Instron 4400 Series Manual

M10-94400-1
Issue C April 1995
Instron
Model 4400
Universal Testing System
Operator’s Guide

Proprietory Rights Notice
This document and the information that it contains are the property of Instron
Corporation. Rights to duplicate or otherwise copy this document and rights to
disclose the document and the information that it contains to others and the right
to use the information contained therein may be acquired only by written
permission signed by a duly authorized officer of Instron Corporation.
© Copyright 1995 Instron Corporation

Amendment Incorporation Record
Amendment
Number Brief Description of Content ECR Numberr
Person
Incorporating
Amendment
1Reverse Strain Mode Switch
Settings B3887 NCW
2
3
4
5
6
7
8
9
10
Preliminary Pages
iii

Amendment Incorporation Record
Amendment
Number Brief Description of Content ECR Numberr
Person
Incorporating
Amendment
11
12
13
14
15
Revision Record
Revision ECR No.
Preliminary Pages M10-94400-1
iv

Materials testing systems are potentially hazardous.
Materials testing involves inherent hazards from high
forces, rapid motions and stored energy. You must be
aware of all moving and operating components which
are potentially hazardous, particularly the actuator in a
servohydraulic testing system or the moving crosshead
in an electromechanical testing system.
Whenever you consider that safety is compromised,
press the Emergency Stop button to stop the test and iso-
late the testing system from hydraulic or electrical
power.
Carefully read all relevant manuals and observe all
Warnings and Cautions. The term Warning is used
where a hazard may lead to injury or death. The term
Caution is used where a hazard may lead to damage to
equipmentortolossofdata.
Ensure that the test set-up and the actual test you will
be using on materials, assemblies or structures consti-
tutes no hazard to yourself or others. Make full use of
all mechanical and electronic limits features. These are
supplied for your safety to enable you to prevent move-
ment of the actuator piston or the moving crosshead be-
yond desired regions of operation.
The following pages detail various general warnings
that you must heed at all times while using materials
testing equipment. You will find more specific warn-
ings and cautions in the text whenever a potential haz-
ard exists.
Your best safety precautions are to gain a thorough un-
derstanding of the equipment by reading your instruc-
tion manuals and to always use good judgement.
Preliminary Pages
v

Warning
Disconnect the electrical power supply be-
fore removing the covers to electrical equip-
ment.
Disconnect the equipment from the electrical power sup-
ply before removing any electrical safety covers or re-
placing fuses. Do not reconnect the power source while
the covers are removed. Refit covers as soon as possible.
Disconnect power supplies before remov-
ing the covers to rotating machinery.
Disconnect the equipment from all power supplies be-
fore removing any cover which gives access to rotating
machinery. Do not reconnect any power supply while
the covers are removed unless you are specifically in-
structed to do so in the manual. If the equipment needs
to be operated to perform maintenance tasks with the
covers removed, ensure that all loose clothing, long hair,
etc. is tied back. Refit covers as soon as possible.
Shut down the hydraulic power supply and
discharge hydraulic pressure before discon-
necting any hydraulic fluid coupling.
Do not disconnect any hydraulic coupling without first
shutting down the hydraulic power supply and discharg-
ing stored pressure to zero. Tie down or otherwise se-
cure all pressurized hoses to prevent movement during
system operation and to prevent the hose from whipping
about in the event of a rupture.
Preliminary Pages M10-94400-1
vi

Warning
Shut off the supply of compressed gas and
discharge residual gas pressure before dis-
connecting any compressed gas coupling
Do not release gas connections without first disconnect-
ing the gas supply and discharging any residual pressure
to zero.
Use protective shields or screens if any pos-
sibility exists of a hazard from the failure of
a specimen, assembly or structure under
test.
Use protective shields whenever a risk of injury to opera-
tors and observers exists from the failure of a test speci-
men, assembly or structure, particularly where explosive
disintegration may occur. Due to the wide range of speci-
men materials, assemblies or structures that may be tested,
any hazard resulting from the failure of a test specimen, as-
sembly or structure is entirely the responsibility of the
owner and the user of the equipment.
Protect electrical cables from damage and
inadvertent disconnection.
The sudden loss of controlling and feedback signals
which can result from a disconnected or damaged cable
causes an open loop condition which may drive the ac-
tuator or crosshead rapidly to its extremes of motion.
Protect all electrical cables, particularly transducer ca-
bles, from damage. Never route cables across the floor
without protection, nor suspend cables overhead under
excessive strain. Use padding to avoid chafing where ca-
bles are routed around corners or through wall openings.
Preliminary Pages
vii

