Lloyd LS SERIES User manual

LLOYD INSTRUMENTS LTD
SERVICE MANUAL FOR THE
LS1, FT1, TA1, LS2K5 AND LS5
MATERIALS TESTING MACHINES
ISSUE 4.0 - NOVEMBER 2014
PART NUMBER 01/3936

LLOYD INSTRUMENTS LTD
Steyning Way
Bognor Regis
West Sussex
PO22 9ST
Telephone: [phone]
Fax: [phone]
ISSUED BY TECHNICAL SUPPORT DEPT
Direct phone line [phone]
email [email protected]

LS SERIES SERVICE MANUAL
ISSUE 4.0 CONTENTS 1
TABLE OF CONTENTS
1 OVERVIEW
1.1 Scope of Manual 1
1.2 General 3
1.3 Full Control Console 4
1.4 Hand Held Remote 5
1.5 Battery Memory (RAM) 5
1.6 Changing a Loadcell 6
1.7 Computer Control 6
1.8 Electronic PCBs and Power Supply 7
1.9 Load Measuring System 8
1.10 Extension Measuring System 9
1.11 Crosshead Drive System 10
1.12 User Limit Switches 10
1.13 Compression Cut-Out 10
1.14 Mains On/Off Switch and Main Input Fuses 11
1.15 Safeline Button and Emergency stop Switch 11
1.16 Optional Splinter Shield 12
2 MICROPROCESSOR CIRCUITS
2.1 General 1
2.2 USB Interface 1
2.3 Console Keypad 2
2.4 Motor Control Signals 2
2.5 Limit Switches 3
2.6 Splinter Shield Wiring 5
3 PROGRAM INFORMATION
3.1 Upgrading the Program 1
3.2 V1.0 Issue 0 - Initial Release for LS1 5
3.3 V1.0 F Issue 1 - Initial Release for FT1 5
3.4 V1.1 Issue 22 - Replaces V1.0 Issue 0 6

LS SERIES SERVICE MANUAL
ISSUE 4.0 CONTENTS 2
4 LOAD MEASURING SYSTEM
4.1 General 1
4.2 Loadcell 1
4.3 Loadcell Gradings 1
4.4 Loadcell Bridge Supply 3
4.5 Loadcell Amplifier 3
4.6 Loadcell Value 3
4.7 Analogue to Digital Converter 4
4.8 Overload Detector 4
5 EXTENSION MEASURING SYSTEM
5.1 Internal Extension Measurement 1
5.2 External Analogue Extensometer 1
5.3 Analogue to Digital Converter 2
5.4 External Encoder Extensometer 2
6 POWER SUPPLIES
6.1 Mains Connections 1
6.2 DC Supplies 1
6.3 Machine Type EEPROM 4
7 CROSSHEAD DRIVE SYSTEM
7.1 General 1
7.2 PWM Driver 1
7.3 Motor Overcurrent Detector 2
7.4 Power Dump Circuit 3
7.5 Safeline Circuit 3

LS SERIES SERVICE MANUAL
ISSUE 4.0 CONTENTS 3
8 MECHANICAL ASSEMBLIES
8.1 General 1
8.2 Performance Checks 1
8.3 Cleaning 2
8.4 Removing the Lower Cover 2
8.5 Opening the Full Control Console 3
8.6 Opening the Hand Held Remote 4
8.7 Removing the Top Cap 4
8.8 Lubrication 5
8.9 Lower Eye End Alignment 6
8.10 Adjusting the Drive Belt Tension 7
8.11 Replacing the Drive Motor, Gearbox and Encoder 8
8.12 Replacing the Loadcell Loom 9
8.13 Removing the Mechanical Assembly 10
8.14 Dismantling the Mechanical Assembly 11
8.15 Replacing a Limit Switch 13
8.16 YLC Loadcell Threads 14
8.17 YLC Loadcell Mounting Rods 14
8.18 Grip Through Pin 14
9 CALIBRATION PROCEDURE
9.1 General 1
9.2 Checking the Extension Measurement 1
9.3 Checking the Crosshead Speed 1
9.4 Load Calibration Principle 2
9.5 Load Calibration Procedure 2
10 FAULT FINDING
10.1 General 1
10.2 Mains Supply Checks 1
10.3 Analogue and Digital Supplies 2
10.4 Motor Drive Supplies 2
10.5 Table of Power Supplies 2
10.6 Error Messages 2
10.7 Fault Finding Charts 4

