Instron 68TM-5 User manual

Model 68TM-5 Dual Column Table Model
Preinstallation Manual
M10-17416-EN Revision C

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This document and the information that it contains are the property of Illinois Tool Works Inc.
(ITW). 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 ITW.
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marks identifying Instron products and services referenced herein are trademarks of ITW and
may not be used without the prior written permission of ITW.
Other product and company names listed are trademarks or trade names of their respective
companies.
Original Instructions
Copyright © 2020 Illinois Tool Works Inc. All rights reserved. All of the specifications shown in
this document are subject to change without notice.
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United States of America
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General Safety Precautions
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 in
the testing system that are potentially hazardous, particularly force actuators or
a moving crosshead.
Carefully read all relevant manuals and observe all Warningsand 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 equipment or to loss of
data.
Instron products, to the best of its knowledge, comply with various national and
international safety standards, in as much as they apply to materials and
structural testing. We certify that our products comply with all relevant EU
directives (CE mark).
Because of the widerange of applications with which our instruments are used,
and over which we have no control, additional protection devices and operating
procedures may be necessary due to specific accident prevention regulations,
safety regulations, further EEA directives or locally valid regulations. The extent
of our delivery regarding protective devices is defined in your initial sales
quotation. We are thus free of liability in this respect.
At your request, we will gladly provide advice and quotations for additional
safety devices such as protective shielding, warning signs or methods of
restricting access to the equipment.
The following pages detail various general warnings that you must heed at all
times while using materials testing equipment. You will find more specific
Warnings and Cautions in the text whenever a potential hazard exists.
Your best safety precautions are to gain a thorough understanding of the
equipment by reading your instruction manuals and to always use good
judgement.
It is our strong recommendation that you should carry out your own product
safety risk assessment.

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4M10-17416-EN
Warnings
Hazard - Press the Emergency Stop button whenever you consider that an
unsafe condition exists.
The Emergency Stop button removes hydraulic power or electrical drive from the
testing system and brings the hazardous elements of the system to a stop as
quickly as possible. It does not isolate the system from electrical power, other
means are provided to disconnect the electrical supply. Whenever you consider
that safety may be compromised, stop the test using the Emergency Stop
button. Investigate and resolve the situation that caused the use of the
Emergency Stop button before you reset it.
Flying Debris Hazard - Make sure that test specimens are installed correctly
in grips or fixtures in order to eliminate stresses that can cause breakage of
grip jaws or fixture components.
Incorrect installation of test specimens creates stresses in grip jaws or fixture
components that can result in breakage of these components. The high
energies involved can cause the broken parts to be projected forcefully some
distance from the test area. Install specimens in the center of the grip jaws in
line with the load path. Insert specimens into the jaws by at least the amount
recommended in your grip documentation. This amount can vary between 66%
to 100% insertion depth; refer to supplied instructions for your specific grips.
Use any centering and alignment devices provided.
Hazard - Protect electrical cables from damage and inadvertent
disconnection.
The loss of controlling and feedback signals that can result from a disconnected
or damaged cable causes an open loop condition that may drive the actuator or
crosshead rapidly to its extremes of motion. Protect all electrical cables,
particularly transducer cables, from damage. Never route cables across the
floor without protection, nor suspend cables overhead under excessive strain.
Use padding to avoid chafing where cables are routed around corners or
through wall openings.

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High/Low Temperature Hazard - Wear protective clothing when handling
equipment at extremes of temperature.
Materials testing is often carried out at non-ambient temperatures using ovens,
furnaces or cryogenic chambers. Extreme temperature means an operating
temperature exceeding 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 notice concerning low or high temperature
operation whenever temperature control equipment is in use. You should note
that the hazard from extreme temperature can extend beyond the immediate
area of the test.
Crush Hazard - Take care when installing or removing a specimen,
assembly, structure, or load string component.
Installation or removal of a specimen, assembly, structure, or load string
component involves working inside the hazard area between the grips or
fixtures. When working in this area, ensurethat other personnel cannot operate
any of the system controls. Keep clear of the jaws of a grip or fixture at all times.
Keep clear of the hazard area between the grips or fixtures during actuator or
crosshead movement. Ensure that all actuator or crosshead movements
necessary for installation or removal are slow and, where possible, at a low
force setting.
Hazard - Do not place a testing system off-line from computer control
without first ensuring that no actuator or crosshead movement will occur
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
manual control, make sure that the control settings are such that unexpected
actuator or crosshead movement cannot occur.
Robotic Motion Hazard - Keep clear of the operating envelope of a robotic
device unless the device is de-activated.
The robot in an automated testing system presents a hazard because its
movements are hard to predict. The robot can go instantly from a waiting state
to high speed operation 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.
Warnings

