Shimadzu AG-IC 100 KN and 300 KN Instruction Manual - 349-05554B

349-05554B

INSTRUCTION MANUAL FOR SHIMADZU AUTOGRAPH AG-100kNIC And AG-300kNIC

To ensure proper use of this equipment, read this manual thoroughly. Keep this manual carefully for your reference.

Before Using the System Introduction Read this instruction manual prior to operating the product. Thank you for purchasing the AG-IC series AutoGraph testing machine. This instruction manual includes guidelines for installing the system, precautions that should be followed when using the system, and a description of relevant accessories and optional parts. Please read the instruction manual carefully before using the testing machine. Keep it stored safely in an accessible location for easy reference.

IMPORTANT

· Read this manual thoroughly before using the product and operate the product in accordance with the instructions in this manual. · If the user or usage location changes, ensure that this Instruction Manual is always kept together with the product. · If this manual or a product warning label is lost or damaged, immediately contact your Shimadzu representative to request a replacement. · To ensure safe operation, read all Safety Instructions before using this product. · To ensure safe operation, contact your Shimadzu representative if product installation, adjustment, or re-installation (after the product is moved) is required. · Contact your Shimadzu representative if product or peripheral disposal is required.

NOTICE

· All rights are reserved, including those to reproduce this manual or parts thereof in any form without permission in writing from Shimadzu Corporation. ã 2009 Shimadzu Corporation. All rights reserved. · Information in this manual is subject to change without notice and does not represent a commitment on the part of the vendor. · Any errors or omissions which may have occurred in this manual despite the utmost care taken in its production will be corrected as soon as possible, although not necessarily immediately after detection. Microsoft and Windows are registered trademarks of Microsoft Corporation

in the United States and/or other countries.

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Inscription of this manual This operation manual defines warnings, cautions and other information as follows:

Inscription

WARNING

Failure to avoid the described condition may result in serious injury or death.

CAUTION

Failure to avoid the described condition may result in slight or middle injury, or damage to the equipment.

NOTE

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Meaning

Includes information necessary for correct use of the equipment.

The warnings on safe for SHIMADZU AUTOGRAPH

The AUTOGRAPH is the measuring equipment intended to measure mechanical strength or other properties of various materials and products, and big power is generated. Depending on a handling situation, there is a danger of causing serious obstacles (an injury, death accident, etc.) to a human body, and material damage. Therefore, you observe the following warning after an understanding enough, and I ask you to use it safely.

WARNING Using this equipment carelessly may result in serious injury or death. While the crosshead is operated, be sure not to put a part of your body (hand, head, etc.) in the testing space.

WARNING The dangerous power according to capacity arises in a part of operation. Surely, an operator needs to read an instruction manual carefully and needs to use it correctly. Moreover, please manage so that only the person who received education about the operation method uses it.

WARNING To avoid electric shock, do not touch the inside of equipment with a hand by any means.

WARNING Except for lubricating work, do not open the ball screw protection cover. Do not test when the ball screw protection cover is opened. During lubricating work, be careful that your hairs will not be caught in the machine.

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The warnings on safe for SHIMADZU AUTOGRAPH

WARNING Please bring neither a face nor the body close to a specimen during a test. In such case, the specimen breaks and a fragment disperses, causing injury to an eye or the body. Please cope with installation of a testing space safety door etc. for the specimen to crush.

WARNING To avoid electric shock, an injury, and a fire, people with special knowledge need to do the work of wiring, maintenance, and check.

WARNING To avoid electric shock, be sure to ground the grounding terminal of a power supply cable (100Ω or less).

WARNING Do not apply force to the crosshead when the load cell is dismounted, or when force cannot be transmitted to the load cell. In such a case, the AUTOGRAPH cannot detect overload conditions, causing damage to the frame or jig.

WARNING Before operating the crosshead, be sure to set the crosshead stroke limit switch to avoid the destruction of a frame, jig, and load cell by the collision of the jig.

iv

The warnings on safe for SHIMADZU AUTOGRAPH

WARNING “Safety function” is attached in this equipment. It detect the force shift applied to the load cell while crosshead moves under jog operation or return function. If the force shift value becomes over a determined value, it makes stop the crosshead immediately. Although this function is one of the safety device, the equipment can not exclude danger by overshoot at the high-speed operation. When the crosshead is operated in the direction of reducing force, the crosshead does not stop in order to remove force at overload and the convenience of operation. Note that this function is not intended to ensure that preventing the objects from running into the others in the test space and overload. Moreover, please do not use this function for control, such as positioning.

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Note on Shimadzu AUTOGRAPH AG-IC Handling

When the load cell and extensometer are installed and exchanged, be sure to turn off the power supply according to the under mentioned notes NOTE Before connecting the CAL cable to the connector (disconnecting the CAL cable from the connector), be sure to turn OFF the power supply. If the cable is connected or disconnected while the power supply is turning ON, the capacity of the load cell and calibration data might break. Moreover, new information on the load cell (extensometer) is not valid and force (elongation) value becomes incorrect without resetting the power.

Load cell CAL. cable

POWER SUPPLY ON

Sensor Amplifier Panel for the AG-IC Series (Floor-type)

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WARNING LABELS ON THE EQUIPMENT (FLOOR-TYPE TESTING MACHINE)

WARNING

HAZARDOUS VOLTAGE To avoid electric shock, do not disassemble.

Warning label

(Backside of testing machine)

WARNING

HAZARDOUS VOLTAGE To avoid electric shock, turn off the power supply before removing the power cable.

Warning label

(Backside of testing machine)

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WARNING LABELS ON THE EQUIPMENT (FLOOR-TYPE TESTING MACHINE)

RISK OF INJURY Keep hands clear while the crosshead is operating.

Warning label

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Countermeasures in Emergency

If the crosshead does not stop or you smell something burning, carry out the following countermeasures: To restart operation, check the equipment, and contact our service representative if required.

    

Procedure for stopping the equipment in emergency 1) Stop the emergency stop button. 2) Turn OFF the power switch of the tester. 3) Turn OFF the circuit breaker on the rear right side of the tester. (Floor-type only) 4）Disconnect the power supply cable from the rear of the tester.

Emergency stop switch

Smart controller

Circuit breaker (Rear right side of the tester) Power switch AG-IC series (floor-type) tester Emergency stop switch and power switch

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Warranty Thank you for purchasing the AG-IC series AutoGraph testing machine. Shimadzu provides the following warranty for this product. 1. Period

Please contact your Shimadzu representative for information about the period of this warranty.

2. Description

If a product/part failure occurs for reasons attributable to Shimadzu during the warranty period, Shimadzu will repair or replace the product/part free of charge. However, in the case of products which are usually available on the market only for a short time, such as personal computers and their peripherals/parts, Shimadzu may not be able to provide identical replacement products. Failures caused by the following are excluded from the warranty, even if they occur during the warranty period.

3. Exceptions: 1) 2)

Improper product handling Repairs or modifications performed by parties other than Shimadzu or Shimadzu designated companies 3) Product use in combination with hardware or software other than that designated by Shimadzu 4) Computer viruses leading to device failures and damage to data and software, including the product's basic software 5) Power failures, including power outages and sudden voltage drops, leading to device failures and damage to data and software, including the product's basic software 6) Turning OFF the product without following the proper shutdown procedure leading to device failures and damage to data and software, including the product's basic software 7) Reasons unrelated to the product itself 8) Product use in harsh environments, such as those subject to high temperatures or humidity levels, corrosive gases, or strong vibrations 9) Fires, earthquakes, or any other act of nature, contamination by radioactive or hazardous substances, or any other force majeure event, including wars, riots, and crimes 10) Product movement or transportation after installation 11) Consumable items Note: Recording media such as floppy disks and CD-ROMs are considered consumable items. If there is a document such as a warranty provided with the product, or there is a separate contract agreed upon that includes warranty conditions, the provisions of those documents shall apply. Separate warranty periods shall be stipulated for custom specification parts and system.

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After-Sales Service and Availability of Replacement Parts After-Services

If any problem occurs with this product, perform an inspection and take appropriate corrective action as described in this manual's troubleshooting section. If the problem persists, or the symptoms are not covered in the troubleshooting section, contact your Shimadzu representative.

Replacement Parts Availability

Replacement parts for this product will be available for a period of seven (7) years after the product is discontinued. Thereafter, such parts may cease to be available. Note, however, that the availability of parts not manufactured by Shimadzu shall be determined by the relevant manufacturers.

Installation To ensure safe operation, contact your Shimadzu representative if product installation, adjustment, or re-installation (after the product is moved) is required.

Action for Environment (WEEE)

To all users of Shimadzu equipment in the European Union: WEEE Mark

Equipment marked with this symbol indicates that it was sold on or after 13th August 2005, which means it should not be disposed of with general household waste. Please note that our equipment is for industrial/professional use only. Contact your Shimadzu service representative when the equipment has reached the end of its life. They will advise you regarding the equipment take-back. With your co-operation we are aiming to reduce contamination from waste electronic and electrical equipment and preserve natural resource through re-use and recycling. Please do not hesitate to ask your Shimadzu office or Shimadzu distributor, if you require further information.

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EMC Directive This instrument is a class A product, designed not for use in residential environment. Accordingly, if using the instrument in residential environment, the user may be required to take adequate measures.

Regulatory Information

For Europe: The product complies with the requirement of the Low Voltage Directive 2006/95/EC and EMC Directive 2004/108/EC Product Name : Universal Testing Instruments Model Name

: Autograph AG-IC Series AG-100kNIC AG-300kNIC

Manufacturer

: SHIMADZU CORPORATION Analytical & Measuring Instruments Division

Address

: 1,NISHINOKYO-KUWABARACHO, NAKAGYO-KU,KYOTO,604-8511, JAPAN

Authorized Representative : SHIMADZU EUROPA GmbH in EU Address

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: Albert-Hahn-Strasse 6-10, 47269 Duisburg, F.R. Germany

CONTENTS

CONTENTS CHAPTER 1 OUTLINE.......................................................................................................1-1 1.1Outline .............................................................................................................................1-2 1.2 Precautions ....................................................................................................................1-2 1. Handling the load cell............................................................................................................. 1-2 2. Handling the grips .................................................................................................................. 1-3 3. Cycle test ................................................................................................................................. 1-3 4. Setting the crosshead limit switch......................................................................................... 1-3

1.3 Specifications................................................................................................................1-4 1. Outline .................................................................................................................................... 1-4 2. Detailed specifications ............................................................................................................ 1-5

1.4 Individual Specifications for Testing machine .....................................................................................................1-9

CHAPTER 2 PARTS IDENTIFICATION .........................................................................2-1 2.1 Main frame....................................................................................................................2-2 2.2 Accessories ..................................................................................................................2-3 2.3 Peripheral Equipment ...................................................................................................2-5 1. Set of load cells........................................................................................................................ 2-5 2. Test jigs .................................................................................................................................... 2-6 3. Recorder/Data processor....................................................................................................... 2-10 4. Maintenance parts ................................................................................................................ 2-11

CHAPTER 3 FEATURES AND FUNCTIONS OF EACH SUBASSEMBLY................3-1 3.1 Main frame .....................................................................................................................3-2 1. AG-ICseries (Floor-type) ......................................................................................................... 3-2 3. Description on the main parts................................................................................................ 3-4

3.2 Smart controller ..............................................................................................................3-6 1. External views and names of the main parts........................................................................ 3-6 2. Description on the main parts................................................................................................ 3-7

3.3 Load Cell (Option), Tension force jig (Option) ................................................................3-9 1. External view and names of the main parts (Floor-type)..................................................... 3-9 2. External view and names of the main parts (Table-type) .................................................. 3-10 3. Part names ............................................................................................................................ 3-11

CHAPTER 4 BASIC OPERATIONS..................................................................................4-1 4.1 Introduction...................................................................................................................4-2 4.2 Precautions for Installation ...........................................................................................4-3 1. 2. 3. 4. 5.