LS SERIES SERVICE MANUAL
ISSUE 4.0 CONTENTS 4
11 DIAGNOSTIC MODES
11.1 General 1
11.2 Selecting the Diagnostic Mode 1
11.3 Loadcell Verification 2
11.4 Installing an External Extensometer 2
11.5 Converting an Analogue Extensometer 3
11.6 Converting an Encoder Extensometer 4
11.7 Extensometer Verification 4
11.8 PC Diagnostic Mode 4
12 FULL CONTROL CONSOLE DIAGNOSTICS
12.1 General 1
12.2 Selecting the Internal Diagnostic Mode 1
12.3 Setting the Machine Type and Serial Number 3
12.4 Changing the Loadcell Value and Serial Number 4
12.5 Checking the Loadcell Offset and Overloads 5
12.6 Loadcell Calibration 7
12.7 Setting the Extensometer Type and Serial Number 10
12.8 Calibrating an Analogue Extensometer 11
12.9 Calibrating an Encoder Extensometer 14
12.10 Exporting and Importing Loadcell Data Points 16
13 NEXYGEN PLUS 3 DIAGNOSTICS
13.1 General 1
13.2 Selecting the NEXYGEN Plus 3 Diagnostic Mode 1
13.3 Setting the Machine Type and Serial Number 3
13.4 Changing the Loadcell Value and Serial Number 3
13.5 Checking the Loadcell Offset and Overloads 4
13.6 Loadcell Calibration 7
13.7 Setting the Extensometer Type and Serial Number 11
13.8 Calibrating an Analogue Extensometer 12
13.9 Calibrating an Encoder Extensometer 14

LS SERIES SERVICE MANUAL
ISSUE 4.0 CONTENTS 5
14 SPARE PARTS
14.1 General 1
14.2 Mains Input Fuses 1
14.3 Spares List 2
15 MODIFICATIONS
15.1 General 1
15.2 Production Changes 1
16 MECHANICAL DRAWINGS
17 ELECTRICAL DRAWINGS

LS SERIES SERVICE MANUAL
ISSUE 4.0 OVERVIEW 1
1. OVERVIEW
1.1 Scope of Manual
This service manual covers the following machines: -
LS1, LS1E, LS1P, LS1X, FT1 and TA1 (1kN capacity)
LS2K5E and LS2K5X (2.5N capacity)
LS5S and LS5P (5kN capacity)
LS with Full Control Console LS With Hand Held Remote
and High Capacity Loadcell and Low Capacity Loadcell

LS SERIES SERVICE MANUAL
ISSUE 4.0 OVERVIEW 2
Notes: -
1 The LS1S, LS1P, FT1 and TA1 are the same frame and motor assembly.
2 The LS1E and LS1X are extended travel machines and have a longer vertical
column, leadscrew, linear rail and limit switch rod.
3 The LS2K5 andLS5 are the same frame and motor assembly but have a different
height vertical column to give 800mm or 1400mm crosshead travel and different
motor/leadscrew pulleys to give 1016mm/min or 2032mm/min crosshead speed.
4 The LS2K5E is only available with 1400mm travel, i.e. it is an extended machine.
5 The LS5S is only available with 800mm travel, i.e. it is a standard machine.
Note that an extended LS5 version is not possible because of mechanical
restrictions due to the leadscrew.
6 The P and X versions are "Pogo" machines and are supplied complete with the
lower bearing assembly.
7 The working throat depth is 180mm for the 1kN frames but 140mm for the 2k5N
and 5kN frames.
8 All machines except for the FT1 can be supplied with either a Full Control
Console or a Hand Held Remote. Note that if a Hand Held Remote is supplied,
then the machine can only perform tests using the NEXYGEN Plus 3 software.
9 The FT1 (Friction Tester) is an LS1 that is supplied complete with a friction table
and is specifically for Friction Testing Applications. This machine uses different
embedded (firmware) to provide friction test setups and test results. This
allows the machine to be used "Stand-Alone" so is always supplied complete
with a Full Control Console.
10 The TA1 (Texture Analyzer) is an LS1 that is supplied complete with fixtures
specifically for Food Testing Applications. This machine uses the same
embedded (firmware) as the LS1.
The basic machine specifications are shown below: -
MACHINE MAXIMUM LOAD CROSSHEAD TRAVEL MAXIMUM SPEED
LS1S / LS1P
FT1 / TA1
1 kN 500 mm 2032 mm/min
LS1E
LS1X
1 kN 800 mm 2032 mm/min
LS2K5E
LS2K5X
2.5 kN 1400 mm 2032 mm/min
LS5S
LS5P
5 kN 800 mm 1016 mm/min

