Instron KPX User manual

www.instron.com
Industrial Products Group
Model KPX Static Hydraulic
Universal Testing System
Operating Instructions
M47-17035-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.
Corporate Headquarters
Instron
825 University Avenue
Norwood, MA 02062-2643
United States of America
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High Wycombe, Bucks HP12 3SY
United Kingdom
Industrial Products Group
Instron
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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
4M47-17035-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
6M47-17035-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
Frame components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
System control components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
System safety and information labeling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Product support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Product documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
System verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Chapter 2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Use limits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Hydraulic power supply physical dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
59 Series control unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Environmental conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Heat load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Noise level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Chapter 3 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Operation of controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Operation of HPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Mount fixtures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Start the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Change height of test opening - J1-style or J3-style crosshead. . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Adjust the position of a J1-style crosshead. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Equipment required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Recommended procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Adjust the position of a J3-style crosshead. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Operation of controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Equipment required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Recommended procedure - 600KPX, 1000KPX and 1500KPX frames. . . . . . . . . . . . 38
Recommended procedure - 2000KPX frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Preliminary Pages
8M47-17035-EN
Run a test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Shut down the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Loss of power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Chapter 4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
General maintenance recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Preventative maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Make daily checks of system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Remove and install console covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Clean the fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Inspect the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Inspect the hydraulic cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Crosshead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Maintain the tensioners of J1-style crosshead. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Check operation of lift and lock cylinders of J3-style crosshead. . . . . . . . . . . . . . . . . . 56
Clean the columns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Hydraulic power supply (HPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Check the oil cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Add oil to reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Equipment and supplies required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Recommended procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Change the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Equipment and supplies required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Recommended procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Change the air breather filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Equipment and supplies required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Recommended procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Inspect the hydraulic hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Replace the hydraulic hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Replace low pressure hydraulic hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Replace high pressure hydraulic hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Oil type and quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Clean the air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Ancillary parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Consumable parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Spare and replacement parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Appendix A CE Certificate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

9
Chapter 1
Introduction
•About these instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
•System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
•Frame components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
•System control components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
•System safety and information labeling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
•Product support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
•Product documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
•System verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
About these instructions
These instructions describe the function, operation and maintenance for various models of the KPX
testing systems. If unsure of your specific model, refer to “System identification” on page 13.
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 M47-17035-EN
Please read these instructions, and any other documents provided, thoroughly and carefully. Be sure to
understand all Warnings and Cautions before attempting to operate any of the system in whole or in part.
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
System overview
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 e r i e s c o n t r ol u n i t 8. Computer system
13
2
67
8
4
5

Chapter 1: Introduction
12 M47-17035-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
System overview
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 M47-17035-EN
Frame components
Refer to Figure 2 and Table 1 to identify components of the frame. For proper operation of the system,
it is important to be able to identify and to understand the basic function of these components.
Figure 2. KPX frame components - 2 column frame shown - for legend see Table 1.
1a
3
6b
1b
2
8
4
5
7
6a

15
System overview
Product Support: www.instron.com
Table 1. Frame component descriptions, see Figure 2.
Component Description
1. Crosshead
a. J3-style
b. J1-style
c. J4-style (not shown)
Provides mounting for hydraulic cylinder.
For J1-style and J3-style crossheads: Position of crosshead can be adjusted to
change the vertical opening of the test space. Refer to “Change height of test
opening - J1-style or J3-style crosshead” on page 33 for more information.
For J4-style crossheads: Position of crosshead is fixed; no adjustment is possible.
2. Load cell Measures the force applied to the specimen. One end of the specimen is
mounted to the load cell using appropriate specimen fixtures (purchased
separately).
3. Columns Connect the crosshead to the base.
4. Test space Area where tests are performed.
For J1-style and J3-style crossheads: The vertical opening of the test space can
be adjusted. Refer to “Change height of test opening - J1-style or J3-style
crosshead” on page 33 for more information.
For J4-style crossheads: The vertical opening of the test space can not be
adjusted.
5. Hydraulic cylinder Applies load to the specimen during the test.
6. Crosshead lock mechanisms
a. J3-style
b. J1-style
Lock the crosshead to the columns. Operated either manually (J1-style
crossheads) or hydraulically (J3-style crossheads). Refer to “Change height of
test opening - J1-style or J3-style crosshead” on page 33 for more
information. Provided on J1-style and J3-style crossheads only.
7. Crosshead lift cylinders Provide hydraulic adjustment of the crosshead on the columns. Refer to “Adjust
the position of a J3-style crosshead” on page 37 for more information.
Provided on J3-style crossheads only.
8. Base Provides mounting surface for fixtures (purchased separately), refer to “Mount
fixtures” on page 31 for more information.

