Instron KPX Series User guide

www.instron.com
Industrial Products Group
Model KPX Static Hydraulic
Universal Testing System
System Concepts Manual
M47-17036-EN Revision A
The difference is measurable
®

Electromagnetic Compatibility
Where applicable, this equipment is designed to comply with International Electromagnetic
Compatibility (EMC) standards.
To ensure reproduction of this EMC performance, connect this equipment to a low impedance
ground connection. Typical suitable connections are a ground spike or the steel frame of a
building.
Proprietary Rights Notice
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.
Trademarks
Instron®is a registered trademark of Illinois Tool Works Inc. (ITW). Other names, logos, icons
and 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 © 2016 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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Instron
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Norwood, MA 02062-2643
United States of America
European Headquarters
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High Wycombe, Bucks HP12 3SY
United Kingdom
Industrial Products Group
Instron
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Grove City, PA 16127
United States of America

3
Preliminary Pages
Product Support: www.instron.com
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 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 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 wide range 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
judgment.
It is our strong recommendation that you should carry out your own product
safety risk assessment.

Preliminary Pages
4M47-17036-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.
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.

5
Preliminary Pages
Product Support: www.instron.com
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, ensure that 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.
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 to testing, 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.
Warnings

Preliminary Pages
6M47-17036-EN
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.
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

7
Preliminary Pages
Product Support: www.instron.com
Table of Contents
Chapter 1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
About these instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
System components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Frame configuration options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Testing accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
System identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Product support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Product documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Calibration and verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Service Agreements/Contracts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Calibration Upon Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Calibration Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Chapter 2 Installation Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Existing transducer rationalization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Computer system - ethernet card availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Interconnections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Hydraulic interconnections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Electrical interconnections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Software and computer setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Load software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Communication setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Initial startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Equipment required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Recommended procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Install covers for crosshead lock cylinders - J3-style crosshead . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Optional accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Chapter 3 Additional System Details. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Test space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Crosshead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Crosshead support collars. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Load measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Position measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Hydraulic cylinder and anti-rotation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Preliminary Pages
8M47-17036-EN
Optional accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Controls and electronics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Tension/compression control switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
59 Series control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Computer system and controlling software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Electrical panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Hydraulic power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Pump and motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Manifold assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Servo manifold assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Lifts and locks manifold assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Lock cylinder pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Pressure settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Oil cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Chapter 4 Parts Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Replacement of fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Inspect/replace 59 Series power entry module fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Equipment required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Recommended procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Replacement or repair of load cells. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

9
Chapter 1
Introduction
•About these instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
•System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
•Product support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
•Product documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
•Calibration and verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
About these instructions
These instructions provide additional information beyond what is necessary to operate the various
models of the KPX testing systems. These instructions are intended for a laboratory or facilities
supervisor, or Instron service personnel.
These instructions assume the following:
•You are an operator familiar with the operation of materials testing systems in general.
•Your system has been installed in its final location according to the requirements outlined in the
system’s Pre-Installation Manual.
•Your system consists of a frame, a hydraulic power supply, a control unit, a computer system with an
Instron materials testing software package, and any testing accessories necessary to secure the
specimen in the test space.
•Software test methods that are appropriate for your testing requirements are available.
These instructions do not include the development of test methods within the materials testing software.
This is covered in more advanced training that can be provided by Instron Service and Training
departments.
Throughout your documentation are NOTE, CAUTION and WARNING statements that alert you to important
information. They appear as follows:
Caution
Cautions alert the user to situations that may cause equipment damage.
Warning
Notes provide further clarification on particular issues.
Warnings alert the user to situations that may cause serious personal injury or death.

Chapter 1: Introduction
10 M47-17036-EN
System overview
Purpose
Warning
The Instron Model KPX Static Hydraulic Universal Testing Systems are available in a variety of capacities.
They are ideally suited for tension, compression, bend, shear, flexure and static cyclic testing on high
strength materials. These frames feature a single, large test space and long test stroke that, together,
provide users with great flexibility in the specimen size that can be tested and in the grips, fixtures and
extensometry that can be used for the test.
System components
Model KPX systems consist of:
•Frame
•Hydraulic Power Supply (HPS)
•59 Series control unit and other system controls and electronics
•Instron approved computer system with Instron materials testing software
Figure 1 identifies the system components and various frame configurations (see “Frame
configuration options” on page 12).
If the equipment is used in a manner not specified by Instron, the protection provided by the
equipment may be impaired. Injury to personnel or damage to the system may result. Be
sure to read and understand the material presented in these instructions and in any other
accompanying instructions.