LS SERIES SERVICE MANUAL
ISSUE 4.0 OVERVIEW 3
1.2 General
The machines are bench mounted, microprocessor controlled, single column loading frames.
The crosshead is driven by a preloaded ballscrew (leadscrew) that is rotated by a permanent
magnet DC motor via a toothed drive belt. On the 1kN frames, the motor is mounted below the
lower crosshead, under the lower cover. On the 2.5kN and 5kN frames, the motor is mounted
behind the vertical column, under the rear vertical cover. All motors are fitted with a digital
encoder that is used to measure the crosshead position. The motor is powered by a PWM
supply from a driver IC on the Motor Drive PCB. The PWM signal is generated on the Main PCB
by monitoring the motor encoder signals.
The rear of the crosshead is attached to a vertical linear rail assembly that accurately defines
the crosshead alignment. This system ensures minimal sideways movement of the crosshead
together with minimal vertical "rocking" of the crosshead under all loading conditions.
The lower eye end design provides accurate alignment to the loadcell eye end. This
arrangement also allows the grips to be rotated without affecting their vertical position.

LS SERIES SERVICE MANUAL
ISSUE 4.0 OVERVIEW 4
The machine measures two parameters during the sample test mode. These are the load
applied to the test sample, by moving the crosshead, together with the crosshead movement
during the test.
The load is measured using either a YLC loadcell or an earlier XLC loadcell. The YLC loadcell is
fitted with an eye end arrangement similar to the lower eye end design fitted to the frame. The
YLC loadcell also has an improved amplifier with lower noise than the XLC loadcell. Therefore,
it is recommended that a YLC loadcell is used with these machines. However, an XLC
loadcell can also be used, noting that the lower limit of verification may be higher (due to slightly
increased noise) and the vertical position of the grips will alter if the grips are rotated.
The load signal is analogue and is converted into data using a 16 Bit ADC (effectively
increased to 18 Bit by the embedded code) but the extension signal is digital. Both types of
signal are measured at 1000 Hertz so the load and extension values are available at a data rate
of 1000 readings per second.
If a single Analogue External Extensometer is used, the load and extension analogue voltages
are multiplexed before being converted so the load data rate and the extensometer data rate are
both 500 readings a second. The digital encoder is still read at the normal speed of 1000
readings per second. Note that the signal from an Analogue External Extensometer is converted
into data using a 16 Bit ADC.
If a single Digital External Extensometer is used, the encoder and extensometer digital signals
are sequentially measured so the encoder data rate and the extensometer data rate are both
500 readings a second. The load is still read at the normal speed of 1000 readings per second.
The frame and covers are designed for ease of maintenance. Removing the lower cover gives
access to the mains input module, power supply, transformer, PCBs, limit switches, safe-line
circuits and the drive belt. To gain access to the motor, the rear backplate and motor cover may
also have to be removed.
1.3 Full Control Console
The Full Control Console contains a 4 line by 40-character backlit alphanumeric LCD display, a
large membrane keypad and a buzzer. The LCD contrast is adjusted by the potentiometer on
the console PCB.
The text on the LCD display can be displayed in one of various languages and the required
language is selected using the EDIT, GLOBAL, >, CURRENT LANGUAGE option.
The console allows positioning of the crosshead using the slow/fast - up/down jog keys and the
return key. The current load and extension values can be zeroed (using the Ø key) and a test
can be started (using the ►key) or stopped/aborted (using the ■key). Note that a NEXYGEN
Plus 3 test can also be started by using the start button if this feature is selected in the software.
The console displays the current load and extension values in various units and these are
selected using the EDIT, SETUP, TEST RESULTS, RESULT UNITS option.
The Full Control Console also enables a test to be defined and performed without using a
computer, i.e. the machine can be used "Stand-Alone".