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6M10-17416-EN
Hazard - Set the appropriate limits before performing loop tuning or running
waveforms or tests.
Operational limits are included within your testing system to suspend motion or
shut off the system when upper and/or lower bounds of actuator or crosshead
travel, or force or strain, are reached during testing. Correct setting of
operational limits by the operator, prior totesting, will reduce the risk of damage
to test article and system and associated hazard to the operator.
Electrical Hazard - Disconnect the electrical power supply before removing
the covers to electrical equipment.
Disconnect equipment from the electrical power supply before removing any
electrical safety covers or replacing fuses. Do not reconnect the power source
while the covers are removed. Refit covers as soon as possible.
Rotating Machinery Hazard - Disconnect power supplies before removing
the covers to rotating machinery.
Disconnect equipment from all power supplies before removing any cover which
gives access to rotating machinery. Do not reconnect any power supply while
the covers are removed unless you are specifically instructed 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.
Hazard - Shut down the hydraulic power supply and discharge hydraulic
pressure before disconnection of any hydraulic fluid coupling.
Do not disconnect any hydraulic coupling without first shutting down the
hydraulic power supply and discharging stored pressure to zero. Tie down or
otherwise secure all pressurized hoses to prevent movement during system
operation and to prevent the hose from whipping about in the event of a
rupture.
Hazard - Shut off the supply of compressed gas and discharge residual gas
pressure before you disconnect any compressed gas coupling.
Do not release gas connections without first disconnecting the gas supply and
discharging any residual pressure to zero.
Warnings

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Explosion Hazard - Wear eye protection and use protective shields or
screens whenever any possibility exists of a hazard from the failure of a
specimen, assembly or structure under test.
Wear eye protection and use protective shields or screens whenever a risk of
injury to operators and observers exists from the failure of a test specimen,
assembly or structure, particularly where explosive disintegration may occur.
Due to the wide range of specimen materials, assemblies or structures that may
be tested, any hazard resulting from the failure of a test specimen, assembly or
structure is entirely the responsibility of the owner and the user of the
equipment.
Hazard - Ensure components of the load string are correctly pre-loaded to
minimize the risk of fatigue failure.
Dynamic systems, especially where load reversals through zero are occurring,
are at risk of fatigue cracks developing if components of the load string are not
correctly pre-loaded to one another. Apply the specified torque to all load string
fasteners and the correct setting to wedge washers or spiral washers. Visually
inspect highly stressed components such as grips and threaded adapters prior
to every fatigue test for signs of wear or fatigue damage.
Warnings

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8M10-17416-EN

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Table of Contents
Chapter 1: Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
System Description and Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Principle of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Hardware Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
System Safety and Information Labeling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Product Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Product Documentation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Chapter 2: Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Responsibilities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Customer’s responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Supplier’s responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Site requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Frame location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Floor loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Table loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Power supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Telephone and network access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Ceiling clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Environmental conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Accessibility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Site requirements for system accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Environmental specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Conformity with EU directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Environmental impact. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Noise levels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
68TM-5 Power Requirements and Cords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

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10 M10-17416-EN
Power requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Power cord selections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Checklist for site preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Site location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Scheduling installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Chapter 3: Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
68TM-5 Dimensions and Weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Frame Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
System weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Accessory Mounting Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Base beam dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Crosshead dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Top plate dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
System Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Chapter 4: Risk reduction and safe use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Rapid crosshead motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Pinching fingers between grip jaw faces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Impact of debris from breaking specimens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Operator Protection Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Chapter 5: Lifting and handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
General handling precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
68TM-5 Packaging dimensions and weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Unpack dual column frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Transport dual column frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Before you begin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Crosshead method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Shipping skid method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

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Crane method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

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Chapter 1
Introduction
•System Description and Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
•System Safety and Information Labeling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
•Product Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
•Product Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
These instructions include the following information:
•system specifications that are required for installation of your testing system, for
example required environmental conditions, system weights and dimensions
•transporting your system to its final location, including instructions for lifting and
handling
•system performance specifications for this frame model
Refer to the Operator’s Guide for instructions on connecting system components,
system configuration, running tests, and performing routine maintenance of the system.

Chapter: Introduction
14 M10-17416-EN
System Description and Terminology
Figure 1. 6800 Dual Column Table Model with Bluehill®Operator Dashboard - Front
View
10
2
7
1
9
5
8
3
46
11

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System Description and Terminology
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Legend for Figure 1
Label Component
1T-slots
2Topplate
3Columncover
4Loadcell
5Upperlimitswitch
6 Limit switch actuator
7Lowerlimitswitch
8 Emergency stop button
9 Indicator panel
10 Bluehill®Operator Dashboard (optional)
11 Handset

Chapter: Introduction
16 M10-17416-EN
Figure 2. 6800 Dual Column Table Model - Rear View
Legend for Figure 2
1
9
2
4
3
6
7
8
5
Label Component
1 Power inlet connection and power switch
2SystemIDlabel