11
About these instructions
Product Support: www.instron.com
Figure 1. KPX testing systems - various configurations shown.
1500KPX Frame
shown with
J3-Style Crosshead
600KPX Frame
shown with
J1-Style Crosshead
2000KPX Frame
shown with
J4-Style Crosshead
1. J1-style crosshead - Crosshead
adjusted and secured manually
2. J3-style crosshead - Crosshead
adjusted and secured with hydraulic crosshead lift and lock cylinders
3. J4-style crosshead - Fixed crosshead 4. HPS enclosed in console 5. Pendant station 6. Lift and lock controls (frames with
J3-style crosshead only)
7. 5 9 S er i e s c o n t ro l u n i t 8. Computer system
13
2
67
8
4
5

Chapter 1: Introduction
12 M47-17036-EN
Frame configuration options
Frames can be configured with a variety of options. These options include:
•Crosshead variations:
•J1-style crosshead - Crosshead adjusted and secured manually
•J3-style crosshead - Crosshead adjusted and secured with hydraulic crosshead lift and lock
cylinders
•J4-style crosshead - Fixed crosshead
•Test opening variations:
•A - Basic test opening
•B - Increase vertical test space by 305 mm (12 in)
•C - Increase vertical test space by 610 mm (24 in)
•D - Increase vertical test space by 915 mm (36 in)
•Load cell options for 600KPX:
•L1 - Tension/compression load cell with capacity of 300 kN (67,500 lbf)
•L2 - Tension/compression load cell with capacity of 400 kN (90,000 lbf)
•L3 - Tension/compression load cell with capacity of 600 kN (135,000 lbf)
The configuration options selected for your frame are identified in the complete model number of the
frame. The complete model number is defined as:
{Capacity (in kN)}{Model family}-{Crosshead style option}{Test opening option}-{Load cell option}
Some examples would be:
600KPX-J1D-L2, 600KPX-J3B-L3, 1000KPX-J3D, 1500KPX-J1D, 2000KPX-J3D
It is very important to be aware of and understand the configuration of your frame as you perform various
operations and procedures so that they can be performed correctly - the complete model number (in
whole or in part) is used throughout this manual to identify specifications and procedures appropriate for
your frame configuration. Knowing the complete model number of your frame is critical. To determine
the complete model number (and thus configuration) of your frame, refer to one of the following:
•The frame serial tag (see “System identification” on page 13)
•The Instron quote
Testing accessories
Testing accessories are purchased separately from the frame. Testing accessories either provide a
means to secure the specimen in the test space or provide additional functionality to the frame.
Instructions on the installation, use and maintenance of Instron testing accessories are provided
separately with each testing accessory. A variety of testing accessories are available. Contact your
Instron Sales Representative for more information.

13
About these instructions
Product Support: www.instron.com
System identification
Your system has been given a unique serial number for system identification. This serial number can be
found on the serial tag located on the rear of the frame (i.e. the frame serial tag). A duplicate serial tag
can also be found on the rear of the HPS console.
In addition, the following components have also been given a unique serial number:
•59 Series control unit - This serial number can be found on the rear of the control unit.
•HPS - This serial number can be found on the rear of the HPS (rear cover of console must be
removed).
The frame serial tag includes other important system information, including information on your frame’s
configuration. Frame configuration information can also be found on your Instron quote. Refer to “Frame
configuration options” on page 12 for explanation of frame configuration.

Chapter 1: Introduction
14 M47-17036-EN
Product support
Instron provides documentation, including manuals and online help, that can answer many of the
questions you may have. It is recommended that you review the documentation sent with the system you
purchased for possible solutions to your questions.
If you cannot find answers in these sources, contact Instron’s Services department directly. A list of
Instron offices is available on our website at www.instron.com. You may email your questions to
[e-mail] (if your system is still in warranty, please include “IPG Warranty” in the
subject line). In the US and Canada, you can call directly at 1-800-473-7838.
Product documentation
Instron offers a comprehensive range of documentation to help you get the most out of your Instron
products. Depending on what you have purchased, your documentation may include some or all of the
following:
We welcome your feedback on any aspect of the product documentation. Please email
[e-mail] with your comments.
Pre-Installation Manual Information about preparing your site for installation of the system,
receiving the system, and lifting and handling of the system.
Operating Instructions How to use your system components and controls, and other frequently
performed operating tasks.
System Concepts Additional information about your system.
Online Help Software products come complete with context sensitive help, which
provides detailed information on how to use all software features.
Accessory Equipment
Reference
How to set up and use any accessories you have purchased, for example
grips, fixtures, extensometers, transducers, hydraulic power units, non-
standard actuators, and environmental chambers.