Warning
Wear protective clothing when handling
equipment at extremes of temperature.
Materials testing is often carried out at non-ambient tem-
peratures using ovens, furnaces or cryogenic chambers.
Extreme temperature means an operating temperature ex-
ceeding 60 °C (140 °F) or below 0 °C (32 °F). You must
use protective clothing, such as gloves, when handling
equipment at these temperatures. Display a warning no-
tice concerning low or high temperature operation when-
ever temperature control equipment is in use. You
should note that the hazard from extreme temperature
can extend beyond the immediate area of the test.
Take care when installing or removing a
specimen, assembly or structure.
Installation or removal of a specimen, assembly or struc-
ture involves working inside the hazard area between the
grips or fixtures. Keep clear of the jaws of a grip or fix-
ture at all times. Keep clear of the hazard area between
the grips or fixtures during actuator or crosshead move-
ment. Ensure that all actuator or crosshead movements
necessary for installation or removal are slow and,
where possible, at a low force setting.
Preliminary Pages M10-94400-1
viii

Warning
Do not place a testing system offline from
computer control without first ensuring that
no actuator or crosshead movement will oc-
cur upon transfer to manual control.
The actuator or crosshead will immediately respond to
manual control settings when the system is placed off-
line from computer control. Before transferring to man-
ual control, make sure that the control settings are such
that unexpected actuator or crosshead movement cannot
occur.
Keep clear of the operating envelope of a
robotic device unless the device is de-acti-
vated.
The robot in an automated testing system presents a haz-
ard because its movements are hard to predict. The robot
can go instantly from a waiting state to high speed opera-
tion in several axes of motion. During system operation ,
keep away from the operating envelope of the robot. De-
activate the robot before entering the envelope for any
purpose, such as reloading the specimen magazine.
Preliminary Pages
ix

Table of Contents
Chapter Page
1 Introduction
Outline .........................................................................1-1
Introduction..................................................................1-2
About this Manual...............................................1-3
Product Support..................................................1-3
General Characteristics...............................................1-4
Console Components..................................................1-7
Front Panel..................................................................1-8
Main Panel Section.............................................1-8
Display Panel Section.........................................1-10
Limits Panel Section ...........................................1-10
Crosshead Control Section.................................1-11
Internal Status Indicators....................................1-12
Recorders ...........................................................1-12
Console Internal Functions..........................................1-14
Central Processing Unit (CPU)...........................1-14
Crosshead Control Function ...............................1-14
Load Sensor Conditioner....................................1-14
Strain Sensor Conditioner...................................1-15
IEEE-488 Interface .............................................1-15
2 Specifications
Introduction..................................................................2-2
Specifications...............................................................2-3
3 Installation
Outline .........................................................................3-1
General Considerations...............................................3-2
Preliminary Pages M10-94400-1
x

Table of Contents (continued)
Chapter Page
3 Installation (continued)
Console Connections...................................................3-3
Mounting the Console.........................................3-3
Attaching the Console...................................3-3
Mounting the Console Bracket......................3-4
Connector Panel.................................................3-5
Installing Cables .................................................3-7
Cabling for Optional Equipment..........................3-9
Cables...........................................................3-9
Analog Output Connector .............................3-9
Opening the Console...................................................3-11
4 Function Of Controls
Outline .........................................................................4-1
Preliminary Considerations..........................................4-2
Function Of Controls....................................................4-3
Main Panel..........................................................4-3
Display Section...................................................4-12
Limits Section .....................................................4-14
Data Storage ...............................................................4-16
Nonvolatile Memory............................................4-16
System Reset .....................................................4-16
Volatile Memory ..................................................4-16
Resident Test Program Overview ................................4-20
Self Test Routine .........................................................4-23
Self Test - Part 1 .................................................4-23
Self Test - Part 2 .................................................4-24
Self Test Result - No Failures .............................4-24
Preliminary Pages
xi