Installation environment....................................................................................................... 4-3 Conditions for Installation location ...................................................................................... 4-3 Delivery/Installation.............................................................................................................. 4-3 Main frame level adjustment ................................................................................................ 4-4 Conditions for the power supply ........................................................................................... 4-5

4.3 Fixing Smart controller ...................................................................................................4-6 1. Mount the smart controller in installation .......................................................................... 4-6

4.4 Cable Connections .........................................................................................................4-7 1. AG-IC series testing machine (Floor-type) ............................................................................ 4-7 2. Connection with a personal computer ................................................................................... 4-8 4.Connecting the analog recorder .............................................................................................. 4-9

4.5 Safety Devices............................................................................................................4-10 1. Emergency stop switch ......................................................................................................... 4-10

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CONTENTS 2. Crosshead stroke limit switch.............................................................................................. 4-10 3. Turnover prevention brackets (Optional) ............................................................................ 4-12 4. Testing space safety door (Optional).................................................................................... 4-12

4.6 Turning ON/OFF Power Supply..................................................................................4-13 1. Introduction........................................................................................................................... 4-13 2. Turning ON the power .......................................................................................................... 4-13 3. Warm-up ................................................................................................................................ 4-14 4. Calibration for Force Amplifier ............................................................................................ 4-15 5 Turning OFF the power ......................................................................................................... 4-15

4.7 How to Use Smart controller.......................................................................................4-16 1. LED display........................................................................................................................... 4-16

4.8 Moving Crosshead Up/Down ......................................................................................4-17 1. Starting a test ....................................................................................................................... 4-17 2. Returning the crosshead (High-speed return to the origin)............................................... 4-18 3. Stopping a test....................................................................................................................... 4-18 4. Manual operation .................................................................................................................. 4-19 5. Safety function ...................................................................................................................... 4-20 6. Setting the crosshead origin................................................................................................. 4-21

4.9 Testing machine Setup ...............................................................................................4-21 1. Mounting the load cell .......................................................................................................... 4-21

2. Mounting the tensile test jig (Optionally available, except for the load cell) 4-24

3. Removing the tensile test jig ..................................................................................... 4-32

CHAPTER 5 PERFORMING A TEST ..............................................................................5-1 5.1 Procedure for Tensile Test

(Example) ..........................................................................5-2

1. Preparations for Test .............................................................................................................. 5-2 2. Procedure for Tensile Test ...................................................................................................... 5-2

5.2 Procedure for Compression/Bending Test (Example) ....................................................5-5 1. Preparations for Test .............................................................................................................. 5-5 2. Procedure for Compression/Bending Test.............................................................................. 5-6

CHAPTER 6 PERFORMANCE

INSPECTION/MAINTENANCE .............................6-1

6.1 Periodic Inspection .........................................................................................................6-2 6.2 Inspection of the Safety Devices ....................................................................................6-2 1. Emergency stop switch ........................................................................................................... 6-2 2. Crosshead stroke limit switches ............................................................................................ 6-2

6.3 Force Inspection.............................................................................................................6-4 1. Force inspection ...................................................................................................................... 6-4 2. Force Calibration (F-CAL)...................................................................................................... 6-6

6.4 Maintenance (Lubrication and Cleaning)........................................................................6-7 1. Maintenance of the ball screw................................................................................................ 6-7 2. Maintenance of the fan filter( Floor type) ............................................................................. 6-8 3. Maintenance of the smart controller ..................................................................................... 6-8 4. Maintenance of the testing machine body............................................................................. 6-8

CHAPTER 7 TRANSPORT/STORAGE ............................................................................7-1 7.1 Precautions for Transport .............................................................................................7-2 1. Installation space .................................................................................................................... 7-2 2. Installation environment........................................................................................................ 7-2 3. Power supply ........................................................................................................................... 7-2 4. Precautions .............................................................................................................................. 7-2 5. Level adjustment (Table-type testing machine).................................................................... 7-3 6. Cable connections.................................................................................................................... 7-3

7.2 Precautions for Storage..................................................................................................7-4

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CONTENTS 1. Precautions for storage ........................................................................................................... 7-4 2. Storing environment ............................................................................................................... 7-4 3. Provisions for storage ............................................................................................................. 7-4

CHAPTER 8 TROUBLESHOOTING ................................................................................8-1 8.1 Introduction.....................................................................................................................8-2 8.2 Alarm Messages and Resetting Alarms..........................................................................8-2 8.3 Other Troubles................................................................................................................8-6 1. Troubles related to key input ................................................................................................. 8-6 2. Other troubles ......................................................................................................................... 8-7

8.4 C-RAM Clear ..................................................................................................................8-8 8.5 Checking the Circuit Breaker (AG-IC Series Floor-type) ................................................8-9

CHAPTER 9 MAINTENANCE PARTS LIST ..................................................................9-1 9.1 Consumable Parts..........................................................................................................9-2 9.2 Maintenance Parts .........................................................................................................9-2

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CONTENTS

(Blank sheet)

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CHAPTER 1 Outline

CONTENTS 1.1 Outline..................................................................... 1-2 1.2 Precautions ............................................................ 1-2 1.3 Common Specifications .......................................... 1-4 1.4 Individual Specifications......................................... 1-9

1-1

1. Outline

1.1 Outline We at Shimadzu appreciate it very much that you have purchased a Shimadzu AUTOGRAPH AG-IC series testing machine. The AG-IC series AUTOGRAPH is a universal testing machine indispensable to quality control and researches of various materials such as metal, ceramic, plastic and rubber, and various products such as screws, electronic components, foods, medical supplies and films, as well as to research and development of new materials. To perform material strength measurement, the universal testing machine must provide extremely-high body rigidity and loading speed, and reliability in force measurements. The AG-IC series AUTOGRAPH is the precision universal testing machine that provides excellent basic performance and enables you to operate various functions easily. We are sure that this product can be used for a long period. The AG-IC series AUTOGRAPH can be used for various tests such as compression and bending tests, in addition to tensile tests. However, this operation manual mainly describes the commonly-performed tensile tests.

1.2 Precautions 1. Handling the load cell Since the load cell is a high-precision equipment for detecting a force, handle the load cell with thorough attention to the following points. To handle the small-capacity load cell, special attention is required. 1 ) Make sure that the force applied to the load cell does not exceed 150% of the rated load capacity. (The force includes the jig mass applied to the load cell.) 2 ) Do not apply eccentric force or impact to the load cell. 3 ) Avoid using the load cell in a place where an extreme temperature change may occur. The operating temperate range is +5 °C to +40 °C. During a test, make sure that temperature fluctuations does not exceed +/－2 °C.

1-2

1. Outline NOTE The AG-IC series AUTOGRAPH provides an over force detecting function. However, if an overshoot occurs before the crosshead stops, the load cell may be damaged. If the force reaches the load cell capacity within approx. 2 seconds or the maximum force is unknown, perform a preliminary test to make sure that the force does not exceed 90% of the load cell capacity. To perform a preliminary test, set the test speed so that the maximum force will be reached in 5 or more seconds. If the maximum force is unknown, select the tester's lowest speed to perform a trial operation.

2. Handling the grips 1 ) Be sure not to use the grips under any conditions other than those specified. 2 ) Grip a specimen by 80 to 100% length of the grip tooth length. Do not grip a specimen by a shorter length. Otherwise, the specimen man slip from the grips, and the grip teeth or grip body may be damaged. 3 ) After completion of a test, or during replacement of the grip teeth, be sure to clean the grip teeth and the sliding part of the grip body. Apply molybdenum grease to these parts so that the grip can work smoothly.

3. Cycle test To maintain the performance of the SHIMADZU AUTOGRAPH for a long period, the following conditions are provided for a cycle test. Use the AUTOGRAPH under the specified conditions. 1 ) Cycle test conditions: a) Cycle frequency: 3 cycles/min or less b) Continuous operation time and number of continuous cycles: 10 hours or less, 1000 cycles or less NOTE The above cycle test conditions are is the limit of the performance of the testing machine. Please examine below on this condition in principle. 2 ) Lubrication Apply the specified lubrication oil to the ball screw periodically. Be careful to prevent oil lacking.

4. Setting the crosshead limit switch Be sure to set the crosshead upper/lower limit switch to the position where the crosshead safely stops. In particular, after switching the test mode (tensile/compression/bending test), make sure that the crosshead limit switch has been properly set. For the crosshead limit switch setting procedure, see Section 4.5 2. .

1-3

1. Outline

1.3 Specifications 1. Outline (1) Loading method

High-precision, constant-speed strain control using two ball screws

(2) Force capacity

100 kN (10 tf) and 300 kN (30tf)

(3) Force measurement accuracy ･ Tensile measurement accuracy

Within +/-1% of an indicated value: Acceptable in JIS B7721 (Within 1/1 to 1/250 range of the rated load cell capacity) (Within 1/1 to 1/500 range of the rated load cell capacity is optional)

Standard accuracy type ･ Compression measurement accuracy

Within +/-1% of an indicated value: Acceptable in JIS B7721 (Within 1/1 to 1/250 range of the rated load cell capacity) (Within 1/1 to 1/500 range of the rated load cell capacity is optional)

･ Tensile measurement accuracy

High accuracy type

Within +/-0.5% of an indicated value: Acceptable in JIS B7721 (Within 1/1 to 1/250 range of the rated load cell capacity) (Within 1/1 to 1/500 range of the rated load cell capacity is optional)

･ Compression measurement accuracy

Within +/-0.5% of an indicated value: Acceptable in JIS B7721 (Within 1/1 to 1/250 range of the rated load cell capacity) (Within 1/1 to 1/500 range of the rated load cell capacity is optional)

(4) Crosshead speed accuracy

Within +/-1% (At a constant crosshead speed of 0.5 to 500 mm/min. Based on the crosshead movement within a specified period)

(5) Installation environments

1) Temperature 2) Relative humidity

1-4

5 to 40 ºC (Temperature fluctuations during test: within +/-2 ºC ) 20 to 80% (no condensation)

1. Outline

2. Detailed specifications (1) Crosshead speed setting Test speed is set up as a part of conditions by the exclusive data-processing software. The number of digits for the speed setting (preset resolution) is different from the control resolution. Although the crosshead speed can be set higher than the control resolution, the actual operation speed is limited to the control resolution. Example) When the crosshead speed is set to 500.5 m/min, the actual operation speed is 500 mm/min for 100kN.

In the case of 100kN capacity testing machine Speed (mm/min) Resolution (mm/min)

0.0005～0.001

0.001～1

1～40

40～100

100～1000

0.0001

0.001

0.2

0.5

1.0

In the case of 300kN capacity testing machine Speed (mm/min) Resolution (mm/min)

0.0005～0.001

0.001～0.5

0.5～20

20～50

50～500

0.0001

0.001

0.1

0.25

0.5

When using inch/min unit for speed, the set speed is calculated to mm/min speed value. There will be some error within above resolution maximum. Example: In the case of the crosshead speed is set to 1 inch/min In Unit Conversion of Inch = 25.4mm, “1 inch/min → 25.4mm/min” is “1 inch/min → 25.25mm/min”

(2) Crosshead control

START/STOP/RETURN JOG UP/JOG DOWN

(3) Crosshead position fine-adjustment

Manual Dial

(4) Force measuring device (Force amplifier) 1)

Measurement magnification

Selected from 7 levels (´1, ´2, ´5, ´10, ´20, ´50, ´100)

2)

Measurement resolution

Approx. 1/16000 of the full scale of each range

3)

Automatic force range switching function

1-5

1. Outline ･ Details on the switching function

When the force exceeds 95% of FS during increasing force Switching to a lower amplitude

When the force falls below 30% of FS during decreasing force Switching to a higher amplitude

Automatic force range switching function cannot be used at the following condition. ・ When controlling by force speed and strain rate (ALSC). ・ When you use ultra high-speed sampling. 4) 5) 6) 7)

Force calibration (Electric calibration) Force to be calibrated Zero-point adjustment Force signal output

(5) Force value display device 1) Display device ・Display module ・Display unit

2) Display resolution

It performs by exclusive data-processing software. Tensile/Compression force It performs by smart controller or exclusive data-processing software. Analog (0 to 5 VDC) Resolution : 1/2048 (Approx. 2.5 mV) Output rate : 10 ms

Digital display on the smart controller and exclusive data-processing software. SI unit system : mN, N, kN [KGF unit system : gf, kgf, tf] [Pound unit system : lbf, kip] ※A unit is not displayed on a Smart controller. 1/5000 of the full scale of each range(smart controller) 1/16000 of the full scale of each range(exclusive data-processing software)

(6) Crosshead stroke measuring device 1) Measuring method Measurement using an optical encoder 2) Measurement resolution 0.001 mm 3) Measurement origin setting The origin is set to a desired position by pressing the position zero key 4) Stroke signal output Analog (0 to 5 VDC) Resolution : 1/2048 (Approx. 2.5 mV) Output rate : 10 ms (7) Crosshead stroke display device (Switched over between (11) the extension value display function) 1) Display device ・Display type Digital display on the smart controller and exclusive data-processing software ・Display resolution 0.001 mm ・Display unit Selected from mm, cm, in ※A unit is not displayed on a Smart controller. (8) Test control mode

1-6

1. Outline 1) Single test control mode(TRAPEZIUM2 SINGLE, TRAPEZIUM Lite) Stroke test control, stress test control, force control, and strain test control are possible by the exclusive data-processing software. Please refer to the user guide of exclusive data-processing software for details. 2) Cycle test control mode(TRAPEZIUM2 CYCLE) Stroke test control, stress test control, force control, and strain test control are possible by the exclusive data-processing software(Max 1000 cycle). Please refer to the user guide of exclusive data-processing software for details. NOTE Cycle test conditions To perform a cycle test with the AUTOGRAPH, observe the following conditions: 1) Cycle frequency 3 cycles/min or less 2) Continuous operation time 10 hours or less 3) Number of continuous cycles 1000 cycles or less 3) Control mode(TRAPEZIUM2 CONTROL) The arbitrary control which combined stroke test control, stress test control, force control, and strain test control are possible by the exclusive data-processing software. Please refer to the user guide of exclusive data-processing software for details. (9) Specimen breakage detecting function(set up by the exclusive data-processing software) 1) Types of detecting functions Desired two values (sensitivity level and breaking level) can be set. 2) Detecting/setting method Breakage is detected when the force is reduced at a speed ・Sensitivity of "A% of the force full scale per second" or a higher speed. (0 £ A £ 1000) Breakage is detected when the force is reduced to "B% of ・Breaking level the force full scale" after exceeding "3% of the force full scale". (0 £ B £ 5) 3) Crosshead action after Stop or return to the origin. (Either action can be detection selected.) When the testing machine repeats loading and unloading 4) Turning ON/OFF the operations during a test such as a cycle test or peel test, specimen breakage detecting this function can be turned OFF. function (10) Extension value display function 1) Input voltage range

(Switched over between (7) the crosshead stroke display function)

2) Display mode

0 to 10 V (5 V full scale is recommended) (Rated absolute maximum input: -15 to +15 V) mm, cm, in: Actual extension value

3) Display type 4) Display resolution

It displays by exclusive data-processing software. 1/16000 (= Approx. 2.5 mV)

1-7

1. Outline

(11) The exclusive data-processing software Windows version (TRAPEZIUM2) ※Please refer to the user guide of exclusive software "TRAPEZIUM2" about specification. Please prepare the computer hardware for control and data processing. (12) Safety/Protection devices 1) Stroke limiter 2) Overload limiter 3) Emergency stop switch 4) Driving motor overcurrent protection 5) Driving motor overheat protection 6) Driving motor amplifier protection 7) Main power supply overcurrent protection 8) Ball screw protection cover 9) Automatic control stop function

1-8

The photoelectric sensor detects preset two points (upper and lower limits). The testing machine automatically stops when "102% of the force full scale" is detected. Provided on the smart controller Provided Provided Provided Provided Provided The feedback control mode automatically stops when the control parameter error exceeds +/-10% of the full scale.