LS SERIES SERVICE MANUAL
ISSUE 4.0 OVERVIEW 5
1.4 Hand Held Remote
The Hand Held Remote contains a 2 line by 12-character backlit alphanumeric LCD display, a
small membrane keypad and a buzzer. The LCD contrast is adjusted by the potentiometer on
the console PCB.
The console allows positioning of the crosshead using the slow/fast - up/down jog keys and the
return key. The current load and extension values can be zeroed (using the Ø key) and a test
can be started (using the ►key) or stopped/aborted (using the ■key). Note that a NEXYGEN
Plus 3 test can also be started by using the start button if this feature is selected in the software.
The hand held remote displays the current load and extension values using 1 of 3 different unit
combinations: -
[a] = N and mm [b] = kgf and mm [c] = lbf and in
To change the displayed units (from [a] to [b], [b] to [c] or [c] to [a]), switch the machine
on then press the ZERO key (Ø) 2 times when "Lloyd Instruments" is shown on the display.
Note that a test cannot be defined without using NEXYGEN Plus, i.e. the machine cannot be
used "Stand-Alone".
Also note that the machine type, loadcell calibration and extensometer calibration cannot be
changed without using the NEXYGEN Plus 3 software console.
1.5 Battery Memory (RAM)
The test setup information is retained in the battery backed RAM so that the predefined set-ups
are ready for use when the machine is switched on. Any previously stored test data is also
stored in the RAM so that statistics may be calculated over a time period when the machine is
used "Stand-Alone".
If the information in the RAM becomes corrupted, for example by excessive voltage surges or
spikes on the mains supply etc. the machine may operate incorrectly and the RAM should be
erased to remove any previous information. The RAM can only be erased by a software routine
called a RAM DUMP, which not only erases the information in the RAM but also automatically
creates three standard test set-ups called LIMIT TEST, CYCLE TEST and BREAK TEST.
The RAM is cleared using the following procedures: -

LS SERIES SERVICE MANUAL
ISSUE 4.0 OVERVIEW 6
a Full Control Console
To perform a RAM Dump, switch the machine on then press the RIGHT HAND key
under the display when "Lloyd Instruments" is shown on the display. A confirmation
request is displayed, so press the key under "Yes" to confirm the request and perform the
RAM Dump.
It is important to note that ALL user defined test set-ups and TEST DATA will be
erased by this procedure so the customer should be informed and asked to save
any data BEFORE performing a RAM DUMP. For safety, a confirmation is
requested when the RIGHT HAND key is pressed.
b Hand Held Remote
To perform a RAM Dump, switch the machine on then press the ►key repeatedly.
The normal start up screen will show "Lloyd Instruments", then the display will show
load and extension values then "Lloyd Instruments" will be displayed again for a short
time period to confirm that the RAM Dump was performed.
Note that if the RAM is REPLACED for any reason, its internal time clock MUST be set to the
correct time by connecting the machine to a computer then starting the NEXYGEN Plus 3
Software Console. When this console communicates with the machine, the clock in the RAM
will be set to the current time of the host computer.
1.6 Changing a Loadcell
The machine is fitted with an S Type YLC (or XLC)loadcell and this is fitted underneath the
moving crosshead using a vertical bolt. The loadcell may be easily interchanged by one of a
different value by disconnecting the plug and unscrewing the mounting bolt. Note that the size of
the thread on the bolt depends upon the loadcell value.
1.7 Computer Control
The machine is fitted with an integral USB interface and is connected to the PC using the
supplied USB cable, part number CBT/1357/00. Note that an FTDI USB driver is required on
the PC before the machine can be connected and this is available on the NEXYGEN Plus 3 CD
or can be downloaded from the FTDI website at http://www.ftdichip.com/FTDrivers.htm
The machine can be fully controlled using the Lloyd Instruments NEXYGEN Plus 3 Software
program, which can be used with either Windows XP or Windows 7. The software controls
the machine, displays a graph during a test and automatically calculates the required test
results at the end of a test. The USB connection allows the machine to be controlled by any
computer, even if the PC is not fitted with a serial (RS232) connector.
Note that if a Hand Held Remote is supplied, then the machine can ONLY perform tests
using the NEXYGEN Plus 3 software.