Chapter 1: Introduction
16 M47-17035-EN
System control components
Refer to Table 2 to identify control components of the system. For proper operation of the system, it is
important to be able to identify and to understand the basic function of these components.
Table 2. System control descriptions.
Component Description
Emergency stop Press this button to immediately stop motion of the frame. This stops
all frame motion and disables the frame. This button will take
precedence over all other system controls. Refer to Table 10 on
page 27 for more information.
Main power disconnect switch Provides control of main power to the system. When the switch is off,
all power to the frame and HPS are shut off. Power to the 59 Series
control unit and computer system are unaffected as they have their
own power supply.
Pump start Press this button to start the HPS. Refer to Table 10 on page 27 for
more information.
59 Series control unit The 59 Series control unit houses control components that: receive
and process data from the various system transducers; communicate
with the system’s controlling software; and provide feedback to the
system’s servo valve to operate the frame as set up in the controlling
software. Refer to Table 10 on page 27 for more information.
59 Series control unit disconnect
switch
Provides control of power to the 59 Series control unit. This
disconnect switch does not affect power to the frame.
User control panel The controls on this panel allow the operator to manually adjust the
hydraulic cylinder, to start and stop tests, to reset and return to the
zero extension point and other testing controls/functions. Refer to
Table 10 on page 27 for more information.
Tension/compression control
switch
Allows the operator to place hydraulic demand at the appropriate side
of the hydraulic cylinder for testing in the direction required (tension or
compression).
Crosshead lift and lock controls Allows the operator to control the hydraulic lift and lock cylinders for
adjustment of the crosshead. Adjustment of the crosshead changes
the height of the test opening. Supplied with J3-style crossheads only.

17
System overview
Product Support: www.instron.com
System safety and information labeling
Table 3 explains the meanings of any safety and information labels that may be attached to any part of
the testing system.
Table 3. Descriptions of safety and information labeling.
Label Meaning and Purpose
Crush hazard - Indicates that a pinching or crush hazard exists from two objects coming together
and instructs the user to read and understand the operator’s manual before using the machine.
Electrical hazard - Indicates that a hazard exists from high voltage or electrical current.
High pressure hazard - Indicates that a hazard exists from high pressure. Do not adjust or reset any
pressure settings until you have read and understood the operator’s manual. Personal injury or
damage to equipment may result. Most pressure settings should only be adjusted by an Instron
service engineer.
Eye protection - Indicates that a flying debris hazard exists either from specimen failure or improper
use of system components. Wear eye protection or use protective shields or screens. Be sure to
read and understand the operator’s manual before using the system.
Read the manual - Read and understand the operator’s manual before using the system.
Guard removal hazard - Indicates that a hazard exists - do not operate the system with covers
removed. Be sure to read and understand the operator’s manual before using the system. Only
authorized personnel should service the equipment.
General hazard - Indicates a general hazard. Be sure to read and understand the operator’s
manual before using or servicing the system. Only authorized personnel should service the
equipment.
Ground stud - Indicates a ground stud. Connect to an appropriate ground/earth system.
Protective earth - Indicates the protective earth terminal for the main power supply.
Three-phase power supply - Indicates that the equipment requires a three-phase power supply.