1. Outline

1.4 Individual Specifications for Testing machine Table 1.1 Model name

Individual Specifications for the AG-IC Series (Floor type) SI unit Gravity unit

Extension quantity

Force capacity Crosshead speed and allowable force Test speed Return speed Standard +250 Crosshead-to-ta +500 ble distance (mm) +750 +1000 Effective test space width (mm) Crosshead-to-table distance (mm) and allowable force

Extension quantity

Testing machine dimensions Width ´ Depth (mm) Standard Testing machine +250 height (mm) / +500 Mass (Approx. +750 Kg) +1000 Driving motor type Maximum power consumption Maximum leak current Required power supply capacity (3-phase, 200-230 V)

AG-100kNIC AG-10TIC 100kN/10tf Full speed

AG-300kNIC AG-30TIC 300kN/30tf

100kN/10tf

Full speed

0.0005～1000mm/min 1100mm/min 1250 1495 1735 1970 2200

300kN/30tf

0.0005～500mm/min 550mm/min 1440 1690 1930 2165 2395 575 Up to 2000 mm 300kN/30tf 2000 mm or longer distance 150kN/15tf

Up to 2000 mm 100kN/10tf 2000 mm or longer distance 50kN/5tf 1170 × 750 2162 2412 2662 2912 3162

/ / / / /

800 850 900 950 1000

2412 2662 2912 3162 3412

/ / / / /

900 950 1000 1050 1100

AC servo motor 1.6 kW

2.0 kW 10 mA

6.0 kVA

7.5 kVA

NOTE The above power supply capacity indicates the value required for the steady state. When the power switch is turned ON, or the crosshead returns, a rush current flows through the circuit. Use a circuit breaker that provides sufficiently large capacity and pass surge current without trip.

1-9

1. Outline

(Blank sheet)

1-10

CHAPTER 2 Parts Identification

CONTENTS 2.1

Main frame.................................................... 2-2

2.2

Accessories.................................................... 2-3

2.3

Peripheral Equipment.................................... 2-5

2-1

2. Parts Identification

2.1 Main frame

Fig. 2.1 shows the external view of the testing machine main frame. The testing machine includes the accessories listed in Table 2.1,2.2.

Model name AG-100ｋNIC

S346-53423

AG-300kNIC

S346-53424

Fig. 2.1a Main frame (Floor-type)

P/N S346-53162-02

Fig. 2.1c Smart controller

2-2

P/N

2. Parts Identification

2.2 Accessories The accessories listed in Table 2.1 and Table 2.2 are included in the testing machine with each capacity. Make sure that all the listed items are included in your testing machine. Table 2.1

Accessories of the AG-IC Series Floor-type Testing machine AG-100kNIC

Connection cables Cable assembly, 200 VAC Cable assembly, Ground Smart controller fixture Holder smart controller Screw, SUS TRUSSHEAD 7.5Y M4X8

Standard tools Tool box Rotation bar Hexagon bar wrench set Screwdriver set Screwdriver for adjustment Hexagon bar wrench H ´ 17 Operation manual (This document) Limit guide sticker Safety Precautionｓ sheet

AG-300kNIC

345-03758-03 345-28183-01 This fixture has clung to the testing machine. 347-54783 020-37013-01(2pieces) 038-03005 344-21855 340-48001-10 340-48002 086-10504-10 086-03813 349-05554 347-50051(Caution) 347-50052-02(Tens.) 347-50052-04(Comp.) 347-02670

2-3

2. Parts Identification

Tool box

Adjustable wrench 250

Fig. 2.2

Cable Assembly (200 V)

Fig. 2.3

Cable Assembly (Ground)

Fig. 2.4

Cable Assembly (100 V)

Rotation bar

Screwdriver for adjustment

Fig2.5 Standard tools

2-4

Hxagon bar wrench set

Hexagon bar wrench H×17

2. Parts Identification

2.3 Peripheral Equipment In addition to the main frame, peripheral equipment is required to perform a test. The main items of the peripheral equipment are listed below:

1. Set of load cells The set of load cells are classified into various types in terms of the force capacity, calibration unit, and guaranteed accuracy. The part number table lists the load cells of JIS Class 1 (Standard type: See Table 2.3a,b) and those of JIS Class 0.5 (High-precision type; See Table 2.4a,b). The set of load cells for the AG-IC series are provided with the special CAL (calibration) cables. Since the load cell capacity and other characteristic data on the load cell are stored in the calibration cable, one CAL cable is always required for one load cell. If a load cell is combined with a different type of calibration cable, the accuracy of the force measurement data cannot be guaranteed. Be sure to store the calibration cable and the load cell as a pair by checking the cell number indicated on the label of the calibration cable.

SFL type load cell (including CAL cable)

Table 2.3 P/N

Load cell type (Force capacity)

Set of the Load Cells P/N

JIS Class 1(Tensile and compression load calibration)

JIS Class 0.5(Tensile and compression load calibration)

SI unit system

Metric unit system

SI unit system

Metric unit system

Reference calibration (N)

Reference calibration (kgf)

Reference calibration (N)

Reference calibration (kgf)

SPL-10kN/1tf

346-52114-11

346-52115-11

346-52116-51

346-52117-51

SFL-20kN/2tf

346-52114-12

346-52115-12

346-52116-52

346-52117-52

SFL-50kN/5tf

346-52114-13

346-52115-13

346-52116-53

346-52117-53

SFL-100kN/10tf

346-52114-14

346-52115-14

346-52116-54

346-52117-54

SFL-300kN/30tf

346-52114-16

346-52115-16

346-52116-56

346-52117-56

2-5

2. Parts Identification

2. Test jigs (1) Tensile test jig

To perform a tensile test, the grips and the attachments for mounting the grips (universal joint and lower joint) are required. The typical jigs used for a tensile test are described below. 1) Wedge-type constant-position grips (Set of upper and lower grips)

Table 2.4 Force capacity 300kN (30tf)

Part No. 343-05840

Table 2.5 Force capacity 100kN (10tf) 50kN (5tf)

Table 2.6 Force capacity 20kN (2tf) 5kN (500kgf)

2-6

Wedge-type Constant-position Grips(300kN) Tooth type file for flat plate

Tooth gap

Tooth size

0～8.5 mm

50(W)×75(L) mm

Wedge-type Constant-position Grips(100kN,50kN) Part No.

Tooth type

Tooth gap

Tooth size

file for flat plate

0～7 mm

40(W)×55(L) mm

346-52791-02 346-52791-01

Small wedge-type Constant-position Grips(20kN, 5kN) Part No.

Tooth type

Tooth gap

Tooth size

file for flat plate

0～7 mm

25(W)×55(L) mm

346-52653-03 346-52653-01

2. Parts Identification

2) Screw-type flat grips (Set of upper and lower grips)

Table 2.7

Screw-type Flat Grips

Force capacity

Part No.

Tooth type

Tooth gap

Tooth size

5kN (500kgf)

346-52326-04

File for flat plate

0～16 mm

60(W)×50(L) mm

1kN (100kg)

346-52327-04

File for flat plate

0～15 mm

50(W)×30(L) mm

50N (5kgf)

346-52328-04

Plane

0～14 mm

35(W)×25(L) mm

3) Joint parts for tensile test jig (Set of upper and lower jigs) Table 2.8

Joint Parts for the Tensile Test Jig Load cell Frame type Part No. capacity AG-300kNIC

300kN（30tf）

343-08798-01

100kN（10tf） AG-100kNIC 344-11101-11 The part numbers in the above table indicate the standard combinations. When the load cell capacity is different from the frame capacity, other joint jigs may be required. For further information, contact SHIMADZU CORPORATION.

2-7

2. Parts Identification

(2) Compression/bending test jigs

1) Joint jig for compression/bending test This joint jig can be used for both compression and bending tests. Table 2.9

Joint Jig for Compression Test Applicable load cell capacity

Frame type

Part No. (For standard-type testing machine)

AG-300kNIC

300kN（30tf）

346-51530-04

AG-100kNIC

100kN（10tf）

346-51530-03

2) Compression plate for compression test

Table 2.10 Compression Plate for Compression Test Type Fixed Ball-seated

2-8

Plate diameter

φ100

Allowable force

300kN

Part No.

343-08095 346-50639-03

2. Parts Identification

3) Bending test jig

a

b

c

d

Table 2. 11 Bending Test Jig Applicable specimen

Plastic

Applicable standards

JIS K6911, K7171,ISO 178 (Thickness:3mm or less)

ASTM D790 Plastic Composite material (3/4-point bending)

JIS K7055, K7074,K6911 K7203

Metal Ceramics (3/4-point bending)

R1601

Punch radius

Support point Maximum radius capacity

R5

R2

10/100ｋN

R5

R5

10/100ｋN

Part No.

Drawing

Application joint jig

346-52697-01/ 343-08171-03

a

346-52697-02/

a

343-08171-01 b

R3,R5

R3,R2

5kN

343-05934-10

R5

R15

100kN

343-08096-01

d

R2.5

R2.5

5kN

343-08892-08

c

See Table 2.9

2-9

2. Parts Identification

3. Recorder/Data processor (1) Data processing software TRAPEZIUM2 *1 TRAPEZIUM2 SINGLE is attached for AG-IC series. Optional software is listed below. Product name TRAPEZIUM2 SET *2 TRAPEZIUM2 SINGLE TRAPEZIUM2 CYCLE TRAPEZIUM2 CONTROL

Part No. 345-47307 345-47307-01 345-47307-02 345-47307-03

Note1) Provide a personal computer separately Note 2) TRAPEZIUM2 SET include SINGLE, CYCLE and CONTROL. (2) XT-P recorder (AR-5422)

P／N

(3)

XTY-P recorder (AR-6422)

P／N

2-10

345-05842

345-05843

2. Parts Identification

4. Maintenance parts (1) Force inspection jig

1) Force inspection jig to be attached to the tensile test jig

Table 2.12 Composition of the forcer and weight in the force inspection Force to be inspected 50 N

Weight

Part No.

50 N (´ 1)

346-51040-31

100 N

100 N (´ 1)

346-51040-17

500 N

100 N (´ 5)

346-51040-32

5 kgf

5 kgf (´ 1)

346-51040-21

10 kgf

10 kgf (´ 1)

346-51040-07

50 kgf

10 kgf (´ 5)

346-51040-22

2-11

2. Parts Identification

(Blank sheet)

2-12

CHAPTER 3

Features and Functions of Each Subassembly

CONTENTS 3.1

Main frame............................................................ 3- 2

3.2

Smart controller .................................................... 3- 8

3.3 Load Cell (Option), Tension force jig (Option)....................3-11

3-1

3. Features and Functions of Each Subassembly

3.1 Main frame 1. AG-ICseries (Floor-type) Fig. 3.1a to Fig. 3.1e show the external views of the main frame and the names of the main parts.

9 Crossyoke

1 Post

10 Load cell

2 Upper limit switch knob

11 Crosshead 3 Ball screw protection cover 6 Rear cover １2 Smart controller

4 Lower limit switch knob 31 Emergency stop switch

31 Emergency stop switch

5 Ball screw(inside the post) 13 Control box

7 Table

14 Power switch 8 Front cover

15 Loadcellconnector

16

Fig 3.1a Main Parts of the AG-IC Series(Floor-type)Main frame

Sensor amplifier connector （EXT1，EXT2）（option）

17 Analog output 1(Force)connector 18 Analogoutput2connector 19 Analoginput 1connector 20 Analoginput 2connector

3-2

Fig 3.1b

Sensor Amplifier Panel for the AG-IC series(Floor-type)

3.Features and Functions of Each Subassembly

21

22

Fan (inside the cover)

Power circuit breaker

Fig. 3.1c Rear View of the AG-IC Series (Floor-type) Main frame 29 23

Smart controller connector

24

RS-232C connector

Power supply input connector (3-phase, 200 V input)

25 Analog recorder connector 26 ACC 1 27

ACC 2

28

ACC 3

30

Fig. 3.1d

I/O Connector Panel for the AG-IC Series (Floor-type)

Ground terminal If the ground terminal of the power supply cable cannot be grounded, ground this terminal via the supplied ground cable.

Fig. 3.1e Power Supply Panel for the AG-IC Series (Floor-type)

3-3

3. Features and Functions of Each Subassembly

3. Description on the main parts 1) Power circuit breaker 22 (for the floor-type only) Power circuit breaker for the whole equipment 2) Power switch 14 (See Figs. 3.1a and 3.2b) Handy switch used to turn ON/OFF the power supply during normal operation. 3) Emergency Stop Switch

31 (See Fig.3.1a and 3.2a) Used to stops the crosshead forcefully. Pressing these switches cut off the power to the servo motor. (See Section 4.5 1.)

4) I/O connector panel (See Figs. 3.1d and 3.2d) The I/O connector panel connects the cables from the optional external units such as the smart controller and the analog recorder. ① Smart controller connector 23 Connects the smart controller cable. ②RS-232C connector 24 This is a connector for personal computer cable connection. ③Analog recorder connector 25 Outputs a signal to the optional analog recorder. ④ACC1 26 to ACC3 28 Extension connector used to connect the optional equipment. 5) Sensor amplifier panel (See Figs. 3.1b and 3.2c) ①Load cell connector 15 The load cell connector is connected with the internal force amplifier. ②Sensor amplifier connector（EXT1，EXT2）（Option） 16

Outputs an analog signal (force, stroke, etc). The full-scale of the analog output is +5 V. ③ Analog output 1/Analog output 2 connectors

17

18

(with standard stereo jack)

Outputs an analog signal (force, stroke, etc). The full-scale of the analog output is +5 V. ④Analog input 1/Analog input 2 connectors 19 20 (with standard stereo jack) Inputs an analog signal from an external device such as an extensometer amplifier. The input level is 0 to 5 V.