LS SERIES SERVICE MANUAL
ISSUE 4.0 OVERVIEW 7
Also note that if a Hand Held Remote is supplied, the machine type, loadcell calibration and
extensometer calibration can ONLY be changed using the NEXYGEN Plus 3 software.
The USB connection can be used to output test data from the machine to a Datalogger or to
Windows Hyperterminal.
1.8 Electronic PCBs and Power Supplies
The main frame contains 2 electronic circuit boards and a switch mode power supply. The Full
Control Console and the Hand Held Remote both contain a Console PCB and an LCD Display
assembly. Each loadcell is supplied with an integral amplifier inside the loadcell plug. Each
extensometer is supplied with an integral amplifier inside the extensometer plug.
The Main PCB contains the microprocessor, digital circuits and analogue circuits. This is
powered from the switch mode power supply that provides +5V, +15V and -15V. This power
supply also powers the loadcell amplifier and any optional external extensometer amplifiers.
The Motor Drive PCB contains the power rectifier, smoothing capacitor and drive electronics.
This is powered from the mains transformer which provides approx. 33V AC for the LS1 variant
machines and 50V AC for the LS2K5E and LS5S machines. This AC supply is rectified and
smoothed to give approximately +45V motor supply for the LS1 variant machines and 65V motor
supply for the LS2K5E and LS5S machines.
The PCB also generates a stable +12V for the motor over-current monitor. The Motor Drive
PCB also uses the +5V and +15V from the switch mode power supply.
Note that the Motor Drive PCB contains an EEPROM that is programmed with the
machine type and its serial number. If this PCB is replaced during servicing, the new
PCB MUST be programmed with the relevant data as shown in Diagnostic Mode
section.
Also note that the PCBs are multi-layered and are fitted with surface mounted
components so are NOT considered to be field repairable. If a PCB fails, the usual
course of action is to replace it with a new one. Therefore it is recommended to keep
spare PCBs in your service stock.
A block diagram is shown in figures 1 and 2

LS SERIES SERVICE MANUAL
ISSUE 4.0 OVERVIEW 8
A numerical list of PCB's is shown below: -
04/1451 Loadcell Amplifier (contained inside the YLC loadcell plug)
SPK/LS/0005 Main PCB
SPK/LS/0004/A Motor Drive PCB including Power Dump Resistor and Loom
SPK/LS/0045 Hand Held Remote PCB and LCD Display
04/1460 Full Console PCB
SPK/LS/0044 Full Console LCD Display
04/1461 Extensometer Interface PCB
EXP/2258 Extensometer Amplifier (contained inside the extensometer plug)
SPK/LS/0042 Digital and Analogue Switch Mode Power Supply Unit
TNT/0185/00 LS1 and variants transformer
TNT/0186/00 LS2K5E and LS5S transformer
1.9 Load Measuring System
The load measuring system consists of a full bridge strain gauged loadcell, which is physically
connected to the test specimen in the loading frame, a loadcell amplifier and a 16 bit ADC
(effectively increased to 18 Bit by the embedded code). The sample is mounted between
the moving and lower crossheads of the machine and the required load is applied to it by moving
the upper crosshead either upwards or downwards.
The loadcell bridge is energised by a stable 4V DC supply from the Main PCB and will give a
potential difference of 8mV when its rated load is applied to it. This output is amplified by a low
noise DC amplifier that is inside the loadcell 15 pin D plug and this also contains an EEPROM,
which stores the loadcell value and calibration information.
The nominal output of this amplifier is 0 volts with no load applied, rising to +8.0 volts for
maximum tensile load and falling to -8.0 volts for maximum compressive load. The analogue
output of this amplifier is converted into 16 bit data by the ADC on the Main PCB, which is
mounted on the base of the machine.
The load measuring system has 2 overload protection features. The first is a software overload,
which will stop the machine if the displayed load exceeds 115% of the loadcell value. The
second is a hardware overload circuit, which will stop the machine if the absolute loadcell output
exceeds approx. 128% of the loadcell value. Therefore, the maximum rated load can ONLY be
achieved if the absolute loadcell offset and the offset introduced by the grips is less than 28% of
the loadcell value.
Note that each occurrence of a loadcell being overloaded by more than 28% is recorded in the
loadcell EEPROM and may be viewed using the diagnostic mode.