Table of Contents (continued)
Chapter Page
4 Function Of Controls (continued)
Self Test Result - Failures...................................4-25
Self Test Result Display......................................4-25
Version Number...........................................................4-31
Selecting Operating Units............................................4-32
Switching Units ...................................................4-32
Operating Units for Self Identified Load Cells
and Load Frames................................................4-33
Operating Units for Non-Self Identified Load
Cells and Load Frames.......................................4-34
Area...................................................................4-35
Energy Units .......................................................4-35
5 System Operation
Outline .........................................................................5-1
Operating Considerations............................................5-2
Pretest Procedures......................................................5-3
Turn Instrument On: Warm-up.....................................5-4
Self Test Routine At Power Up ....................................5-5
System Reset At Initial Power Up................................5-7
Load Calibration ..........................................................5-8
Overview ............................................................5-8
Electrical Calibration of Self Identifying
Load Cells ..........................................................5-9
Manual Calibration of Self Identifying
Load Cells ..........................................................5-10
Electrical Calibration of Non-Self Identifying
Load Cells...........................................................5-12
Preliminary Pages M10-94400-1
xii

Table of Contents (continued)
Chapter Page
5 System Operation (continued)
Manual Calibration of Non-Self Identifying
Load Cells..........................................................5-13
Load Weighing System Balance ........................5-15
Calibration And Balance Errors...........................5-16
Strain Calibration.........................................................5-18
Overview.............................................................5-18
Strain Operating Mode........................................5-18
Strain Gauge Extensometers..............................5-20
Electrical Calibration of Self Identifying Strain
Gauge Extensometers ......................................5-22
Manual Calibration of Strain Gauge
Extensometers...................................................5-22
Extensometers - Operating Notes.......................5-25
Display Panel...............................................................5-26
Description..........................................................5-26
Operation............................................................5-26
Establish Gauge Length ..............................................5-28
Electronic Limits...........................................................5-30
Operating Notes - Limits Panel...........................5-30
Operation............................................................5-31
Set Crosshead Travel Limit Stops ...............................5-34
Set Crosshead Speed .................................................5-35
Crosshead Jog Control................................................5-37
Area Compensation.....................................................5-38
Install Specimen ..........................................................5-42
Set Testing Area ..........................................................5-43
Run a Test ...................................................................5-45
Preliminary Pages
xiii

Table of Contents (continued)
Chapter Page
6 System Options
Overview......................................................................6-1
Introduction..................................................................6-2
Strip Chart Recorder....................................................6-3
Description..........................................................6-3
Specifications......................................................6-4
Power Requirements ....................................6-6
Installation...........................................................6-7
Operation............................................................6-8
Pen Scaling...................................................6-8
Pen Calibration .............................................6-9
X-Y Recorder...............................................................6-12
Description.........................................................6-12
Specifications......................................................6-13
Installation...........................................................6-15
Power Requirements ....................................6-15
Signal Input Connection................................6-15
Operation............................................................6-16
Initial Setup...................................................6-16
Calibration.....................................................6-19
Time Base Operation....................................6-22
Normal Operation..........................................6-23
Printer..........................................................................6-24
Description..........................................................6-24
Installation...........................................................6-24
Operation............................................................6-25
Printout Format...................................................6-25
Printer Units........................................................6-26
Preliminary Pages M10-94400-1
xiv

Table of Contents (continued)
Chapter Page
6 System Options (continued)
AC/DC Strain Conditioner............................................6-30
Specifications......................................................6-31
Installation...........................................................6-31
Operation............................................................6-32
Preset Points ...............................................................6-34
Description..........................................................6-34
Operation............................................................6-35
Energy .........................................................................6-37
Description..........................................................6-37
Operation............................................................6-37
Cycle Counter..............................................................6-39
Pip Control...................................................................6-41
Air Kit Option ...............................................................6-44
Overview.............................................................6-44
Description..........................................................6-44
Operation............................................................6-45
Manual Operation .........................................6-46
Grip Control Function Operation...................6-47
Pretension and Excess Tension Operation...6-47
Automatic Start Operation.............................6-48
Automatic Release Operation.......................6-49
Set pretension Level .....................................6-49
Set Excess Tension Level.............................6-50
Time Delays..................................................6-50
Continuous Pretension Testing .....................6-50
Preliminary Pages
xv