3-4

3.Features and Functions of Each Subassembly

6) Limit switch knobs 2 4 Used to set the upper and lower limits of the crosshead moving range. Be sure to set the limit switch before starting a test. （See Section 4.5 2. ） 7) Fan 21 (for the floor-type only) The filter is fixed with the retainer. The filter can be easily cleaned and replaced. (See Section 6.4.2) Fan fixing bracket Filter Retainer

Fig. 3.3

Fan

3-5

3. Features and Functions of Each Subassembly

3.2 Smart controller 1. External views and names of the main parts 7

1

LED display for Force

2

LED display for Position

8

Manual lamp

Up lamp

9 Down lamp lamp

3 Jog up key

10 Force zero key

4 Jog down key

11 Position zero key

5 Start key

12 Manual dial

6 Return key

13 Manual key 14 Stop key

A lid is shifted downward. Press waveform area and shift downward. Open in case of optional accessories are attached. Such as a pneumatic grip controller and an automatic extensometer.

Smart controller(Front View)

ａ. 15 Extension meter open／close key 16

Upper arm key

17 GL set key 20 Close upper/lower grip key

18 Lower arm key

1st Upper , 2nd Lower

19 Arm park／set key 21 Open upper & lower grips key

ｂ.

Smart controller option key （opened the lid）

Fig3.4 External views of Smart controller

3-6

3.Features and Functions of Each Subassembly

2. Description on the main parts 1）

LED display for Force

1

Force is displayed in usual.

2）

LED display for position.

2

Position is displayed in usual.

3）

Jog up key

3

Used to move the crosshead upward when the MANUAL mode is ON. Only when this key is being pressed, the crosshead moves upward.

4）

Jog down key

4

Used to move the crosshead downward when the MANUAL mode is ON. Only when this key is being pressed, the crosshead moves downward.

5）

Start key

5

Used to start a test.

6）

Return key

6

Used to return the crosshead to the origin. If it continues pushing the key 3 seconds or more, the crosshead moves.

It does not operate, when manual mode is ON. 7）

Manual Lamp 7 The Lamp is switched on the light/put out by Manual mode ON/OFF.

8）

Up Lamp 8 The Lamp is switched on the light, blinked and put out by the operation method of a crosshead. It is 4.7 for details. Please refer to how to use a Smart controller.

9）

Down Lamp 9 The Lamp is switched on the light, blinked and put out by the operation method of a crosshead. It is 4.7 for details. Please refer to how to use a Smart controller. Force zero key 10 Zero balance of force is performed.

10） 11）

Position zero key 11 Position display makes zero.

12）

Manual dial 12 Used to move the crosshead upward or downward when the MANUAL mode is ON. Turning this dial clockwise moves the crosshead upward, and turning this dial counterclockwise moves it downward.

13）

Manual key 13 Used to turn ON/OFF the crosshead manual control operation.

14）

STOP key 14 Used to stop a test.

3-7

3. Features and Functions of Each Subassembly

15）

Extension meter open／close key 15 (Optional operation) Used to open／close individual extension meter’s arms.

16）

Upper arm key 16 (Optional operation) Used to move upper arm of individual extensometer.

17）

GL set key 17 (Optional operation) Used to move upper and lower arms of individual extensometer to original GL position.

18）

Lower arm key 18 (Optional operation) Used to move lower arm of individual extensometer.

19）

Arm park／set key 19 (Optional operation) Used to keep arms to parking position or measuring position.

20）

Close up→down key 20 (Optional operation) Used to close grip teeth, interlocked with pneumatic controlled grips.

21）

Open up & down key 21 (Optional operation) Used to open grip teeth, interlocked with pneumatic controlled grips. For the operating procedure of the optional key each instruction manual for optional units.

3-8

15 －21

, ｐlease refer to

3.Features and Functions of Each Subassembly

3.3 Load Cell (Option), Tension force jig (Option) 1. External view and names of the main parts (Floor-type)

1 Lock nut （UJ） 2 Load cell mounting volt 3 Load cell （SFL type） 4 Crosshead 5 Universal joint

6 Fixing pin

7 Upper grip

8 Lower grip

9 Lock nut（Grip） 10 Fixing pin 11 Lower joint 12 Table 13 Center pin

Fig. 3.5a

External View of the Tensile Test Jig for AG-IC Series (Floor-type) The above figure shows the tensile test jig for the AG-100kNIC type. With other types, the size of the parts is different.

3-9

3. Features and Functions of Each Subassembly

2. External view and names of the main parts (Table-type)

2

Load cell mounting volt 14 Auxiliary plate 4 Crosshead 3 Load cell

1 Lock nut（UJ） 5 Universal joint 6 Fixing pin 7 Upper grip 8 Lower grip 9 Lock nut（Grip） 10 Fixing pin 11 Lower joint 12 Table 13 Center pin

Fig. 3.5b

External View of the Tensile Test Jig for AG-IC Series (Table-type) The above figure shows the screw-type plane grips. With other types, the shape of the parts is different.

3-10

3.Features and Functions of Each Subassembly

3. Part names 1)

Load cell 3 The load cell converts force (tensile or compression force) into an electric output through a strain gauge. The force detecting unit in the load cell is equipped with a strain gauge that develops elastic deformation when force is applied. The load cell converts the magnitude of the applied force into a change in the resistance of the strain gauge, and outputs the converted value as an electric signal. Various load cells with different capacity are provided for both tensile and compression tests. Users can select desired force capacity depending on the test purpose and the force to be applied. NOTE The allowable force applied to the load cell is within 150% of the rated load capacity, for both tensile and compression tests. In particular, when using a load cell with small capacity, make sure that the force does not exceed the load cell capacity. Be careful not to touch the detecting unit or drop the load cell.

The load cell and the CAL cable have been calibrated as a pair before shipment. Be sure to use the CAL cable compatible with the load cell, because the CAL cable and load cell are combined as a pair. If an incompatible CAL cable is connected to the load cell, force measurement becomes abnormal, disabling proper overforce detection.

2)

3)

4)

Universal joint 5 (Option) The universal joint for tensile test is mounted between the load cell and the upper grip. Only the vertical component of the force applied to the upper grip is transmitted to the load cell through the universal joint. The type of the universal joint depends on the load cell capacity. Grips (Upper grip 7 , Lower grip 8 )(Option) The AG-IC series provides optional grips applicable to various specimens. Fig. 3.5a shows the wedge-type constant-position grips suitable for metal and plastic, plate and rod specimens. The lower grip is equipped with the lock nut 9 to eliminate the clearance around the pin 10 at the lower joint 11 connecting part. During a test, be sure to tighten the lock nut slightly to eliminates the clearance around the pin. Other types of grips and grip teeth are also available, in addition to those shown in Fig. 3.5a. Prepare various grips suitable for your specimens. Lower joint 11 (Option) The lower joint connects the lower grip by using a pin.

3-11

3. Features and Functions of Each Subassembly

(Blank Sheet)

3-12

CHAPTER 4 Basic Operations

CONTENTS 4.1 Introduction...................................................... 4-2 4.2 Precautions for Installation .............................. 4-3 4.3 Fixing the Smart controller .............................. 4-8 4.4 Cable Connections ........................................... 4-9 4.5 Safety Devices ............................................... 4-13 4.6 Turning ON/OFF Power Supply.................... 4-16 4.7 How to Use Smart controller ......................... 4-19 4.8 Moving Crosshead Up/Down ........................ 4-20 4.9 Testing machine Setup................................... 4-23

4-1

4. Basic Operations

4.1 Introduction

The AG-IC series operating procedures are described in Chapter 4 through Chapter5. The outline of each chapter is as follows: Chapter 4

To operate the AG-IC series for the first time, be sure to read this chapter before turning ON the power supply. This chapter describes how to use the smart controller, outline of the menu structure, how to mount the load cell and test jig to the main frame, and basic procedures for operating the crosshead.

Chapter 5

Describes the basic test procedures.

This chapter describes the following preparations for starting a test. ■ ■ ■ ■ ■ ■ ■ ■

4-2

Installation environment Smart controller fixing procedure Cable connections Functions of the safety devices Turning ON/OFF the power supply Basic procedure for using the smart controller Crosshead operating procedure Mounting the test jigs

4. Basic Operations

4.2 Precautions for Installation 1. Installation environment 1) 2) 3) 4)

Operating temperature 5 to 40 °C (Temperature fluctuations must be within +/-2 °C during a test.) Humidity 20 to 80% (No condensation) Vibration Frequency : less than 10Hz Amplitude : less than 0.005mm Electro-magnetic wave influence Avoid Electro-magnetic wave. Measurement value might be shifted and error will occur.

2. Conditions for Installation location Before installing the AG-IC series testing machine, check the conditions of the installation location. 1)

Make sure that the floor provides sufficient force capacity that can withstand the testing machine mass. With the table-type testing machine, use a table with sufficient force capacity that can withstand the testing machine mass and the jig mass. Never mount the testing machine on a table whose withstand force capacity is unknown. For the mass of each type of frame, refer to the table1.4 and 1.5 in Section 1.4.

2)

Provide a clearance between the top of the testing machine and the ceiling. For delivery and installation, a clearance of at least 30 cm is recommended.

3)

Make sure that the testing machine can be easily accessed during maintenance.

3. Delivery/Installation The AG-IC series testing machine must be delivered and installed by the staff of SHIMADZU CORPORATION and an authorized service company. For transport of the testing machine, some prohibitions are prescribed. If any persons other than our staff transport this equipment after installation, be sure to read the instructions described in Chapter 10 "Transport/Storage" carefully beforehand. 1)

To lift the main frame, use a belt and lifting device with withstand load capacity two times or larger than the main frame mass. For the mass of each type of main frame, refer to the table in Section 1.4.

2)

To lift the main frame, be careful that the main frame body is not largely tilted. If the belt slips, the main frame may shake, resulting in injury to the working personnel.

4-3

4. Basic Operations

3)

With both the floor-type and table-type, do not lift the main frame by the crossyoke (top plate). Otherwise, the crossyoke may break, or the main frame may drops, resulting in injury to the working personnel.

4. Main frame level adjustment After installing the testing machine, perform main frame level adjustment. With the floor-type main frame, adjust the front, rear, right and left level adjusting bolts on the mounting base. With the table-type main machine, adjust the level adjusting feet located at 4 corners bottom. The optional table for the table-type machine is also equipped with the level adjusting feet. 1)

Level adjustment for floor-type testing machine ･ Level meter ・ Hexagon wrench H ´ 17 (Accessory) (a) Place a level meter on the main frame table laterally. (b) While reading the indication on the level meter, adjust the level adjusting bolts at the four corners by using the hexagon wrench. (c) Re-place the level meter on the main frame table in the front-rear direction, and adjust the bolts in the same way. (d) Repeat the above steps several times until the main frame is correctly leveled.

2)

Level adjustment for the table-type testing machine.

・ Level meter (a) Place a level meter on the testing machine table laterally. (b) While reading the indication on the level meter, turn the level adjusting feet at the four corners bottom of the machine manually. (c) Re-place the level meter on the testing machine table in the front-rear direction, and adjust the feet in the same way. (d) Repeat the above steps several times until the testing machine is correctly leveled.

4-4

4. Basic Operations

5. Conditions for the power supply Before connecting the power supply, check the power supply ratings. 1) With the floor-type testing machine, use a power supply rated for 200 to 230 V (3-phase). For the power supply capacity for each type of testing machine, refer to the table 1.4 in Section 1.4. 2)

Allowable voltage fluctuation

Within +/－10% of the rated voltage

3)

Grounding condition

Class D or higher level grounding condition is required. (Ground resistance:100 ohm or less) NOTE

When power supply voltage becomes +10% or more of rating, and －10% or less, incorrect operation is carried out or there is a possibility that parts may damage parts. When change of power supply voltage is large, please install a stabilization power supply.

4-5

4. Basic Operations

4.3 Fixing Smart controller 1. Mount the smart controller in installation The hook on the back of a smart controller is hooked on the holder attached on the right post, and the same time, the magnet of the back lower part attaché to the holder, too.

Smart controller （Backside）

Hook

Magnet

.

4-6

Holder smart controller

4. Basic Operations

4.4 Cable Connections 1. AG-IC series testing machine (Floor-type)

Load cell

Load cell

Main frame

Load cell cable

Smart controller

CAL cable

Controller unit

Ground cable Power supply cable Smart controller cable

Note) For the location of each connector, see Figs 3.1b through 3.1e. Fig. 4.5a

Cable Connections for the AG-IC Series Floor-type Testing machine

4-7

4. Basic Operations

2. Connection with a personal computer AUTOGRAPH AG-IC series must be connected with a personal computer. So, the AUTOGRAPH enables data processing using the special data processing software. Prepare a personal computer of the model/specifications recommended by the data processing software. This section describes how to connect a personal computer to the AUTOGRAPH. For the software installation procedure and operating procedure, read the operation manual included in the data processing software. The parameters operated through the personal computer are described in the operating procedure in CHAPTER 5.

RS-232C connector

Fig 4.6b

I/O connector panel of the AG-IC series (Floor-type)

Connect the RS-232C connector (round connector with 5 pins) on the I/O connector panel of the main frame with the RS-232C connector (D-sub square connector with 9 pins) of the personal computer through the special cable followed.

5pins DIN

4-8

D-sub 9pins

4. Basic Operations

4.Connecting the analog recorder The speed of the optional analog recorder can be set on the data processing software TRAPEZIUM2’s window. Analog recorder's other operations (turning ON/OFF the power supply, switching the chart feed mode, moving the pen up/down, turning ON/OFF the chart feed function, zero/span adjustment, etc.) should be performed on the recorder. Before using the analog recorder for the first time, the "Recorder Connected" status must be registered. Please refer to the user guide of TRAPEZIUM2 for details.