LS SERIES SERVICE MANUAL
ISSUE 4.0 OVERVIEW 9
1.10 Extension Measuring System
The machine is fitted with a digital encoder and this is used to provide the crosshead extension
measurement and also to control the motor speed. The encoder is connected directly to the
motor shaft. The encoder pulses are counted in an up/down counter to provide the high-
resolution extension measurement.
The crosshead movement is normally used to calculate the sample elongation but an external
extensometer may be required when testing dumbbell samples etc.
Note that the LS Series use the same type of extensometers as the Plus Series but the
external connector is different. Therefore, either an adaptor cable or an external
extensometer interface box is required before ANY extensometer can be connected to the
machine.
A single ANALOGUE external extensometer may be connected to the machine by using an
adaptor cable, part number 09/1047 (37 way female to 25 way female).
A single DIGITAL external extensometer (e.g. single encoder or twin/differential encoders) may
be connected to the machine by using an adaptor cable, part number 09/1047 (37 way female
to 25 way female).
One, two or three ANALOGUE external extensometers can be connected simultaneously to
the machine by using an extensometer interface box, part number 01/3905. This interface
box is powered from the LS series machine and requires no external power supply. It is
supplied with a 37 way to 37 way cable that goes from the rear of the LS series test machine
to the rear of the interface box.
The front of the interface box is fitted with three 25 way D sockets which are used to connect
one, two or three extensometers to the LS series test machine. The sockets can be used in
any order because each extensometer has a unique identity and is selected either using the
LS series control console or the NEXYGEN Plus 3 software console.
In addition to an ANALOGUE external extensometer, a single DIGITAL external extensometer
(encoder - single or twin/differential) may also be connected to the extensometer interface box,
i.e. only ONE DIGITAL external extensometer can be connected and used. The DIGITAL
external extensometer can be connected to any of the three sockets on the front of the box.
The 25 way D plug on the end of the extensometer lead contains a small PCB which is fitted with
an EEPROM which stores the extensometer calibration information. The PCB also contains a
DC amplifier with 4 fixed ranges and a stable strain gauge excitation voltage so is suitable for
use with a self-powered extensometer, a strain gauge extensometer, an LVDT or an encoder.
Note that the signal from an Analogue External Extensometer is converted into data using a 16
Bit ADC.