Table of Contents (continued)
Chapter Page
7 Test Check List
8 Maintenance
Overview......................................................................8-1
Introduction..................................................................8-2
General...............................................................8-2
Special Maintenance Considerations..................8-2
Preventive Maintenance..............................................8-3
Cleaning - Control Console.................................8-3
Error Messages ...........................................................8-4
Overview.............................................................8-4
Displaying Error Messages.................................8-4
Rear Panel Indicators..................................................8-10
Rear Panel Indicators .........................................8-10
General.........................................................8-10
Power Supply Condition Indicators...............8-11
Green Test LEDs...........................................8-11
Red Activity LEDs .........................................8-12
Red Latch Indicator LEDs.............................8-13
IEEE-488 Interface Indicators.......................8-14
Summary of Operating Sequence for
Rear Panel Indicators ..................................8-15
Fault Indications ..........................................................8-16
Appendix A Test Planning
Applications .................................................................A-2
Load Requirements .....................................................A-4
Selection Of Grips........................................................A-5
Preliminary Pages M10-94400-1
xvi

Table of Contents (continued)
Chapter Page
Appendix A Test Planning (continued)
Establishing Gauge Length..........................................A-7
Selection Of Testing Speed .........................................A-8
Strain Rate...................................................................A-9
Area Compensation.....................................................A-10
Description..........................................................A-10
Determining Stress Range..................................A-11
Limitations Due To Load Cell Capacity ...............A-12
Chart Magnification......................................................A-14
Appendix B Glossary
Preliminary Pages
xvii

List of Illustrations
Figure Page
1-1. Functional Block Diagram............................................1-5
1-2. Control Console Front Panel ......................................1-9
3-1. Console Rear Panel Connectors .................................3-6
3-2. Rear Panel Cable Arrangement...................................3-8
3-3. Access to Interior of Console.......................................3-12
4-1. Main Panel...................................................................4-3
4-2. Display Section............................................................4-12
4-3. Limits Section ..............................................................4-14
4-4. Console Section Numbers Assigned to
Main Panel Display for Self Test Result......................4-26
4-5. Coding of Display Results for Self Test Result ............4-27
4-6. Characters Displayed in Self Test Result....................4-27
6-1 Model 4400 X-Y Recorder Panel.................................6-17
6-2. Typical Test Curve with Preset Points..........................6-34
8-1. Rear Panel Indicators .................................................8-12
8-2. Closeup Detail of Console Status and
Fault Indicators............................................................8-13
Preliminary Pages M10-94400-1
xviii

List of Tables
TablePage
3-1. Series 4400 Console Option Cables............................3-9
3-2 Analog Output Connector Pin Assignments ................3-10
4-1. Main Panel Functions..................................................4-3
4-2. Display Section Functions ...........................................4-12
4-3. Limits Section Functions..............................................4-14
4-4. Variables and Functions in Nonvolatile
Memory........................................................................4-17
4-5. Control Console Sections ............................................4-26
4-6. Characters Possible in Self Test Result for
Each Digit of Main Panel Display.................................4-29
4-7. Operating Units for Self-Identified Load
Cells 4-33
5-1. Low Capacity Load Cells Calibration Data ..................5-13
5-2. Transducer Calibration/Balance Errors........................5-17
6-1. Strip Chart Recorder Supplies.....................................6-6
6-2. Recorder Line Voltage Selection .................................6-7
6-3. Calibration Signal for Load Cells .................................6-10
6-4. Recorder Supplies.......................................................6-14
6-5. Chart Speed Conversions............................................6-22
6-6. Strain Units Printout.....................................................6-26
6-7. Energy Units Printout...................................................6-27
6-8. Printout with Strain as Independent
Variable........................................................................6-28
6-9. Printout with Extension as Independent
Variable........................................................................6-28
Preliminary Pages
xix

List of Tables (continued)
Table Page
6-10. Example Pip Delay Values vs Test Speeds.................6-43
6-11. Air Kit Functions ..........................................................6-46
8-1. Sections of the Control Console ..................................8-5
8-2. Error Messages ...........................................................8-7
8-3. LED Error Codes for IEEE-488 Section Tests .............8-14
8-4. Fault Indications ..........................................................8-16
A-1. Gripping Techniques....................................................A-6
A-2. Typical Testing Speed Ranges for Various
Materials......................................................................A-8
Preliminary Pages M10-94400-1
xx