15
Product documentation
Product Support: www.instron.com
Calibration and verification
Before shipment from the factory, your system is calibrated and tested to ensure that it meets its
performance specifications. The factory calibration is traceable to national standards, but is not a full
calibration meeting all the requirements of the relevant ISO and ASTM standards. ISO 7500-1 and
ASTM E4 both state that a calibration must be performed after installation for it to meet their standard.
This helps ensure that any changes in calibration during shipment are corrected before any test data is
taken. These standards also recommend that verifications are performed annually or whenever the
system is moved.
Service Agreements/Contracts
In many countries and territories Instron Service offers a variety of service agreements and contracts to
cover such things as annual verification, maintenance, repair coverage, and hotline support for your
system. Contact your local Instron office for details on a service agreement or contract that best matches
your needs. A listing of Instron offices can be found on the Instron web site at www.instron.com.
Calibration Upon Installation
ASTM, ISO, and EN standards require the system be calibrated when it is installed or when it is moved or
relocated. Instron calibrates the system at the factory, and provides a record of readings for the load cell.
This frame may be verified on-site to ASTM E-4, BS 1610, DIN 51221, ISO 7500/1, EN 10002-2, JIS
B7721, JIS B773 or AFNOR A03-501 standards. The factory calibration is not a complete verification to
any current version of any of the above standards. Installation and Basic Software training are included
with the purchase of your system. Verification services are available at a reduced rate if performed as
part of the installation, but must be purchased separately. Contact your local Instron office for more
information about our on-site verification services. Refer to “Calibration Services” below for more
information about Instron’s calibration services.
Calibration Services
In addition to the initial calibration service available at installation, Instron recommends verifying your
transducers on a regular schedule (at least annually) to ensure that your system operates properly and
meets ISO and ASTM standards.
Instron’s Professional Services Department provides a wide range of calibration services including:
•Force
•Strain
•Torsion
•Temperature
•Crosshead displacement
•Crosshead speed
Contact your local Instron office for more information about our on-site verification services. Refer to
“Product support” on page 14 for Instron’s contact information.

Chapter 1: Introduction
16 M47-17036-EN
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17
Chapter 2
Installation Notes
•Existing transducer rationalization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
•Computer system - ethernet card availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
•Interconnections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
•Software and computer setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
•Initial startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
•Install covers for crosshead lock cylinders - J3-style crosshead . . . . . . . . . . . . . . . . . . . . 31
•Optional accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Existing transducer rationalization
If you will be using existing extensometers or low-range load cells with your new system, the additional
transducers may need to be rationalized in order to work correctly with the new system. Contact your
local Instron office for more information about our on-site rationalization services. Refer to “Product
support” on page 14 for Instron’s contact information.
If factory rationalization was purchased, these transducers will be requested 2-3 weeks prior to shipment
of the system in order to integrate them. Some instruments can be rationalized separately from the
shipment of the system, if necessary, to maintain your testing commitments. Contact your local Instron
office for more information.
Field rationalization of some transducers is also available, though it is a more expensive option. This is
often preferable because it will allow using the instrument on your existing system until the new system is
installed.
Computer system - ethernet card availability
The system uses an Ethernet Frame Interface (EFI) to provide communication between the 59 Series
control unit and the computer system. The EFI is housed inside the 59 Series control unit. Use of this EFI
requires an Ethernet card in the computer system:
•If a new computer system is purchased as part of the testing system and is supplied from the factory,
then the computer includes two Ethernet ports - one for use with the EFI and one for normal network
use. The computer system is ready for use and no preparation is required.
•If the computer system is customer supplied, then it must include at least one Ethernet port for use
with the EFI and, if the computer will be connected to a network, then it must include a second
Ethernet port. Be sure the Ethernet cards/ports are installed in the computer.
The second Ethernet port must be used exclusively for communications between the computer and the
59 Series control unit. If you want to connect the computer to a network, you will need to use the first
(Motherboard) Ethernet port or install an additional Ethernet card. Contact your IT department or Instron
service for assistance if required.

