Instron 6800 Series Manuel

6800 Series Single Column Table Model

Operator’s Guide

M10-17410-EN Revision A

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

this document are subject to change without notice.

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825 University Avenue

Norwood, MA 02062-2643

United States of America

European Headquarters

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Preliminary Pages

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General Safety Precautions

Materials testing systems are potentially hazardous.

Materials testing involves inherent hazards from high forces, rapid motions, and

stored energy. You must be aware of all moving and operating components in

the testing system that are potentially hazardous, particularly force actuators or

a moving crosshead.

Carefully read all relevant manuals and observe all 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

judgement.

It is our strong recommendation that you should carry out your own product

safety risk assessment.

Preliminary Pages

4M10-17410-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.

Preliminary Pages

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High/Low Temperature Hazard - Wear protective clothing when handling

equipment at extremes of temperature.

Materials testing is often carried out at non-ambient temperatures using ovens,

furnaces or cryogenic chambers. Extreme temperature means an operating

temperature exceeding 60 °C (140 °F) or below 0 °C (32 °F). You must use

protective clothing, such as gloves, when handling equipment at these

temperatures. Display a warning notice concerning low or high temperature

operation whenever temperature control equipment is in use. You should note

that the hazard from extreme temperature can extend beyond the immediate

area of the test.

Crush Hazard - Take care when installing or removing a specimen,

assembly, structure, or load string component.

Installation or removal of a specimen, assembly, structure, or load string

component involves working inside the hazard area between the grips or

fixtures. When working in this area, 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.

Warnings

Preliminary Pages

6M10-17410-EN

Hazard - Set the appropriate limits before performing loop tuning or running

waveforms or tests.

Operational limits are included within your testing system to suspend motion or

shut off the system when upper and/or lower bounds of actuator or crosshead

travel, or force or strain, are reached during testing. Correct setting of

operational limits by the operator, prior 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.

Rotating Machinery Hazard - Disconnect power supplies before removing

the covers to rotating machinery.

Disconnect equipment from all power supplies before removing any cover which

gives access to rotating machinery. Do not reconnect any power supply while

the covers are removed unless you are specifically instructed to do so in the

manual. If the equipment needs to be operated to perform maintenance tasks

with the covers removed, ensure that all loose clothing, long hair, etc. is tied

back. Refit covers as soon as possible.

Hazard - Shut down the hydraulic power supply and discharge hydraulic

pressure before disconnection of any hydraulic fluid coupling.

Do not disconnect any hydraulic coupling without first shutting down the

hydraulic power supply and discharging stored pressure to zero. Tie down or

otherwise secure all pressurized hoses to prevent movement during system

operation and to prevent the hose from whipping about in the event of a

rupture.

Hazard - Shut off the supply of compressed gas and discharge residual gas

pressure before you disconnect any compressed gas coupling.

Do not release gas connections without first disconnecting the gas supply and

discharging any residual pressure to zero.

Warnings

Preliminary Pages

Product Support: www.instron.com

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

Preliminary Pages

8M10-17410-EN

Preliminary Pages

Product Support: www.instron.com

Table of Contents

Chapter 1: Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

System Description and Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Principle of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Hardware Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

System Safety and Information Labeling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Conformity with EU directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Product Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Product Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Location of your Preinstallation manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Chapter 2: Risk reduction and safe use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Rapid crosshead motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Pinching fingers between grip jaw faces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Impact of debris from breaking specimens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Operator Protection Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Chapter 3: Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Level the load frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Power supply compatibility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Set the input voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

System components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Single column load frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Connect the system components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Bluehill®Operator Dashboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

First time startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Preliminary Pages

10 M10-17410-EN

Chapter 4: Function of controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Power input connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Emergency Stop button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Handset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Indicator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Bluehill®software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Home Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Operator Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Move between modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Jog at High Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Operator Protection Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Bluehill®Operator Dashboard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Basic touch functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Touchscreen gestures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Pneumatic Grips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

How Operator Protection works with grips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Operate grips using footswitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Operate grips using toggle switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Grips not in use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Chapter 5: Assemble the load string . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Select a load cell. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Before you begin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Install the load cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Install a 2530 load cell (capacities 5 N through 100 N) . . . . . . . . . . . . . . . . . . . . . . . 78

Install a 2580 load cell (capacities 500 N through 5 kN) . . . . . . . . . . . . . . . . . . . . . . 80

Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Base adapters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Coupling adapters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Select Grips and Fixtures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Insert Jaw Faces into Grips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Install grips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

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