To use the X-Y record mode, the Y-axis (extension) input must be connected.

Analog recorder connector

Fig4.7b

I/O connector panel of the AG-IC series (Floor-type)

Connect the above analog recorder connector (D-sub square connector with 9 pins) of the AUTOGRAPH with the CONTROL connector (square connector with 36 pins) of the analog recorder through the special cable followed.

D-sub 9pins

IDC 36pins

4-9

4. Basic Operations

4.5 Safety Devices The AG-IC series testing machine provides the following two types of safety devices: 1) Emergency stop switch 2) Crosshead stroke limit switch The following safety/protection equipment are optionally available. 1) Overturn prevention bracket 2) Safety door for the testing area

1. Emergency stop switch The emergency stop switches are provided at the both left and right side of the posts for floor-type machine. And at the both left and right side of front cover for table-type machine. If the crosshead unintentionally moves, press one of this switch immediately. Pressing this switch cuts off the power to the motor circuit and stops the crosshead forcefully in any condition (even in a machine trouble). To reset the emergency stop switch, turn OFF the main power at once, and turn it in the direction indicated on the switch surface. Then, the switch is reset by spring force.

2. Crosshead stroke limit switch The crosshead stroke limit switch is used to set mechanical limits of the crosshead. If the crosshead is improperly operated, this function prevents the crosshead or crosshead jig from hitting against the crossyoke jig or testing machine table jig. Upper limit switch knob

Actuator

MAX Lower limit switch knob

Tensile stroke

Zero position Gauge length (GL) Table Fig. 4.7 Setting the limit switch (example)

4-10

4. Basic Operations

During a tensile test, the lower limit is usually set to the test start position, and the upper limit is set to the expected maximum tensile stroke (maximum extension). 1)

Setting the upper limit Loosen the upper limit switch knob, and fix it to the upper limit position of the crosshead moving range. The limit switch is activated when the crosshead moves upward by approx. 2 mm from this position. Set the upper limit in consideration of this margin.

2) Setting the lower limit Loosen the lower limit switch knob, and fix it to the lower limit position of the crosshead moving range. The limit switch is activated when the crosshead moves downward by approx. 2 mm from this position. Set the lower limit in consideration of this margin.

3) When the actuator fixed to the top of the crosshead reaches either the upper or lower limit switch knob, alarm is displayed on the display of a personal computer.and the limit switch is activated to stop the crosshead forcefully. CAUTION

The crosshead upper and lower limits expected during a test must be set to proper values. If setting these limits is difficult, determine the setting range so that the gap between the crosshead top jig and the crossyoke and the gap between the crosshead bottom jig and the table jig are 20 mm or more.

NOTE If alarm screen does not appear even when the crosshead stops during limit switch activate, turn OFF the main power at once before resetting the limit switch. a) Loosen the (upper or lower) limit switch knob, and slide it upward or downward to reset the limit switch. b) When the personal computer has connected with the main frame, please cancel according to the message displayed on a display. When the personal computer is not connected with the main frame, please push and cancel the stop key of a smart controller. c) After resetting the limit switch, set the upper and lower limit switch knobs to the proper positions again.

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4. Basic Operations

3. Turnover prevention brackets (Optional) The SHIMADZU AUTOGRAPH AG-IC series a floor-type tester with 100kN and 300kN load capacity. To use the floor-type tester, you must fix the tester to a floor by using dry pit. Note that these turnover prevention brackets are not intended to ensure turnover prevention in occurrence of a natural disaster such as an earthquake. The part numbers of the turnover prevention brackets are listed below: Type Floor-type A

Floor-type B (For the extended special width tester)

Part No. 346-50278-08

346-50278-09

Remark AG-100kNIC and 300kNIC (Capacity: 100kN and 300kN) Effective testing width of tester: 575 mm AG-100kNIC and 300kNIC (Capacity: 100kN and 300kN) Effective testing width of tester: 975 mm

4. Testing space safety door (Optional) When a specimen may scatter during a test, it is recommended to use the testing space safety door. The specifications of the testing space safety door vary depending on the tester's capacity and the type of the specimen being used. Contact SHIMADZU for further information.

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4. Basic Operations

4.6 Turning ON/OFF Power Supply 1. Introduction The AG-IC series floor-type testing machine needs a power supply rated for 200 to 230 V AC (3-phase). The power is supplied through the power supply input connector (socket) at the rear of the testing machine. Before turning ON the power, check the following points: 1) Make sure that the primary power supply capacity is proper. AG-IC series floor-type AG-300kNIC : 7.5 kVA AG-100kNIC : 6 kVA 2) Make sure that the testing machine is properly grounded. (Required class D ground condition) 3) Make sure that the power supply cable is properly connected to the connector. Note that most of the accessories such as the recorder and data processor needs a single-phase 100 VAC power supply. Provide a power supply for such equipment separately, in addition to the power supply for the testing machine.

Fan Fig. 4.6ａ Power supply input connector （Floor-type）

Power supply input connector

2. Turning ON the power 1) 2)

Supply power to the primary side. Turn ON the power supply circuit breaker of the testing machine. (Floor-type only)

Power supply circuit breaker

4-13

4. Basic Operations Fig. 4.8a 3)

Power Circuit Breaker (AG-IC Series Floor-type)

Turn ON the power switch.

Power switch

Fig. 4.8b Power Switch (AG-IC Series Floor-type) 4)

The LED part of a smart controller becomes the following displays.

ROM version display (In the case of version1.0)

Load cell capacity display (In the case of 500N)

Force Position display (The present value is displayed.)

Fig4.9 Initial display of the LED part 5)

If the emergency stop switch on the main frame is locked, turn this switch to unlock it. When the emergency stop switch is locked, power cannot be supplied to the servo amplifier.

3. Warm-up To stabilize the measurement system of the AG-IC series testing machine, take a warm-up time of approx. 15 minutes after turning ON the power. (The testing machine can be warmed up even when the emergency stop switch is being pressed.)

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4. Basic Operations

4. Calibration for Force Amplifier To calibrate the force amplifier, the AG-IC series provides the electric calibration (E-CAL) function that sends a calibration signal corresponding to each load cell to perform automatic span adjustment for the force amplifier.

Perform this calibration once a day before starting a test. Every time the force polarity (tension/compression) is switched or the load cell is replaced, be sure to perform this calibration. NOTE To perform the force calibration, warm up the testing machine for at least 15 minutes after turning ON the power supply. Electric force calibration (E-CAL) is performed by data-processing software "TRAPEZIUM2." Please choose the "test | sensor | calibration" of the menu of TRAPEZIUM2, or carry out a right click in a sensor display part, and choose a calibration from a pop-up menu.

5 Turning OFF the power 1) Turn OFF the power switch. (If you do not turn ON the power supply for one or more days, turn OFF the circuit breaker as follows.) 2) Turn OFF the power supply circuit breaker. (Floor-type only) 3) Turn OFF the circuit breaker of the primary power supply (at the user's site). NOTE Do not turn OFF the power supply while the crosshead is being operated. Otherwise, the service life of this equipment may be shortened.

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4. Basic Operations

4.7 How to Use Smart controller 1. LED display . There are a LED display part and a crosshead operation switch part in a smart controller. The LED display part displays by the following specifications in order to make the action of a crosshead links clearly. 

The operation mode is divided in the color of LED. LED COLOR



OPERATION MODE

Green

Program（Test） control

Red

High Speed Return control

Orange

Manual & Jog control

The motion is expressed with the method of lighting. Lighting of LED

OPERATION MODE Test condition is not set by PC and Putting out lights START key is not available. Keep stopping under Manual ON Test condition is already set by PC and Putting on(Green) START key is available. The test start direction is shown. While pressing RETURN key, return Putting on(Red) direction is shown until starting return. Blink(Green, Red, Orange) Crosshed is moving.

Example1．

When the test condition is not set from the PC

（LED is putting out） Putting out

Example2.

When a crosshead is going up

Putting on

Putting out

Example3.

In the case of testing （Blinking by Green） In the case of returning （Blinking by Red） In the case of manual and jog running （Blinking by Orange）

When a crosshead is stopping (Test is ready) In the case of UP Start “UP” LED is putting on Green. In the case of DOWN Start “DOWN”LED is Putting on Green.

4-16

4. Basic Operations Example4. At the time of a hold (experimental stop, Force hold / Force zero hold under test) state UP and DOWN LED blink Green

4.8 Moving Crosshead Up/Down The AG-IC series provides the test start switch, high-speed return switch (to return the crosshead to the origin), and test stop switch for test. And the MANUAL (manual operation) mode is provided to move the crosshead to a desired position (test start position) while preparing a test. To operate the crosshead, use the above crosshead control switches on the smart controller. Jog up key Manual dial

Jog down key Start key

Manual On/Off key

Return key

Stop key

Fig4.10 Crosshead operation switch

1. Starting a test Either UP/DOWN LED lights on to green when the testing condition is set from the PC, and the crosshead start moving in the direction when the start key is pressed. LED is blinking while moving. When LED of UP/DOWN light off, the operation by the start key is invalid. Moreover, the START key operation is disabled while manual control function is ON.( See 4.8 4.) Example 1.

Testing upward “UP” LED is Blinking to green.

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4. Basic Operations

2. Returning the crosshead (High-speed return to the origin) If Return key is pressed, the LED of the returning direction lights up red. Keep pressing 3 seconds or more, crosshead start returning and the LED of the returning direction blinks red. It is not available when the manual mode is ON. The return speed is 1100 mm/min (AGIC-300KN type: 550 mm/min, Table-type: 1000 mm/min). When the crosshead reaches the origin, the testing machine reduces the return speed, allowing the crosshead to stop at the origin without overshooting. If the return switch is executed when the crosshead is near the origin, the testing machine moves the crosshead at a reduced speed, and may take a long time to return the crosshead to the origin. The system watches the force change while returning the crosshead from the start of the operation. If the force change more than constant value is applied to the load cell, the crosshead is stopped by alarm (Safety function) Example1. Under returning upward Beep sound sounds and “UP”LED blinks in red.

3. Stopping a test Pressing the STOP key stops the crosshead at the current position, and finish the current test. Example1. When a stop button is pushed during test operation “UP” or ”DOWN” LEDs light green. (When batch test is continued, the direction of a test start is displayed. When batch test is finished, both LEDs light off.)

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4. Basic Operations

4. Manual operation 1) Jog operation using the UP/DOWN key a) Press the Manual On/Off key As for the manual mode, Manual LED lights up on a smart controller. Manual ON/OFF is repeated whenever pushing a key. b) Only while pushing the Jog up key, a crosshead goes up and “UP”LED blinks it in orange. c) Only while pushing the Jog down key, a crosshead goes down and “DOWN”LED blinks it in orange. Please refer to the user manual of the software "TRAPEZIUM2" of exclusive use about change of speed. The system watches the force change while the crosshead is operating by jog operation from the start of the operation. If the force change more than constant value is applied to the load cell, the crosshead is stopped by alarm. (Safety function)

2) Operation using the manual dial Users can move the crosshead within a minute range by using the manual dial to perform fine adjustment on the crosshead position and to eliminate the initial force. a) Press the Manual On/Off key to turn ON the Manual mode. b) Turning the manual dial ⑧ moves the crosshead upward or downward depending on the direction of rotation. The crosshead moving distance depends on the number of turns and turn speed. Turning the dial counterclockwise moves the crosshead downward.

Fig. 4.11

Example1.

Turning the dial clockwise moves the crosshead upward.

Manual dial

When continuing pushing a Jog up key in manual mode

“UP” LED is Blinking to orange.

4-19

4. Basic Operations

5. Safety function Safety function detect the force shift applied to the load cell while crosshead moves under jog operation or return function. If the force shift value becomes over a determined value, it makes stop the crosshead immediately. The functions are to stop the crosshead as early as possible at unexpected emergency accident---the jigs hit against the others--- and to improve safety. Because the following limitations exist, note that this function is not intended to ensure that preventing the objects from running into the others in the test space and overload. The amount of the detected force is decided depending on the capacity of the load cell. The response of detection is 0.5-1 seconds. Danger by the overshoot can not be excluded. When the crosshead is operated in the direction of reducing force, the crosshead does not stop in order to remove force at overload and the convenience of operation. The discernment of a direction is decided by setting UP START/DOWN START of the testing condition. This function does not work from beginning of operation for about one second. Therefore, it is invalid when the crosshead is operated by the jog operation as little by little as inching. Moreover, the crosshead moves only for one second even when the load is applied to the load cell beforehand. In the case of applying the load intentionally by the jog operation, the safety function can be released. Keep pushing the stop key for about two seconds when manual mode OFF. The beep "pee!" sound continues sounding and the safety function changes in the state of OFF. The beep "pee!" sound continues sounding until the safety function returns to turning ON for the attention rousing. The safety function does not work when the manual mode is turned on and the crosshead is operated by jog operation in this condition. When the manual mode is returned OFF, or the stop key is pushed after the manual mode is turned on, the safety function returns to turning ON and the beep sound "pee!" stops.

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4. Basic Operations

6. Setting the crosshead origin Press the Position zero key on the smart controller to reset the position display to zero. The crosshead origin is set to the current position.

UP MANUAL DOWN FORCE

ZEROL

POSITION

ZEROL

Position Zero key

4.9 Testing machine Setup 1. Mounting the load cell CAUTION The load cell and the CAL cable have been calibrated as a pair before shipment. Be sure to use the CAL cable compatible with the load cell, because the CAL cable and load cell are combined as a pair. If an incompatible CAL cable is connected to the load cell, force measurement becomes abnormal, disabling proper over force detection.

