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.