Chapter 2: Installation Notes
18 M47-17036-EN
Interconnections
The following interconnection information is provided for reference. It is not intended to be a complete
step-by-step installation procedure, but it does provide a general guideline of what and how system
components should be interconnected. Depending on the components supplied with your system, all the
interconnections listed may not be necessary for your system. This list may also be used as a reference if
it becomes necessary to move the system or frame at a later date.
Hydraulic interconnections
It is necessary to connect the supplied hydraulic hoses between the HPS and the frame. Multiple
connections may be necessary depending on system configuration or options purchased. Table 1
provides the connection information.
Table 1. Hydraulic connections between frame and HPS.
Make Connections For: Hose Description
Connection on Frame
Manifold (See Figure 2)
Connection on
HPS Panel
(See Figure 3)
All frames
Hydraulic cylinder pressure/return
hose (rod end) A2
Hydraulic cylinder pressure/return
hose (piston end) B4
Frames with
hydraulic crosshead lift and
lock cylinders
(J3 option)
Lift and lock pressure hose PRESSURE 1
Lift and lock return hose RETURN 3
Frames with optional
high capacity hydraulic grips
Grips pressure hose Refer to the grip’s
“Installation Drawing”
(supplied separately) for
connections
5
Grips return hose 6
Figure 2. Frame manifold connections - located on base of frame.

19
Interconnections
Product Support: www.instron.com
Figure 3. HPS connection panels.
Electric connections
A through F
Hydraulic connections
1 through 6
(typical connections
shown, not all connections
may be used by your
system)

Chapter 2: Installation Notes
20 M47-17036-EN
Electrical interconnections
Before making electrical interconnections, all system components (including the 59 Series control unit,
pendant station and computer system) should be unpacked and in place at the installation site. Also, the
computer system components can and should be interconnected as outlined by the computer
manufacturer. Check the electrical nameplate of each computer component and connect to an
appropriate power source.
Refer to Table 2, Figure 3 and Figure 4 as you step through the interconnection process.
Electrical cables that connect to components on the frame are routed through the flexible track that is
mounted at the rear of the frame, so these connections are made at the bottom of the flexible track.
Table 2. Electrical connections required.
Cable Connect From Connect To
Ethernet crossover cable, male RJ45 Auxiliary Ethernet connection on
rear of computer
Ethernet connection on front of
59 Series control unit (see
Figure 4)
User control panel cable, female 7-pin User control panel (typically
hardwired)
Connection Non rear of 59 Series
control unit
HPS control box cable, male 15-pin HPS control box (typically
hardwired)
Connection Mon rear of 59 Series
control unit
HPS emergency stop cable, male 6-pin HPS control box (typically
hardwired)
Connection Fon HPS connection
panel
HPS cable, male 14-pin Connection Aon rear of 59 Series
control unit
Connection Aon HPS connection
panel
Frame cable, male 10-pin Junction box on frame (typically
hardwired)
Connection Ron rear of 59 Series
control unit
Load transducer cable, male 25-pin LOAD connection on front of
59 Series control unit
Load transducer on frame
Position cable, male 9-pin Connection Hon rear of 59 Series
control unit
Position encoder on frame1
For systems that include an optional
enclosure
Interlock cable
Junction box on frame - usually
needs to be hardwired
Enclosure interlocks - typically
routed along inside of enclosure to
its exit point
Ground cable Ground stud on rear of 59 Series
control unit
Ground stud on frame
Power cable for 59 Series control unit Power module on rear of 59 Series
control unit
Appropriate outlet or power strip
HPS main power cable Connection Don HPS connection
panel
Customer power supply of
appropriate rating
For systems that include an optional AVE
video extensometer
Coaxial cable, male BNC
SYNC (BNC) connection on front
of 59 Series control unit (see
Figure 4)
BNC connection on AVE
extensometer
For systems that include the optional
Versachannel or Multichannel
Coaxial cable, male BNC
SYNC (BNC) connection on front
of 59 Series control unit (see
Figure 4)
BNC connection on the
Versachannel or Multichannel box