NOTE When you insert a CAL cable in a connector (it extracts), please be sure to turn OFF a power supply. There is a possibility that a CAL value may turn into an unusual value. NOTE When mounting the load cell to the crosshead, fix the load cell tightly with the supplied bolts. If the load cell is mounted loosely, accurate measurement results may not be obtained.

NOTE After mounting the load cell, be sure to perform force calibration. (See 4.6

4).

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4. Basic Operations

a) load cell can be read in the normal direction. Then, fix the load cell to the crosshead with the mounting bolt.

Fig. 4.12

Load Cell Cable Connection (Floor-type)

b) Connect the load cell terminal of the load cell cable to the load cell connector securely, and fix the connector. (With the load cell with 10 kN or less capacity, this cable connection is not necessary, since the load cell incorporates the load cell cable.) c) Fix the load cell cable to a position where it does not block the crosshead movement, as shown in Fig. 4.12. d) Connect the CAL cable and load cell cable to the connector. CAL cable

Load cell cable

Load cell with 20 kN or more capacity Fig4.13 Load Cell Cable/CAL cable

4-22

Load cell

4. Basic Operations

e) Connect the D-SUB connector of the CAL cable to the testing machine's connector. (The connector positions on the floor-type testing machine and the table-type testing machine are shown in Fig. 4.14a and Fig. 4.14b, respectively.) Then, fix the connector with the screw included in the connector.

Connect the CAL cable.

Fig. 4.14a CAL Cable Connection (for Floor-type)

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4. Basic Operations

2. Mounting the tensile test jig (Optionally available, except for the load cell) Fig. 4.15a and Fig. 4.15b show the external views of the testing machine with the tensile test jig attached. Table 4.2 shows the mass of each unit of the test jig for the testing machines with 5 kN (500 kgf) or more capacity. To mount each unit of the test jig, perform the procedure described in steps 1) to 3).

CAUTION Some test jig components mass 10 kg or more. During transport of a heavy component, be careful not to drop it. When transporting such a heavy component, exercise through attention not to drop it. The jig weighting 20 kg or more must be handled by a person trained for transporting heavy objects. To transport a heavy component, use an appropriate device such as a crane, as required.

Lock nut Load cell mounting bolt Load cell (SFL type) Crosshead Universal joint Fixing pin

Upper grip

Lower grip

Lock nut Fixing pin Lower joint Table Center pin Fig. 4.15a Mounting the Tensile Test Jig to the AG-IC Series (Floor-type) (AG-100 kNIC)

4-24

4. Basic Operations

Load cell mounting bolt Auxiliary plate Crosshead Load cell Lock nut Universal joint Fixing pin Upper grip

Lower grip Lock nut Lower joint Fixing pin Center pin Fig. 4.15b

Mounting the Tensile Test Jig to the AG-IC Series (Table-type) Table 4.2

Mass of the Tensile Test Jig For AG-100kNIC

For AG-300kNIC

Lower joint

2.5

10.5

Universal joint

8.5

26

Grips

10

33

Load cell

3.9

16 (Unit: kg)

4-25

4. Basic Operations

1) Mounting the lower joint a) Insert the center boss into the center hole (f 20) at the top of the table to center the lower joint. b) Fit the center boss into the lower joint , and position the pin hole of the lower joint in the front-rear direction. c) Fix the lower joint with the lower joint mounting bolt.

2) Mounting the universal joint to the floor-type testing machine a) In case of 100 kN or less capacity (See Fig. 4.15a) Insert the universal joint from the bottom of the crosshead, and insert the external thread of the universal joint into the hole of the load cell. Position the pin hole of the universal joint in the front-rear direction, and insert the universal joint stopper pin into the groove of the load cell. Then, fix the universal joint with the lock nut (UJ). b) In case of 300 kN capacity (See Fig. 4.16) ① Align the periphery of the universal joint with that of the lower joint , and place the universal joint on the lower joint so that the pin hole of the universal joint is positioned in the front-rear direction. ② Lower the crosshead, and pass the external thread of the universal joint through the hole of the load cell . (See Figs 4.16a and 4.16b.)

NOTE To insert the universal joint into the hole of the load cell , lower the crosshead while watching the universal joint from the top of the crosshead to center the universal joint in the hole of the load cell, in order to prevent the universal joint from hitting against the load cell . Lower the crosshead at a low speed of approx. 1 mm/min.

4-26

4. Basic Operations

Load cell Crosshead

Universal joint

Lower joint

Fig. 4.16a Mounting the Universal Joint

Make sure that the driving hole faces up. Detailed drawing

Fig. 4.16b Mounting the Universal Joint

Table Fig. 4.16b Mounting the Universal Joint

4-27

4. Basic Operations

③ Stop the crosshead at the position where the shaft of the universal joint protrudes from the top of the load cell by approx. 40 mm. Then, mount the lock nut (UJ) . (See Fig. 4.16b) ④ Turn the lock nut (UJ) by using the driving rod to pull down the universal joint . Give several turns to the lock nut until the universal joint is raised. Then, turn the universal joint 113 , and make sure that the universal joint stopper pin is inserted in the groove. ⑤ If the stopper pin is not set in the groove, give more turns to the lock nut (UJ). Then, make sure that the stopper pin is set in the groove. After the stopper pin is set in the groove, tighten the lock nut (UJ) completely. After tightening the lock nut (UJ) completely, move the crosshead upward. (See Figs. 4.16c and 4.16d) Lock nut (UJ) Driving rod Load cell Crosshead

Table

Lower joint

Cover

Fig 4.16c Mounting the Universal Joint Universal joint

Table

Fig 4.16d Mounting the Universal Joint

4-28

4. Basic Operations

3) Mounting the grips (Wedge-type constant-position grips/Standard screw-type plane grips) a) Mounting the wedge-type constant-position grips with 5 to 100 kN capacity (See Fig. 4.15a)/standard screw-type flat grips (See Fig. 4.15b) ① Insert the boss of the upper grip into the hole at the bottom of the universal joint . Align the pin holes with each other, and insert the fixing pin into the pin holes. ② Insert the boss of the lower grip into the hole of the lower joint . Turn the lock nut (grip) by using the supplied hook wrench so that the pin holes are aligned with each other. Then, insert the fixing pin into the pin holes. b) Mounting the grips with the capacity of 300 kN ① To mount the grips with the capacity of 300 kN, remove the handle attached to the lower grip before mounting the lower grip. Mount the handle to the threaded hole at the side of the grip body so that you can transport the grip by holding this handle. (See Fig. 4.18a) (Perform this step with the grip laid.) ② Before mounting the grips, turn the open/close handle of the upper and lower grips in the direction to open the grip teeth, so that the grip teeth do not protrude from the grips.(See Fig.4.18a)

Make sure that the grip teeth does not protrude from the grips. Lower grip Grip handle

Lock nut (grip) 図 5.1１a つかみ具の

Fig. 4.18a Mounting the grips

4-29

4. Basic Operations

③ Insert the boss of the lower grip into the hole of the lower joint . Turn the lock nut (grip) by using the hook wrench so that the pin holes are aligned with each other, and insert the fixing pin into the pin holes. (See Figs. 4.18b)

Crosshead

Lower grip

Lower joint

Fig. 4.18b Mounting the grips

④ After inserting the fixing pin , tighten the lock nut (grip) by using the hook wrench to prevent the fixing pin from being loosened. (See Figs. 4.18c)

Universal joint Lower grip

Hook wrench Fixing pin

Fig. 4.18c Mounting the grips

4-30

4. Basic Operations

⑤ Put the upper grip on the lower grip . (See Fig. 4.18d)

Universal joint Upper grip

Lower grip

Fig. 4.18d Mounting the grips

Crosshead ⑥

Lower the crosshead . Insert the boss of the grip into the hole of the universal joint . Align the pin holes with each other, and insert the fixing pin into the pin holes. (See Fig. 4.18e)

Universal joint Fixing pin Upper grip Lower grip Lower joint

Fig. 4.18e Mounting the grips NOTE To insert the upper grip into the hole of the universal joint , lower the crosshead while centering the boss of the upper grip in the hole of the universal joint , in order to prevent the boss of the upper grip from hitting against the universal joint .Lower the crosshead at a low speed of approx. 1 mm/min.

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4. Basic Operations

⑦ Move the crosshead upward. (See Fig. 4.18f) Remove the handle of the lower grip from the grip body, and re-mount it to the original position (rotating part).

Fig. 4.18f

Mounting the Grips

3. Removing the tensile test jig To remove the tensile test jig, reverse the test jig mounting procedure described in 4.10 Section 2. Before removing the test jig, turn the open/close handle in the direction to open the grip teeth, so that the grip teeth do not protrude from the grips. (See Fig. 4.18a) When removing the test jig from the testing machine, handle heavy components with thorough attention.

4-32

CHAPTER 5 Performing a Test CONTENTS 5.1

Procedure for Tensile Test ............................ 5-2

5.2

Procedure for Compression/Bending Test .... 5-6

5-1

5. Performing a Test

5.1 Procedure for Tensile Test (Example) Normally, the test procedure should be repeated several times in the CYCLE mode. This section describes the operating procedure for routine work (e.g. tensile test using the analog recorder). For the specific procedure for each step, see the section corresponding to each step. For compression and bending tests, see Section 7.2

1. Preparations for Test 1 ) Turning the power ON (AUTOGRAPH, Recorder) 2 ) Force amplifier calibration Electric force calibration (E-CAL) 3 ) Mounting the tensile test jig

®4.6 ®4.6 4 ®4.9 2

2. Procedure for Tensile Test In the case of using the exclusive data-processing software “TRAPEZIUM2”, you can operate parts by personal computer.

5-2

(1)

Setting the limit switch knob

Set the limit switch knob to the position where it does not block the crosshead when the crosshead is moved to the test start origin. ®4.5

(2)

Moving the crosshead to the test start origin

Move the crosshead in the JOG or MANUAL mode to the test start origin according to the GL (the distance between grips suitable for a specimen). ®4.8

(3)

Setting the crosshead zero position (origin)

(4)

Setting the limit switch knob

Please choose zero reset of a position from the test menu of "TRAPEZIUM2." This position becomes the starting point of a crosshead. (The Position zero key of a Smart controller can be pushed and zero reset can also be carried out.) To move the crosshead up/down safely, set the limit switch knob within the range of "Tensile stroke +α". ®4.5

(5)

Setting the test type and test mode

Excepting a special case, select the TENSILE - UP START test type, and the SINGLE or CYCLE test mode.

(6)

Setting the test speed

Set the test speed.

5. Performing a Test (7)

Setting the test load range

Set the test load range.

(8)

Setting the MAX/MIN values

For the SINGLE mode, enter the MAX limit value. For the CYCLE mode, enter the MAX/MIN setting values.

(9)

Setting MAX/MIN ACT

For the SINGLE mode, set MAX ACT. For the CYCLE mode, set MAX/MIN ACT.

(10)

Setting breakage detection

Set the breakage detecting function to ON/OFF, and set the conditions for breakage detection.

(11)

Setting up the recorder

Set the chart mode, chart speed and chart ratio of the recorder.

In the case of using the exclusive data-processing software “TRAPEZIUM2”, you can set chart speed by personal computer. (12)

Chucking a specimen in the upper grip

(13)

Test load amplifier zero adjustment

(14)

Chucking a specimen in the lower grip

(15)

Removing the initial test load

Move the crosshead to the position where the test load becomes zero using the manual dial. After finishing the manual operation, be sure to turn OFF the manual control function. ®4.8 4.

(16)

Starting the recorder

Turn ON the chart drive, and lower the pen. ® Recorder Operation Manual (separate sheets)

(17)

Starting a test

(18)

Ending the test

Press the START key of the crosshead control switch on the smart controller to start a test. ®4.8 4. Depending on the preset test conditions, the AUTOGRAPH stops or returns the crosshead to the origin to end the test.

(19)

Stopping the recorder

Turn OFF the chart drive, and raise the pen. ® Recorder Operation Manual (separate sheets)

(20)

Removing the specimen

① Loosen the lower grip, and remove the lower end of the specimen from the grip. ② Loosen the upper grip, and remove the upper end of the specimen from the grip.

(21)

Returning the crosshead to the origin

Please choose zero reset of an Force sensor from the test menu of "TRAPEZIUM2." Zero balance of examination power is performed. (The Force zero key of a Smart controller can be pushed, and zero balance can also be performed.)

(Press the Return key of the Smart controller to return the crosshead to the origin. ®4.8 ) This operation is not necessary if "MAX RETURN" has been selected for the test mode, since the crosshead will automatically return to the origin when specimen breakage is detected.

5-3

5. Performing a Test ・ To repeat the same test, return to Step (12). To test a specimen with a different GL or to

execute a different test mode, perform the above procedure from Step (1).

CAUTION A broken surface of a hard specimen may be a sharp edge. To touch such a specimen, be careful not to be injured. It is recommend to wear gloves.

CAUTION If the crosshead improperly moves during a test due to a setting error, press the emergency stop switch. To stop the AUTOGRAPH normally during a test, press the Stop key.

CAUTION While the crosshead returns to the origin, it is moving at a high speed. Please do not put a hand into an operation part. Moreover, be careful for a jig not to be equivalent to a surrounding vessel. When an examination machine carries out unusual operation, please push an emergency stop key immediately.

NOTE If the breakage detecting function has not been properly set, the breakage cannot be detected, and the crosshead continues to move in the tensile direction and does not stop until the limit switch is activated, even when specimen breakage occurs in the CYCLE mode. Set the limit switch with sufficient margin so that the jig mounted to the crosshead upper surface will not hit the yoke.

5-4

5. Performing a Test

5.2 Procedure for Compression/Bending Test (Example) For the specific procedure for each step, see the section corresponding to each step.

