable or turn on the force gauge. Note: When the crosshead moves up, only the tension overload setting is active. When the crosshead moves down, only the pressure overload setting is active. 5.4 Automatic reverse operation With this setting, the crosshead moves to a limit switch, a force setpoint or the end of the maximum travel distance, whichever occurs first, and stops. Then the crosshead moves back to the other governor at maximum speed and stops.The speed at which the crosshead moves is determined by the SPEED setting or, if independent speeds are activated, UP SPEED (upward speed) and DN SPEED (downward speed). To start a sequence with automatic reversing, press the UP or DOWN button. 19th

20 The crosshead can be stopped at any time during an automatic reverse sequence by pressing the STOP button. To continue the test, press UP or DOWN again. Note: If the crosshead has stopped at a force setpoint or at the end of maximum travel, this condition can be overridden by holding the UP or DOWN button for two seconds. 5.5 Cycle operation In this operating mode, the crosshead moves back and forth between limit switches, force setpoints or the end points of the maximum travel distance, whichever occurs first. A cycle comprises the following steps: 1. The crosshead moves at the specified speed up to a limiter. 2. The crosshead stops for the specified dwell time. 3. The crosshead moves at the specified speed in the opposite direction to the other limiter and stops. A cycle sequence can be started from any position and in any direction. When the crosshead is on a governor, cycling can only be started in the direction of the other governor. To start a cycle sequence, press the UP or DOWN button. During a cycle sequence, a counter is displayed indicating the number of cycles remaining (see figure below): C Y C L E S m e n u m i n ma x S E T As in basic operation, the min, max, and set softkeys are available while the crosshead is moving. If the cycle sequence and the crosshead has stopped at a force setpoint or at the end of the maximum travel, this state can be overridden by holding the UP or DOWN button for two seconds Seconds) that the crosshead stops at a limiter during a cycle sequence. When the crosshead has reached a limiter, a counter is displayed (see figure below): DWE LL: menumin ma x SET If the setting DWELL U (dwell time above) and / or DWELL L (dwell time below) is set to 0, it runs When reaching the limiter, cross head immediately in the opposite direction and no counter is displayed. The cycle sequence can be interrupted prematurely by pressing the STOP button. The RESET softkey is then displayed: C Y C L E S: R E S E T There are two options at this point: 20

21 1. Aborting the cycle sequence: To abort and reset the cycle sequence, press RESET. The cycle counter again shows the number of cycles that was originally programmed. 2. Continuing the cycle sequence: Press the UP or DOWN button to continue. When the sequence is complete, the display shows the number of cycles that was originally programmed. To start another test cycle, press the UP or DOWN button. Operation with travel display and limit switch is the same as in basic operation. 5.5 Preload mode In this mode, the crosshead moves at an approach speed of 250 mm / min until the programmed preload value has been reached. When the crosshead moves upwards, a tensile preload is necessary. When the crosshead is moving down, a pressure preload is necessary. When the preload is reached, the programmed preload setting occurs as a sequence of events (see section 4.7.1). If the ZERO, GO setting is activated, the speed of the crosshead is reset to the set speed as soon as the travel path is zeroed. Note 1: Before starting a preload sequence, the crosshead must be positioned at the upper or lower limit switch. Note 2: Preload and Load Holding cannot be activated at the same time. 5.6 Load-hold operation In this mode, the crosshead moves until the setpoint programmed in the measuring device is reached. The crosshead then dynamically adjusts its position to maintain the programmed force. The capacity of the force gauge should be matched as closely as possible to the intended load for optimal performance. Both target values ​​must be specified in the force measuring device. The upper setpoint refers to the maximum force in the upward direction (force). The lower setpoint refers to the maximum force in the downward direction (pressure). The opposite setpoint must be set to any value in the opposite direction of the measurement. For example, if you require 10N pressure for a test, then set the upper setpoint at 30N force (as an example) and the lower setpoint at 10N pressure. If the option CYCLING has been activated, the load-hold mode will be active for the period according to the Dwell Time (dwell time) setting. If CYCLING has not been activated, the load-hold operation is continued indefinitely. Before starting a load-hold sequence, the crosshead must be positioned at one of the two limit switches. Either at the upper limit switch for pushing or at the lower limit switch for pulling. The test speed should be adapted to the sample. Fine tuning may be necessary to ensure optimal adjustment of the crosshead. Stiff samples require a slower test speed; softer samples can be tested at higher speeds. If the speed is too high for the stiffness of the specimen, the crosshead can overshoot the setpoint. This requires an adaptation sequence in which the crosshead turns, then it moves again several times in the original direction before it reaches the setpoint. A sufficiently high speed can repeat this correction cycle indefinitely. For softer samples, the amplitude oscillations are smaller, but they are still present for the duration of the loading of the holding period. This is typical for rehearsals that can relax, e.g. Rubber, foam, etc .. The lowering of the test speed reduces the vibration. 21