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ISSUE 4.0 OVERVIEW 10
1.11 Crosshead Drive System
A DC permanent magnet motor moves the crosshead via a gearbox, pulleys, toothed timing belt
and a leadscrew. The motor is powered by a PWM Driver IC, which is fed with a PWM signal
from the Main PCB. The motor speed is controlled by a PWM signal that is generated on the
Main PCB and the value of the PWM is calculated by measuring the speed of the motor encoder
pulses.
1.12 User Limit Switches
The machine is fitted with two mechanically activated limit stops that are fitted onto a vertical
rod mounted on the right hand side of the vertical column. An actuator bar is fitted to the
right hand side of the moving crosshead and this operates the limit stops if the crosshead
moves up or down to touch the relevant stop.
If the crosshead moves up so that the actuator bar touches the upper limit stop, the vertical
limit rod moves up and operates the N/C upper limit switch. If the crosshead moves down so
that the actuator bar touches the lower limit stop, the vertical limit rod moves down and
operates the N/C lower limit switch. Both limit switches (microswitches) are mounted on the
right hand side of the lower casting, under the lower cover.
The machine will stop if one of these switches is operated. An error message will be displayed
on the Full Control Console or an error number will be displayed on the Hand Held Remote.
To reset the machine, accept the error by pressing the ACCEPT key then move the crosshead
away from the limit stop using the appropriate JOG keys.
These stops are provided to prevent the grips from being accidentally driven together.
Therefore, these limit stops should be set to the appropriate position whenever a loadcell and/or
grip are changed.
Please note that these are NOT Cycle limits.
1.13 Compression Cut-Out
The safety compression cut-out load feature is provided by the microprocessor monitoring the
load applied to the loadcell. The machine will stop if a compressive load greater than the user
defined SAFETY JOG LOAD is applied when driving the machine downwards by using either
the down jog key, the return key or during automatic return.
Therefore, it is recommended to manually zero the machine whenever a loadcell and/or
grip are changed.

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ISSUE 4.0 OVERVIEW 11
1.14 Mains On/Off Switch and Main Input Fuses
The mains power switch is located at the rear of the machine. This is part of the mains input
module which contains the mains input fuses and voltage selector. The selected mains
voltage is displayed in the small window as shown below. Note that the fuseholder is
designed to use either 20mm fuses or 1-1/4 inch fuses but 20mm fuses MUST always be
used. Also note the fuse locations within the fuseholder.
1.15 Safeline Button and Emergency Stop Switch
The safeline button and emergency stop switch are located on the base at the left hand side
of the machine.
The red emergency stop switch is used to stop the machine in an emergency. It operates by
disconnecting the mains from the machine. The emergency stop is wired in series with the
mains input and will latch in the off position when the red mushroom is pushed downwards.
When the red mushroom is down, the mains power is removed from the machine. To release
the switch, rotate the red mushroom clockwise until it lifts by spring pressure.
The safeline circuit isolates the Motor Drive transformer from the Motor Drive Power Supply
until the operator has pressed the safeline button. This ensures that if the Motor Drive PCB
is faulty, the motor will not run when the machine is first switched on.
The safeline circuit contains a relay (K1), which has 2 sets of change-over (C/O) contacts.
The first set of contacts (4, 5 and 6) are used to power the safeline lamp and also provide a
"Hold-on" supply for the relay. The second set of contacts (1, 2 and 3) are used to connect
the transformer to the bridge rectifier on the Motor Drive PCB.
When the machine is first switched on, the safeline relay is de-energised and the yellow
safeline button is lit. The machine cannot be driven until the safeline is energised. If a jog
key etc is pressed, a "Safe Line Open" error message will be displayed on the Full Control
Console or an error number will be displayed on the Hand Held Remote.
When the yellow safeline button is pressed, the relay will energise, the light in the safeline
button will turn off and the motor power supply is connected.
Note that the fuses MUST be
fitted with one end against
the pin end of the holder

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ISSUE 4.0 OVERVIEW 12
1.16 Optional Splinter Shield
An optional safety shield, part number 01/3909, may be used to enclose the testing machine
and this shield can be electrically interlocked to the motor drive system. This shield prevents
the user from contacting the moving crosshead or grips during a test and also prevents
fragments of broken sample from flying out of the work area.
The optional safety shield is supplied complete with the internal and external interlock looms
(09/1046 and 09/1051) so that it can be easily interlocked if required. If an electrical interlock
is not required, then the internal loom (09/1046) is not fitted inside the LS frame. See section
2.6 for details.
The user operating instruction manual provides complete specifications, control
functioning and operational data and should be referred to for this information.

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ISSUE 4.0 OVERVIEW 13
FIGURE 1 - LS1 BLOCK DIAGRAM