1. Preparations for Test To perform a compression/bending test, adjustment work such as jig replacement is required. This section describes the procedure for changing the AUTOGRAPH setup conditions from the tensile test mode to the compression/bending test mode. To change the compression/bending test to the tensile test condition , follow the same procedure. (1) (2) (3)

Turning the power ON (AUTOGRAPH, Recorder) Force amplifier calibration Electric force calibration (E-CAL) Mounting the compression test jig

®4.6 ®4.6 4

Remove the tensile test equipment (universal joint, lower joint and grips) (® Section 4.9 3), and mount the compression/bending test equipment.

Tensile

Compression

Bending

5-5

5. Performing a Test

2. Procedure for Compression/Bending Test In the case of using the exclusive data-processing software “TRAPEZIUM2”, you can operate parts by personal computer. (1)

Setting the limit switch knob

Set the limit switch knob to the position where it does not block the crosshead when the crosshead is moved to the test start origin. ®4.5

(2)

Moving the crosshead to the test start origin

Move the crosshead in the JOG or MANUAL mode to the test start origin until the upper jig nearly touches the specimen. ®4.8

(3)

Setting the crosshead zero position (origin)

Please choose zero reset of a position from the test menu of "TRAPEZIUM2." This position becomes the starting point of a crosshead. (The Position zero key of a Smart controller can be pushed and zero reset can also be carried out.)

(4)

Setting the limit switch knob

To move the crosshead up/down safely, set the limit switch knob within the range where it does not touch the upper or lower jig such as compression plate. ®4.5

(5)

Setting the test type and test mode

Excepting a special case, select the COMPRESSION - DOWN START test type, and the SINGLE or CYCLE test mode.

(6)

Setting the test speed

Set the test speed.

(7)

Setting the force range

Set the force range.

(8)

Setting the MAX/MIN values

For the SINGLE mode, enter the MAX limit value. For the CYCLE mode, enter the MAX/MIN setting values.

(9)

Setting MAX/MIN ACT

For the SINGLE mode, set MAX ACT. For the CYCLE mode, set MAX/MIN ACT.

(10)

Setting NUM (number of cycles)

For the CYCLE mode, set the number of cycles. If you do not intend to set this parameter, select OFF.

(11)

Setting breakage detection

Set the breakage detecting function to ON/OFF, and set the conditions for breakage detection.

(12)

Setting up the recorder

Set the chart mode, chart speed and range of the recorder. ® Recorder Operation Manual (separate sheets)

In the case of using the exclusive data-processing software “TRAPEZIUM2”, you can set chart speed by personal computer.

5-6

(13)

Mounting a specimen

(14)

Force amplifier zero adjustment

Please choose zero reset of an Force sensor from the test menu of "TRAPEZIUM2." Zero balance of examination power is performed. (The Force zero key of a Smart controller can be pushed, and zero balance can also be performed.)

(15)

MANUAL operation to move the crosshead to the point where the initial force is applied

Through MANUAL operation, move the crosshead until it touches the specimen. After finishing the manual operation, be sure to turn OFF the manual control function. ®4.8 4..

5. Performing a Test

(16)

Starting the recorder

Turn ON the chart drive, and lower the pen. ® Recorder Operation Manual (separate sheets)

(17)

Starting a test

Press the START key of the crosshead control switch on the smart controller to start a test. ®4.8

(18)

Ending the test

Depending on the preset test conditions, the AUTOGRAPH stops or returns the crosshead to the origin to end the test.

(19)

Stopping the recorder

Turn OFF the chart drive, and raise the pen. ® Recorder Operation Manual (separate sheets)

(20)

Removing the specimen

Remove the specimen from the lower jig.

(21)

Returning the crosshead to the origin

(Press the Return key of the Smart controller to return the crosshead to the origin. ®4.8 ) This operation is not necessary if "MAX RETURN" has been selected for the test mode, since the crosshead will automatically return to the origin when specimen breakage is detected.

・ To repeat the same test, return to Step (13). To test a specimen with a different thickness

or to execute a different test mode, perform the above procedure from Step (1).

CAUTION If the crosshead improperly moves during a test due to a setting error, press the emergency stop switch. To stop the AUTOGRAPH normally during a test, press the Stop key.

CAUTION While the crosshead returns to the origin, it is moving at a high speed. Please do not put a hand into an operation part. Moreover, be careful for a jig not to be equivalent to a surrounding vessel. When an examination machine carries out unusual operation, please push an emergency stop switch immediately.

5-7

5. Performing a Test (Blank Sheet)

5-8

CHAPTER 6 Performance Inspection/Maintenance CONTENTS 6.1 Periodic Inspection.................................................. 6-2 6.2 Inspection of the Safety Devices............................. 6-2 6.3 Force Inspection...................................................... 6-4 6.4 Lubrication and Cleaning........................................ 6-8

6-1

6.Performance Inspection/Maintenance

6.1 Periodic Inspection This system incorporates the highly-stabilized electric force calibration function. To enhance the stability of this function, it is recommended that this system should undergo an annual force inspection using actual force. This force inspection will be conducted based on the documents supplied from SHIMADZU by the service company that received the education and training in our company. They also perform inspection and maintenance of each part of the driving system. To ensure traceability and long-term safe operation of this system, ask SHIMADZU service representatives for the periodic inspection. Furthermore, in case of repair and adjustment made by any person other than SHIMADZU or our authorized service company, I am afraid that SHIMADZU CORPORATION cannot warrant the product.

6.2 Inspection of the Safety Devices If any of the safety devices does not operate during the following inspections, contact SHIMADZU CORPORATION or our authorized service company. In case of repair and adjustment made by any person other than SHIMADZU or our authorized service company, I am afraid that SHIMADZU CORPORATION cannot warrant the product.

1. Emergency stop switch (1) (2) (3)

While pressing the [Jog] key to move the crosshead, press the emergency stop switch. If the crosshead stops and it will not be moved again by pressing the [Jog] key, the emergency stop switch is judged to be normal. Turn the emergency stop switch in the direction indicated by arrow to reset it.

2. Crosshead stroke limit switches (1) (2) (3) (4) (5)

6-2

While pressing the [Jog] key to move the crosshead, push up the upper limit collar and hold it. If the crosshead stops and it will not be moved again by pressing the [Jog] key, the upper limit switch is judged to be normal. Stop pushing up the upper limit collar, and make the limit rod free. The Stop key of a Smart controller is pushed. In this status, press the [Jog] key, and make sure that the crosshead can be moved.

6.Performance Inspection/Maintenance (6)

While pressing the [Jog] key to move the crosshead, push down the lower limit collar and hold it.

(7)

If the crosshead stops and it will not be moved again by pressing the [Jog] key, the lower limit switch is judged to be normal. Stop pushing down the lower limit collar, and make the limit rod free. In this status, press the [Jog] key, and make sure that the crosshead can be moved.

(8)

This completes the inspection procedure. The working points of the limit switches are shown below.

A Upper limit point Free position B Lower limit point

A + B is approx. 4 mm. Since the free position includes a return error of approx. 1 mm, A and B are 1 mm to 3 mm. If A or B is too small, the limit switch may be improperly activated by vibration during a test. If such a problem occurs, hold the limit collar with your hand, and push it toward A or B , smaller one. If the above adjustment does not work, contact our authorized service company.

6-3

6.Performance Inspection/Maintenance

6.3 Force Inspection When force data seem to be doubtful, or during monthly inspection, check the force according to the procedure described in "1. Force Inspection". If the force accuracy falls below the allowable range, contact our authorized service company or SHIMADU corporation.

1. Force inspection This method allows users to check whether a force value is approximately normal or not, simply by using light weights. (The following values are examples.) Check whether the displayed force value is normal by using the following weights: For the load cell with 1 kN to 300 kN capacity: Use a single weight corresponding to 100 N. For the load cell with 100 N to 500 N capacity: Use a single weight corresponding to 50 N.

UJ Ring joint Plate to hang weight

Weight (1) Mount the ring joint for the weight hanging plate to the universal joint with a pin. (2) Hang the weight hanging plate on the ring joint. (3) Set the force range to the minimum range within the prepared weight force. (4) Set the force polarity (test type) to "Tension". (5) Perform the electric force calibration (See Section 4.6 4.). (6) Push the weight hanging plate by hand to make sure that the displayed force value is increased. (7) Place a weight gently. (8) Make sure that the displayed force value is equal to the weight load. (9) The tolerance range is +/-1% of the indicated value (for the standard type), or +/-0.5% of the indicated value (for the high-precision type). NOTE

Inspection of compression Force cannot be performed in a SFL type (20kN-250kN) Load cell. When you inspect, please inspect using a loop detection machine (Option).

(1) (2) (3) (4) (5)

6-4

Remove the load cell from the crosshead, and place it on a hard level table upside down. Screw the weight plate into the load cell. Set the force range to the minimum range within the prepared weight load. Set the force polarity (test type) to "Compression". Perform the electric force calibration (See Section 4.6 4.).

6.Performance Inspection/Maintenance

Weight Plate to hang weight

Load cell Table

(6) (7) (8) (9)

Push the weight hanging plate by hand to make sure that the displayed force value is increased. Place a weight gently. Make sure that the displayed force value is equal to the weight load. The tolerance range is +/-1% of the indicated value (for the standard type), or +/-0.5% of the indicated value (for the high-precision type).

6-5

6.Performance Inspection/Maintenance

2. Force Calibration (F-CAL) If a significant force error is found in the inspection described above, or during periodic inspection, force calibration by applying actual load (named F-CAL in followed) must be performed. This force calibration identify electrical calibration value. In principle, the F-CAL should be performed by our service representatives. If the user has calibration weights or a loop force meter, the F-CAL can be performed by the user. In this case, however, it must be conducted by a person trained for the calibration procedure. Improper calibration may cause significant errors in measurement results. Note that, if a user conducts the F-CAL, SHIMADZU cannot guarantee the force accuracy. To perform the F-CAL, the operation of applying actual load is required. This operation varies depending on whether tensile force or compression force is applied, and also varies depending on whether the hanging weights or loop force meter is used to apply each force. These operating procedures are described in the separate manual. Contact our sales representatives to request this manual, as required. This manual also includes the description on necessary components.

Force calibration (F-CAL) is performed by control and data-processing software "TRAPEZIUM2." Please choose the "Tool | Adjustment of testing machine amplifier | FCAL" of the menu of TRAPEZIUM2. Please refer to the user guide chapter 5 of software "TRAPEZIUM2" for details.

6-6

6.Performance Inspection/Maintenance

6.4 Maintenance (Lubrication and Cleaning)

1. Maintenance of the ball screw

Lubricate the ball screw periodically to prevent oil lack. While rotating the ball screw at a middle speed (50 to 100 mm/min) (moving the crosshead up/down), apply grease throughout the ball screw by using a soft brush. Universal grease NLGI No. 2 (Shell Albania Grease No. 2) Monthly

Fig. 6.1 Cleaning the Ball screw

CAUTION To lubricate the ball screw, open only one of the ball screw protection covers. (The protection covers are located at the top left, bottom left, top right and bottom right.) Do not open two or more covers simultaneously. During lubricating work, be careful that your fingers, hairs or a part of your clothes will not be caught in the machine. After completion of the lubricating work, be sure to mount the ball screw protection cover.

6-7

6.Performance Inspection/Maintenance

2. Maintenance of the fan filter( Floor type) A filter is attached to the rear panel fan of the floor-type AG-IC series. Although the filter cleaning interval varies depending on the operating frequency or surrounding conditions, the filter should be cleaned approximately once a month. This filter is attached between the fan and the retainer. Remove the retainer by pulling the both sides in the directions indicated by arrows. If the filter is extremely dirty or damaged, replace it with a new filter. Filter

Fan Retainer

Fan filter 9325-M Part No. 042-60934-19 Fig. 6.2 Maintenance of the Fan

3. Maintenance of the smart controller [Control keys] Wipe the control key by using soft cloth damped with a little water. [LED display part] Wipe the LED display part gently by using dry soft cloth or soft cloth damped with a little ethanol. [Case] Wipe the case by using dry soft cloth or soft cloth damped with a little neutral detergent.

4. Maintenance of the testing machine body [Table surface] The table surface is grind-finished. To prevent the table from rusting, wipe dust off, and apply grease to the parts with no jig. [Other casing] Wipe other casing by using dry soft cloth or soft cloth damped with a little neutral detergent. NOTE Keep water off the internal components of the tester, smart controller and controller unit.

6-8

CHAPTER 7 Transport/Storage CONTENTS 7.1 Precautions for Transport ........................................ 7-2 7.2 Precautions for Storage ........................................... 7-4

7-1

7.Transport/ Storage

7.1 Precautions for Transport If you intend to transport this equipment, it is recommended to ask our authorized service company. But if you need to transport this equipment by yourself, observe the following instructions. If your testing machine has undergone the official certification, the certification may become ineffective after the testing machine is transported. It is recommended that you should take the certification's effective period into consideration and transport the testing machine before it undergoes the next certification. Moreover, in case of repair and adjustment made by any person other than SHIMADZU or our authorized service company, I am afraid that SHIMADZU CORPORATION cannot warrant the product.

1. Installation space Ensure the installation place conditions described in Section 4.2 "Precautions for Installation".

2. Installation environment Ensure the installation environment described in Section 4.2 "Precautions for Installation".

3. Power supply Ensure the power supply conditions described in Section 4.2 "Precautions for Installation".

4. Precautions NOTE To lift the testing machine, use a belt or lifting machine apply with load capacity twice or more than the testing machine mass. For the testing machine mass, refer to the table given in Section 1.3.2.

7-2

7.Transport/ Storage

1) When lifting the testing machine by forklift, put wood attachment to lower surface of crosshead. Make sure to keep balance and lift testing machine carefully.