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System Description and Terminology
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Components
The major components of an Instron®electromechanical testing system include:
•Load frame with integral controller
•Load cell mounted to the crosshead
•Grips for tension testing or table-mounted anvils on a platen for compression
testing.
•Instron®approved computer system with Instron Bluehill®software.
Special fixtures are available for applications such as flexure and peel testing. For strain
measurement, an optional strain gauge extensometer attaches to the specimen. You
can use non-contacting extensometers with specimens that are unable to support a
contacting extensometer. Contact your regional Instron®office or check our web site at
www.instron.com for assistance with Instron’s grips and fixtures.
The following table defines the components of the testing system:
3Rearpanel
4 Controller panel
5Framebase
6 Base beam
7 Base adapter
8Crosshead
9Ballscrewcover
Label Component
Table 1. Testing System Components
Component Description
Load Frame The load frame comprises a base, one or two columns, a moving crosshead,
and a top plate. It is a high stiffness support structure against which the test
forces react.
Each column comprises a guide column and a ballscrew. The crosshead is
mounted on both the guide column and the ballscrew. Rotation of the
ballscrew drives the crosshead up or down while the guide column provides
stability.

Chapter: Introduction
18 M10-17416-EN
Principle of Operation
The system communicates primarily through the controller. The controller contains
sensor conditioning cards for the system transducers and transfers data between the
transducers and the computer. The controller also communicates with the load frame
via a Safety Monitoring Board (SMB) via a Break Out Board (BOB) inside the load frame.
The Break Out Board links all the electrical components of the frame together.
Hardware Controls
The hardware controls consist of:
•Emergency stop button - to be used whenever you need to stop the crosshead
immediately because an unsafe condition exists.
•Limit stops - these must be set before each test session to protect the operator and
load string components against unexpected crosshead movement.
•Indicator panel - indicators showing the status of the testing system.
•Handset - holds all the controls for the testing system.
Controller The hardware that controls the frame and any ancillary equipment connected
to the testing system.The controller panel contains all the connectors for load
cells, extensometers and any other sensors that are required for testing.
Indicator Panel Indicators showing the status of the testing system.
Handset Holds all of the controls for the testing system.
Load String Comprises all of the components that you install between the moving
crosshead and the load frame base (or fixed crosshead). Typically this involves
a load cell, a set of grips, any adapters that are required to connect the
components, and the specimen to be tested.
Typically, you mount a load cell on the crosshead, then a pair of grips or
fixtures on the load cell and frame base. The grips or fixtures secure the
specimen and when you start a test the crosshead moves up or down applying
a tensileor compressive load to the specimen. The load cell converts this load
into an electrical signal that the software measures and displays.
Bluehill®Software Instron®testing software that controls the testing system, running tests and
analyzing test data to produce test results.
Specimen A single piece of material to be tested.
Table 1. Testing System Components (Continued)
Component Description

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System Safety and Information Labeling
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Software
Control of the testing system is carried out via Instron Bluehill®software. Setting test
parameters, operating the system, and collecting test data is done through the software
program.
System Safety and Information Labeling
Table 3 on page 19 explains the meanings of any safety and information labels that
may be attached to any part of the testing system.
Table 2. Software Terminology
Term Description
Test Method InBluehill®software, a test method is a file that contains a set of defined
parameters that the system uses to run tests, analyze the test data, and
produce calculated results.
Sample A group of material specimens, whose properties are studied and
compared to gain statistical or quality assurance information. For
example, you could take a specimen from different parts of a single
manufacturing run of a material to form a sample of the material. The
sample is then representative of the complete run and you can test it to
ensure that the material quality has remained stable over the complete
run. You perform the same test on each specimen in a sample.
Table 3. Safety and Information Labeling Descriptions
Label Meaning Purpose
Electrical
hazard Indicates that an electrical hazard exists from high voltage and/or electrical current.
Disconnect power
supply Disconnect the power supply before servicing machine.

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20 M10-17416-EN
Electrical - fuse warning Indicates an electrical hazard exists.
Advises disconnecting power mains before
changing fuses and using only specified
fuses.
Belt
entanglement hazard Indicates that a hazard exists from the drive belt and pulley system.
High
temperature hazard Indicates that a heat hazard exists. Stay clear of area when operating the machine.
Rotating machinery
hazard Indicates that a rotating hazard exists. Keep clear of these areas (and tie back
long hair and loose clothing).
Ground stud Indicates a ground stud.
Read the manual Read and understand the operator’s
manual before using the machine.
Crosshead direction Indicates the direction to turn the pulley to
manually move the crosshead upward.
Pulleys can be turned by hand when power
is disabled.
Table 3. Safety and Information Labeling Descriptions (Continued)
Label Meaning Purpose