Chapter 1: Introduction
18 M47-17035-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.
System verification
Caution
System verification is vital to ensure the accuracy of your calibration. Current standards
recommend that you do not exceed 18 months between verifications.
Instron provides a fully traceable verification service including UKAS/NVLAP certification where
appropriate. Contact your local Instron Representative for details.
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.

19
Chapter 2
Specifications
•Use limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
•Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
•Hydraulic power supply physical dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
•59 Series control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
•Environmental conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
•Heat load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
•Noise level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Use limits
Table 4 gives information on the use limits of the testing system, as determined in accordance with
ISO 12100, section 5.3.2.
Table 4. Use limits of the testing system.
Intended use
and
foreseeable
misuse:
When fit with appropriate fixtures, the system is intended to conduct static tension, compression, bend, flexure
and shear tests on a variety of specimen shapes and material types. The material types must be limited to those
that break into no more than two pieces that will be retained in the fixtures or whose failure does not result in
hazardous projectiles. The system can operate in servo control mode only through an Instron Materials Testing
Software package. The system must never be left unattended while in operation.
The system should not be used for any purpose other than static testing of the material types specified above. It
must not be used to test specimens of material types that result in hazardous projectiles unless an interlocked
guard with an appropriate performance level is added. You must conduct your own risk assessment and take
appropriate measures to prevent operator injury and guard the equipment. Instron offers safety rated guards for
this purpose. Please contact your local Instron representative for more information.
The system must not be used as a press. The system should not be operated by anyone who does not fit the
criteria specified in the “Operator characteristics:” and “Operator training/experience:” sections of this
table.
Intervention
procedures:
The system is equipped with Emergency Stop and software reset (frame enable) controls (see Table 2 on
page 16 and separately supplied Software documentation).
Use type: Industrial
Operator
characteristics:
Typical adult in good health with no disabilities that prevent safe operation of the testing system.
Operator
training/
experience:
Operators should be familiar with the operation of materials testing systems in general and with the inherent
hazards of such testing in particular. Operators should gain a thorough understanding of this equipment by
reading these instructions and all other documents provided. Initial basic safety and operational training is
provided by Instron Service personnel during installation of the system.
Maintenance personnel or technicians should have sufficient training and skills so that they can safely perform
all procedures outlined in Chapter 4 beginning on page 51.
Trainees and apprentices should only operate or maintain the system under direct supervision of a qualified
operator or maintenance personnel.
The general public should not have access to the system.

Chapter 2: Specifications
20 M47-17035-EN
Frame
The technical specifications for the various standard KPX frames can be found in Table 5. If unsure of
the options included with your frame, check the model number listed on the frame’s serial number tag; it
includes option designations.
Exposure of
other persons
to hazards:
Exposure to hazards is greatly reduced by the knowledge of qualified operators. Anyone who does not fit the
criteria specified in the “Operator characteristics:” and “Operator training/experience:” sections of this
table should not have access to the system.
Table 4. Use limits of the testing system. (Continued)
Figure 3. KPX specification measurements.
G
E
A
B
F
For legend, refer to Table 5.
C
D
Table 5. KPX frame technical specifications.
Specification1600KPX 1000KPX 1500KPX 2000KPX
Maximum Capacity2600 kN
60,000 kgf
135,000 lbf
1,000 kN
100,000 kgf
225,000 lbf
1,500 kN
150,000 kgf
337,500 lbf
2,000 kN
200,000 kgf
450,000 lbf
Design Capacity3480 kN
48,000 kgf
108,000 lbf
800 kN
80,000 kgf
180,000 lbf
1,200 kN
120,000 kgf
270,000 lbf
1,600 kN
160,000 kgf
360,000 lbf
(A) Test Opening (per crosshead style, frame height and lift cylinder range)4
J1B N/A 0 to 1930 mm
(0 to 76 in) N/A N/A N/A