2) When lifting the testing machine by belt, make sure Fig.7.1AG-IC（table-type） that the testing machine body is not tilted. If the testing Lift by forklift. machine body is tilted, the belt may slip, causing the testing machine to shake and injure working personnel. 3) Do not lift the testing machine by the crossyoke (top plate). Lifting the testing machine by the crossyoke may break the crossyoke, causing the testing machine to fall and injure working personnel. 4) Do not lift the testing machine by any part other than the crosshead.

Fig.7.2 AG-IC（table-type）Lift by belt.

5. Level adjustment (Table-type testing machine) For level adjustment, refer to the testing machine level adjustment described in Section 4.2 "Precautions for Installation".

6. Cable connections For cable connections, refer to Section 4.4 "Cable Connections (AG-IC series Table-type)".

7-3

7.Transport/ Storage

7.2 Precautions for Storage 1. Precautions for storage If the testing machine is stored for a long period, the battery for the memory that stores test conditions will be exhausted in approx. six months, and the system becomes the C-RAM clear status. To use the testing machine again, test conditions must be registered.

2. Storing environment Store the testing machine in the following environment: 1) 2) 3) 4) 5)

Temperature: –10 to 60 °C Humidity: 20 to 80% (no condensation) In a place with little dust In a place free from corrosive gas or vapor In a place where the testing machine is not exposed to direct sunlight

3. Provisions for storage The table-type testing machine's table surface has been ground. When the testing machine is stored for a long period, this part may become rusty. Before storing the testing machine, apply a rust-preventive agent or spindle oil to this part. The floor-type testing machine's table surface and crosshead upper and lower surfaces have been ground. When the testing machine is stored for a long period, these parts may become rusty. Before storing the testing machine, apply a rust-preventive agent or spindle oil to these parts.

7-4

CHAPTER 8 Troubleshooting CONTENTS 8.1 Introduction............................................................. 8-2 8.2 Alarm Messages and Resetting Alarms................... 8-2 8.3 Other Troubles......................................................... 8-5 8.4 C-RAM Clear.......................................................... 8-7 8.5 Checking the Circuit Breaker (AG-IC Series Floor-type) ...................................... 8-9

8-1

8. Troubleshooting

8.1 Introduction Generally, troubles cannot be predicted. However, in many cases, some troubles are found to be only operation errors. This chapter includes examples of such troubles. Before judging this equipment to be defective, find a similar condition in this chapter. If an abnormal condition or system error which is not described in this chapter occurs, contact SHIMADZU plant, or our authorized service company or distributor. In case of repair and adjustment made by any person other than SHIMADZU or our authorized service company, I am afraid that SHIMADZU CORPORATION cannot warrant the product.

8.2 Alarm Messages and Resetting Alarms When the AUTOGRAPH detects an abnormal condition, an alarm message will be displayed on the smart controller and display of the personal computer. An example of the alarm display on the smart controller is shown in below, and the alarm messages and the corresponding troubleshooting procedures are listed in Table from next page. While an alarm message is displayed, the crosshead is not in operation, and the display cannot be switched. After reading the displayed alarm message, take an appropriate countermeasure, and then reset the alarm display. Example. In the case of Alarm code 0000

NOTE When an emergency stop switch or a limit switch operates, a crosshead carries out an emergency stop and the above-mentioned alarm indication is not given, please turn OFF a power supply immediately. Please cancel each switch after rebooting.

8-2

8. Troubleshooting

Table 8.1 Alarm messages and the corresponding troubleshooting procedures. Alarm code

0000

Alarm name

BATTERY ERROR

Alarm condition and countermeasure Data cannot be retained due to deterioration of the backup battery on the CPU board. ® The CPU board must be replaced. Contact our authorized service company. The emergency stop switch is pressed when the SET signal is ON.

0010

EMERGENCY SWITCH ON

® Examine the cause of the emergency stop. After making sure that the dangerous conditions are avoided, turn the emergency stop switch to reset it. The limit switch is activated when the SET signal is ON.

0020

CROSS-HEAD LIMIT

®

Examine the cause that the limit switch has been activated. After making sure that the dangerous conditions are avoided, release the limit collar to reset the limit switch.

A user attempted to move the crosshead when the SET signal is OFF.

0030

SERVO OFF

® Make sure that the emergency stop switch or the limit switch is not ON. If either switch is ON, check the safety, and reset this switch. Force exceeding 102% of the load cell capacity is applied to the load cell.

0040

OVER LOAD

®

Reduce the force by using the manual dial. If the force has already been removed, execute the force auto-zero function.

The Start key of a smart controller was pushed without setting up test conditions.

0043

TEST READY ERROR

® LED of a rise and descent blinks and a test machine does not operate. Please push a start key again after setting up examination conditions. Force exceeding -102% of the load cell capacity is applied to the load cell.

0045

UNDER FORCE

®

Reduce the force by using the manual dial.

If the force has already been removed, execute the force auto-zero function. During automatic control, the deviation exceeds 10% of the full scale, resulting in a control error.

0050

0060

OUT OF CONTROL

PARAMETER ERROR

®

Change the gain for the automatic control. If the response speed is too slow, increase the gain. If hunting occurs, lower the gain.

The test condition setting is improper. (Example: The MAX setting is lower than MIN setting for the CYCLE test mode.) ®

Check the preset test conditions.

The maximum point setting is improper. (Example: The MAX point is larger than the full scale.)

0062

MAX PARAMETER ERROR

® Set a proper range for the force/extension amplifier, or turn ON the automatic range switching function. ® The preset value is too high.

8-3

8. Troubleshooting Alarm code

Alarm name

Alarm condition and countermeasure The minimum point setting is improper. (Example: The MIN point is lower than the negative full scale.)

0064

®

Set a proper range for the force/extension amplifier, or turn ON the automatic range switching function.

®

The preset value (negative value) is too low.

MIN PARAMETER ERROR

The speed setting is improper.

0066

SPEED PARAME. ERROR

®

The preset speed is beyond the rated speed range. Set a proper speed.

The servo amplifier alarm is activated. ® Turn OFF the main switch, and then turn it ON again. ® Request service to SHIMADZU. In table-type, the motor brush must be checked.

0070

SERVO ERROR

0075

SERVO READY ERROR

The servo amplifier cannot be started. ® Turn OFF the main switch, and then turn it ON again.

0080

CALIBRATION ERROR

The system failed in the AUX input calibration. ® Make sure that the AUX input voltage is between 4 V and 10 V during span adjustment. Auto zero error

0082

AUTO ZERO ERROR

®

Repeat the auto-zero procedure two or three times. If the zero adjustment does not work, a load cell failure or system error may be considered.

Actual force calibration error ®

Make sure that the force is applied in the preset forcing direction. Make sure that the amplifier range setting is suitable for the applied force.

0084

F-CAL ERROR

0086

E-CAL MAKE ERROR

E-CAL signal generation error ® System error

0088

E-CAL ERROR

E-CAL error ® System error

0100

TOUCH LOAD

Touch detection error by Safety function ® If the force is applied to the load cell during returning operation or jog operation, the crosshead is stopped by alarm (Safety function). For the explanation of a safety function and release, refer to item 5 of section 4.8.

00b0

RS-232C ERROR

RS-232C communication error (Example: Buffer error) ® System error

00d0

I/O EEP-ROM ERROR

I/O board memory error ® System error

00d5

SENS. EEP-ROM ERROR

CAL cable memory error ® System error

CAL. CONNECTOR ERROR

CAL cable memory error ® Sensor amplifier type and CAL. cable is not matched. (Force / SG / DTF)

00e0

8-4

®

8. Troubleshooting

1. In case of Alarm dialog is displayed on PC Click “ALARM RESET” in alarm dialog box and click ”YES” of next dialog box. 2. In case of Alarm dialog is not displayed on PC Press STOP key on the smart controller.

8-5

8. Troubleshooting

8.3 Other Troubles This section describes example of troubles except being shown in Table 8.1 and its countermeasure.

1. Troubles related to key input If the following key inputs are disabled, the causes listed in the right column may be considered. Disabled key

Start key

Return key

Jog key Manual dial

Cause 1) This key can be operated after PC works, test condition is selected and show the test screen (PC). Confirm the test ready status. 2) Operation of this key is disabled when the manual control function is turned ON. Before operating this key, press the MANUAL key, and make sure that the manual control function is OFF. 1) To ensure safety, the Return key input is enabled only by keep pressing this key for at least two seconds. After confirming the safety in the testing area, keep pressing the Return key. 2) Operation of this key is disabled when the manual control function is turned ON. Before operating this key, press the MANUAL key, and make sure that the manual control function is OFF. 1) These operations are disabled unless the manual control function is turned ON by pressing the manual on /off key. Before operating the Jog keys or manual control dial, make sure that the manual control function is ON. 1)

All keys

8-6

2)

All keys are disabled while an alarm message is displayed both on the PC and smart controller.. All keys other than the STOP key are disabled while an alarm message is displayed only on the smart controller.

8. Troubleshooting

2. Other troubles

Problem Numerical LED are not displayed.

Countermeasure 1) 2)

Connect the smart controller cable correctly. Make sure that the power supply is connected. Make sure that the distribution panel is ON.

3) 4)

Turn OFF the power supply, and then turn it ON again. Check the fuse for blowout (with the AG-IC series table-type). ® See Section 8.6.

5)

Check the circuit breaker for tripping (with the AG-IC series

6)

Execute the C-RAM clear. ® See Section 8.4.

[----] appears on the force display.

1) 2)

Connect the load cell correctly.

The force display blinks.

1) 2) 3) 4) 5)

floor-type). ® See Section 8.5

The SET signal cannot be turned ON.

1) 2) 3)

Execute the C-RAM clear. ® See Section 8.4. Check the load cell for over-force. Set the force range to “´ 1”. Connect the load cell correctly. Execute the force auto-zero function. Execute the C-RAM clear. ® See Section 8.4. Check if the emergency stop switch is not activated. Check if the crosshead limit switch is not activated. Execute the C-RAM clear. ® See Section 8.4.

The beep "pee!" sound continues sounding.

The safety function is OFF mode.

Crosshead is running without control.

Press emergency stop switch and turn OFF the main power at once.

Press the STOP key after manual mode is turned ON, so that the safety function returns to ON. Turn ON the power again.

8-7

8. Troubleshooting

8.4 C-RAM Clear The internal parameters of this equipment will be reset to the factory settings. This equipment provides two kinds of the procedure to clear the C-RAM as follows.

NOTE When the C-RAM clear is executed, the crosshead position will be reset and the zero point of the force and the extension shifts to the initial value. It is necessary to readjust about each item. Moreover, the testing condition is initialized and the force range changes one time.

C-RAM Clear is performed by control and data-processing software "TRAPEZIUM2." Please choose the "tool | adjust of force amplifier | other" of the menu of TRAPEZIUM2. Please refer to the user guide Chapter5 of software "TRAPEZIUM2" for details. Keep pressing the STOP key, turn ON the power supply.

8-8

8. Troubleshooting

8.5 Checking the Circuit Breaker (AG-IC Series Floor-type) The power supply circuit breaker is located at the rear right side of the testing machine. When the lever is not at the uppermost position, the circuit breaker has been tripped due to overcurrent, or turned OFF. To turn ON the circuit breaker again, turn it OFF (lower the lever to the lowermost position) once, and then turn it ON.

(Rear of the floor-type )

Power supply circuit breaker

8-9

8. Troubleshooting

（Blank Sheet）

8-10

CHAPTER 9 Maintenance Parts List CONTENTS

9.1 Consumable Parts.................................................... 9-2 9.2 Maintenance Parts ................................................... 9-2

9-1

9. Maintenance Parts List

9.1 Consumable Parts For daily maintenance, use the consumable parts listed below: Part No. 042-60934-19 017-30308-03

Part name Filter, 9325-M Grease (Albania EP2) EP2

Floor-type ○ ○

9.2 Maintenance Parts The maintenance parts listed here are used to repair exhausted/deteriorated parts. Replacement of these parts should be conducted by SHIMADZU service representatives. The supply period for each part is 7 years after stop of the production of this product. However, supply of PCBs, electric components and components made of special materials may not be stopped exceptionally even within 7 years from the production stop, for the component manufacturer’s reasons. Moreover, the term of a guarantee of maintenance parts has become someday or and the direction which reached early of 18 months after use 6 months or, and our company factory shipments. However, as for the parts that are not pure products of SHIMADZU, I would like to fix it for the supply period that the maker where the part was manufactured determined. Moreover, in case of repair and adjustment made by person other than SHIMADZU or our authorized service company, I am afraid that SHIMADZU CORPORATION cannot warrant the project. Part No. Part name Floor-type 345-08127-70 PCB ASSY,CPU/AG-I ○ 345-08130-71 PCB ASSY,I/O ○ 345-09800 PCB ASSY,MOTHER ○ 346-52110-01 FORCE AMP /I ○ 074-80382-02 Power supply LWT30H-5FF ○ 074-80383-27 Power supply ZWS30-24 ○ 347-50211 Fan ASSY(ASF80171) ＊ ○ 042-60934-03 Filter unit (9325-F) ＊ ○ 346-53162-01 Smart controller ○ Note 1 Theses parts can be replaced by users Note 2 Four motor brushes per testing machine are required. Note 3 The filter unit (9325-F) includes the filter (9325-M) and retainer as a set. See Fig. 6.2 in CHAPTER 6.

9-2

＊1 ＊3 ＊1

9.Maintenance Parts List

Part name Servo amplifier Servo motor

Part No. AG-100kNIC

AG-300kNIC

339-87089-01 339-87089-11

339-87090-01 339-87090-11

■ For the part numbers of the standard accessories (such as cables) and peripheral equipment (such as the load cell), refer to CHAPTER 2. ■ For components other than the above, ask SHIMADZU plant, or our authorized service company/distributor.

9-3

9. Maintenance Parts List

（Blank Sheet）

9-4