22 For non-relaxed materials such as metal springs, the vibrations should stop shortly after the holding force is reached. Note: Preload and Load Holding cannot be activated at the same time. 5.7 Break detection mode In this mode, the crosshead stops when the sample is broken. The test stand is triggered when the force has decreased by a certain percentage of the peak value. For example: a specimen is pulled to 50 N, then it breaks. The breakage detection is programmed to a percentage up to 50%. After the specimen is broken, the force decreases rapidly when 25 N (50% of the peak value) is reached, then the test stand stops. The breakage detection is activated only when the full 5% of the force gauge scale has been reached. For example, if you are using a force measuring device with a capacity of 50 N, the breakage detection function will not be active until 2.5 N is reached. If the breakage detection is activated, an autom. Reverse or follow a single cycle sequence on break detection. 5.8 PC operation The ESM301 can be controlled via a serial connection with a computer. The following is a list of the supported ASCII commands: All commands must be entered in lower case. abcdefghijklmnopqrstu vwxz Query speed Set travel units to inches Change to cycle mode Move crosshead down Set speed (e.g. e10.00 = in / min) Define cycles (e.g. f0500 = 500 cycles) Define lower travel limiter (e.g. g = in) Determine upper travel limiter (e.g. h = in) Set the travel units to millimeters Set the crosshead speed to the maximum speed Set the crosshead speed to the minimum speed Change to operation with the travel limiter Change to manual mode Transmit travel and force measurement values ​​Set the crosshead speed to the programmed speed Query the test stand status Query the number of cycles performed Query the number of Query set cycles Stop crosshead Set cycle counter to zero Move crosshead up Query upper travel limiter Query lower travel limiter Query travel path value Set travel path to zero * The test bench status is returned by transmitting the ASCII command p. The return codes and their meanings are listed below. Crosshead status U = crosshead moves up D = crosshead moves down S = crosshead stopped 22

23 Operating mode limit switch status C = cyclic operation L = operation with travel limiter M = manual operation UL = crosshead at upper limiter DL = crosshead at lower limiter The commands for Mark-10 force gauges do not correspond to those specified in the respective en. Below is a list of the supported ASCII commands. All commands must be entered in capital letters. A F P R S U X or? Y Z Displays the current unit. Switches between normal and data acquisition mode. Switches between normal operation, Tension Peak mode, and Compression Peak. Sets the force gauge to zero (sets all operating modes to zero) Sends the currently selected operating mode (Normal, Tension Peak, Compression Peak, or Data Collect). Switches through the units. Sends the current display value. Activates RS-232 output and a continuous stream of data when data acquisition mode is active. Sets the currently selected operating mode to zero. The ESM301 is compatible with the Nexygen TCD software, which also works with the commands listed above. The cable is required for data exchange between a Mark 10 measuring device and the test bench. The serial cable is required for data exchange between a computer and the test bench. The baud rate, stop bits and parity must be programmed in the test bench in accordance with the settings in the computer program. If parameters are changed on the control unit under PC control, these settings are ignored, unless the automatic reverse operation or cycle operation is active. In this case, the PC control is automatically deactivated. 6 DATA EXCHANGE WITH MESUR TM GAUGE The ESM301 can communicate with data acquisition software MESUR TM gauge. The test bench can either output force measurement data only or force measurement data and travel data (if the optional integrated travel indicator ESM is installed). To exchange data with MESUR TM gauge, certain settings in the test bench, in the force measuring device and in the software must be changed as follows: 1. Check physical connections (see section 3.4) 2. Settings in the force measuring device 1. Set to RS-232 output 2. Baud rate set to 9.600 3. Settings in the test bench 1. Set the baud rate to 115.200. 23

24 4. MESUR TM gauge settings 1. Select System Configuration, Gauge + ESM301 / DC Controller with Travel or without Travel for force versus time or force versus displacement measurement. 2. In the Configuration tab, create the COM port numbers that are accessible to the number of Windows that are assigned in the Device Manager. 7 ACTIVATING FUNCTIONS The activated and deactivated functions are displayed in this menu. Deactivated functions can be activated. Activated functions are marked with ON, deactivated functions with OFF. 7.1 Calling up the menu for function activation Change to the operating mode and press the STOP and menu buttons at the same time. The following screen is displayed: KEYS: OFFESC <> ENTR Scrolls to the next function Selects the function Closes the menu for function activation 7.2 Activating functions Functions that were not originally purchased with the product can be activated using an activation code become. To activate a function, scroll to the function you want in the menu and press. If the function is already activated (indicated by on), pressing has no effect. If the function is deactivated, a request code is shown on the display by pressing. The following figure shows an example: K E Y S: E S C + E N T R The request code must be submitted by Mark-10 or a sales partner. This will then send you a corresponding activation code to activate the function. To enter the activation code, proceed as follows: 1. The first digit of the activation code flashes. Press + to increase the digit. If the number 9 is displayed and + is pressed, it will start over from 0. 2. Press> to go to the next digit and change it in the same way. 3. Press to activate the function. If an incorrect code has been entered, the control unit will return to the function activation menu without activating the function. In this case you need to repeat the above steps. 24

