Emco-test DuraJet 10 G5 Instruction Manual Download Page 35

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Hardness Tester

Design and Functions

DuraJet 10

3-4

WARNING

Risk of crushing by the nose cone.

Severe injuries.



In an emergency, press the EMERGENCY OFF button to stop the unit immediately.



Never modify the safety equipment of the unit without authorization.

An EMERGENCY OFF button (1) sits on the left side of the control unit as a safety

device. If you press this button, the current operation is cancelled and the machine is

switched off.
The test unit stops moving and the touch screen light is dimmed. The DANGER

pictogram appears.

To release the EMERGENCY OFF button, turn it clockwise.

Safety equipment

Summary of Contents for DuraJet 10 G5

Page 1: ......

Page 2: ...uction DuraJet 10 G5 1 1 Instruction manual Original instruction manual DuraJet G5 A2015 05 EN EMCO TEST Pr fmaschinen GmbH Kellau 174 A 5431 Kuchl Tel 43 6244 20438 Fax 43 6244 20438 8 office emcotes...

Page 3: ...ic Operation 4 1 4 1 Switching the Machine On and Off 4 1 4 2 Touch Screen 4 1 4 3 Virtual Keyboard 4 1 4 4 Symbols and Buttons 4 3 4 5 Test Sequence 4 7 4 6 Testing Without the Nose Cone 4 12 5 Advan...

Page 4: ...tion DuraJet 10 G5 1 3 7 2 External machine control via hardware interface 7 2 7 3 Foot button 7 6 7 4 Replacing the Fuses 7 6 7 5 Replacing the Test Anvil 7 8 7 6 Test Methods and Indenters 7 11 8 Me...

Page 5: ...or other property may be damaged Icons are used to highlight these risks in the relevant chapters Read all operating instructions before you start the machine Keep the operating instructions in the vi...

Page 6: ...appropriate fixings to secure any workpieces that do not stay in place without support Never hold workpieces in place by hand Wear protective gloves when handling heavy or sharp workpieces or removin...

Page 7: ...e used to test hardness in accordance with the following methods Metals plastic material and carbon material Rockwell EN ISO 6508 ASTM E18 Plastics EN ISO 2039 1 Brinell and Vickers depth hardness onl...

Page 8: ...te For more information about recycling this product contact your relevant local authority The warranty period for new machines is 24 months from the date of delivery by the manufacturer with unlimite...

Page 9: ...and take greatest care using protective equipment for example to face the danger Persons must work very carefully in this area WARNING The safety instruction WARNING stands for a very dangerous situat...

Page 10: ...b of persons Danger indicates a risk that threatens life and limb of persons Note indicates a risk of damage to property or the need to proceed with special care Information indicates additional infor...

Page 11: ...ltage fluctuations 6 10 Frequency Hz 50 60 Max power consumption W max 120 W Main fuse rating at 230 V A T T 6 3 A Main fuse rating at 110 V A T T 6 3 A Touch screen inches 7 in Dimensions Basic unit...

Page 12: ...raJet 10 G5 1 8 DANGER Electric current Connect the machine only to a grounded electrical outlet with a protective earth conductor contact Any intervention in the electrical electronic part of the uni...

Page 13: ...g on the country of delivery and the delivery agreements Remove the packaging Use a lifting vehicle to move the machine on the pallet WARNING Overturning parts with improper transport Severe injuries...

Page 14: ...our supplier or insurance provider immediately Please specify the serial number of the machine when you make a complaint You can find this serial number on the rating plate at the rear of the machine...

Page 15: ...luded in the delivery and must be mounted To order additional accessories and replacement parts contact your supplier Only approved products have been tested for use with this machine Calibrated test...

Page 16: ...t 10 2 4 2 3 Weight and Dimensions excluding pallet and transportation rails approx 110 kg including pallet and transportation rails approx 150 kg 2 4 Installing the Machine Weight and dimensions Lift...

Page 17: ...Hardness Tester Startup DuraJet 10 2 5 Loosen the four fastening screws 1 Use a crane to lift the machine off the pallet by the ring screw...

Page 18: ...RNING Dropping parts Severe injuries of head and limbs When using a crane for lifting never exceed the maximum lifting capacity of the rope or chain Ensure that nobody stays under the suspended load P...

Page 19: ...ies flat on any surface when the feet are not attached The bench on which the machine is installed must meet the following requirements The bench must be level and have a height of approx 700 mm It mu...

Page 20: ...tended to optimize operation During installation ensure that the work station has adequate lighting Avoid direct glare dazzling light sources within the operator s line of vision and reflected glare r...

Page 21: ...the connector of the fixed control unit cable into the connection on the control unit Ensure that the control unit cable is firmly screwed into place Plug the power cable into the mains connection Plu...

Page 22: ...d shortly afterwards by the main menu The default language of the software is English If you want to use the software in a language other than English you must configure this first Select the button w...

Page 23: ...column Select Time or Date Enter the current data and time in the numeric box Touch the button to abort the input Touch the button to confirm the input Touch the and buttons to move the cursor Touch...

Page 24: ...utton DANGER Risk of crushing from dropping test unit Crushed hands arm or fingers Keep your hands away from the area around the moving test unit Use the Nose Cone Up button on the control unit to mov...