25 The menu for activating functions also offers a function for deactivating the password. Scroll through the functions to the following screen: D I S AB L E P A S S WOR D E S C <> E N T R Press to request an activation code, then follow the activation procedure. 7.3 Demo mode All ESM301 test stands are delivered in demo mode, which offers the full range of functions (with the exception of the integrated travel display) for a test period of 160 operating hours. The demo mode can be deactivated by holding down the STOP button when switching on the test stand. The mode can be reactivated in the same way for the remainder of the period. 8 TROUBLESHOOTING 1. The ESM301 shows the following error messages: Error message CHECK GAUGE (check measuring device) GAUGE COMM ERROR (measuring device communication error) GAUGE OVERLOAD (measuring device overloaded) M REQD The force measuring device is in a menu, switched off or not connected to the stand controller. Message for overload protection is switched on. The test bench tries to move the crosshead up or down, but no communication with the force gauge is established. The programmed overload of the force measuring device has been reached. Immediately reduce the force or adjust the settings for the overload. A Series 5 force gauge with firmware version 1.7 or newer is required for proper operation of the selected functions in the test bench. To clear any of the above errors, press STOP. The yellow light in the STOP button flashes when the error message is displayed. 2. The crosshead only moves in one direction or not at all. Possible causes: 1. Make sure that all cables are connected correctly as described in section 2.2. 2. Make sure that the force value has not exceeded the configured overload limits on the measuring device. 3. Ensure that the force gauge setpoints have been configured correctly. See section The travel indicator value is not changed when the crosshead moves. Check that the coding cables are connected correctly. 4. Certain menu items are no longer displayed. All functions of the test stand are temporarily activated for 160 operating hours in demo mode. If the demo mode has expired and not all features have been purchased, those features (and their associated menu items) will no longer be available. 25th

26 9 MAINTENANCE AND SERVICE The ESM301 must be operated in a dry and clean environment. If these conditions are met, only a few regular maintenance measures are required: 9.1 Greasing the trapezoidal spindles (ACME spindles) twice a year 1. Remove the right column cover by loosening the screws. 2. Use a brush to apply a small amount of silicone lubricant to the lead screw. 3. Move the crosshead up and down several times until the applied lubricant is evenly distributed over the entire spindle. Replace the column cover. 9.2 Check for loose handles and attachments - Check daily that the handles attached to the force gauge and the base plate are securely attached. Loose handles can create a potentially hazardous situation. 9.3 Check for loose components once a month 1. Remove the test sample from the test stand. 2. Switch off the test stand and pull out the power plug. Try to loosen the components on the test bench (e.g. fasteners, brackets, etc.). All components must be securely attached. If loose components are found, take the test stand out of operation and contact Mark-10 or a sales partner about how to proceed. 26

27 10 TECHNICAL DATA Load range: Standard speed range: Maximum travel: Accuracy of the speed setting: Speed ​​change under load: Limit switch Repeat accuracy: Travel accuracy: Travel repeatability: Travel resolution: Power supply: Fuse: Weight (without optional components Included in delivery: Environmental conditions: 1.5 kn at up to 610 mm / min 1 kn at> 610 mm / min mm / min ESM301: 292 mm ESM301L: 457 mm ± 0.2% ± 0% [drive via stepper motor] 0.03 mm ± 0.05 mm 0.03 mm 0.02 mm Universal input VAC, 50/60 Hz 1.2 A, 250V, 3AG, slow ESM301: 15.4 kg ESM301L: 23.7 kg Extension rod, small hook, medium hook, # 10-32 coupling, compression plate, assembly set for force gauge, tool set 5-40 C, max. 96% humidity, not condensing 11 DIMENSIONS # 10-32 UNF-2B X DEEP X [12.7] TYPE [12.7] TYPE 3.26 [82.8] [71.1] 5 / 16-18 UNC-2B X DEEP A [58.4] 2.76 [70.1] 4.90 [124.5] 4.20 [106.7] 0.35 [8.9] BC 3.00 [76.2] MOUNTING PLATE TOP VIEW 6.50 [165.0] [335.3] Model AB (Series 3) C (Series 5/4) ESM [622] [89-381] [58-351] ESM301L 31.5 [800] [89- 546] [58-516] 27