Page 25: ...Hardness Tester Startup DuraJet 10 2 13 1 Screws 2 Allen wrench socket head wrench Use the allen wrench supplied to loosen the three screws Removing the nose cone...

Page 26: ...Hardness Tester Startup DuraJet 10 2 14 Remove the nose cone Inserting the indenter...

Page 27: ...Hardness Tester Startup DuraJet 10 2 15 Insert the indenter...

Page 28: ...uraJet 10 2 16 Use the socket wrench provided to secure the indenter NOTE Risk of damage Risk of damaging the unit or the indenter Do not overtighten the indenter Do not tighten the indenter too firml...

Page 29: ...Hardness Tester Startup DuraJet 10 2 17 Place the nose cone over the indenter so that the indenter is visible from the front...

Page 30: ...Hardness Tester Startup DuraJet 10 2 18 Correct positioning of the indenter and nose cone ensures precision testing...

Page 31: ...switch to the ON position The hardness tester is supplied with calibrated factory settings To ensure correct testing you should have your machine calibrated by an authorized institute manufacturer or...

Page 32: ...he test anvil Operation is controlled via the control unit The control unit is equipped with an EMERGENCY OFF button for shutdown The machine stand is made from grey cast iron The stand contains all e...

Page 33: ...ase when not in use in order to avoid damage The machine has the following ports 2 x USB 1 x control unit socket connection 1 x serial RS232 USB RS232 adapter 1 x Ethernet interface 1 x hardware inter...

Page 34: ...when using sharp objects Use your finger or a touch pen for data input Use your finger or a touch pen for input Use only genuine EMCO TEST accessories The three buttons Nose cone up Nose cone down an...

Page 35: ...the safety equipment of the unit without authorization An EMERGENCY OFF button 1 sits on the left side of the control unit as a safety device If you press this button the current operation is cancell...

Page 36: ...light is dimmed 4 2 Touch Screen The control unit display is a so called touch screen You can operate the touch screen by selecting the buttons with your finger or with a suitable touch pen Your fing...

Page 37: ...character to the right completes the entry You can enter or edit text with the alphanumeric keyboard moves one character to the left moves one character to the right switches between lower and upper c...

Page 38: ...input Emergency OFF is active no operation or movement of the machine possible Shows that selections are active in a menu tab page Opens the main menu Measuring Opens the measuring sequence start scr...

Page 39: ...version is active the test method and the converted method Shows warnings for example Conversion boxes or values below and above the selected hardness line Start measurement Starts a test when the wor...

Page 40: ...ens the menu to output the list as csv file or pdf report at the selected drive define the drive at settings at a connected USB flash drive or to print it on a connected printer The progress bar indic...

Page 41: ...Hardness Tester Basic Operation DuraJet 10 4 6 The buttons take you to the following menus Measuring sequence menu Main menu Archive menu Menu types...

Page 42: ...nhanced operation chapter gives a further description of the setting options Start testing In the Sample menu select the Standard option from test data management In the Test method menu select Single...

Page 43: ...onversion is selected Select the Limits menu Actuate the slide switch at Limits Touch the value The numeric keypad opens for input Enter the required value at Minimum Enter the required value at Maxim...

Page 44: ...u 2 Actuate the slide switch at Component correction 3 Select the shape Convex cylindrical or Convex spheric Touch the value at Diameter in mm The numeric keypad opens for input 4 Enter the required v...

Page 45: ...d the test unit stops automatically 1 Touch screen 2 USB connection 3 Start Testing button 4 Nose Cone Down button 5 Nose Cone Up button 6 EMERGENCY OFF button 7 LED indicator lamp Select the Start me...

Page 46: ...Hardness Tester Basic Operation DuraJet 10 4 11 Measurement starts automatically if the Auto Start function is activated after clamping The function can be found at Settings...

Page 47: ...all values measured as standard are displayed Press the Measuring profile button to change to the measuring profile view shows a line diagram of all previously measured values In addition all results...

Page 48: ...3 The function Auto start after clamping can not be used in a measurement without nose cone You must therefore lower the test unit with the Nose cone down button The test unit moves slower in this met...

Page 49: ...rom the area around the moving test unit In an emergency press the EMERGENCY OFF button to stop the unit immediately Approach the test unit with the Nose cone down button as closely as possible to the...

Page 50: ...achine 5 1 Opening the setting menu Select the button with your finger or with the touch pen The following screen appears on the touch screen monitor Select the button Settings The following screen ap...

Page 51: ...ping Measurement is triggered automatically after the workpiece has been clamped Fast mode not corresponding to standard Permits faster test cycles the times can be reduced to 0 1 seconds the forces a...

Page 52: ...e test procedure for example the Rockwell button Preload 1 main load and preload 2 of the test procedure are displayed Touch the numeric value for example Holding time preload 1 in sec The numeric key...

Page 53: ...shown here Number of measurements The number of measurements performed with the unit is shown here Error list All system errors are listed here The Modules submenu shows the following information Mod...

Page 54: ...an be filled for each measurement data group in the workflow step Sample and be output with the test report Touch the button to clear the boxes User boxes menu Press the blank box below one of the 10...

Page 55: ...Specify delimiter and output format Touch Adapt export to select the columns you want to export Export menu 5 5 Report In the Report menu you can select the information you want to show in the report...

Page 56: ...name Press the button to accept the name The new name is defined and is used You can enter a logo in your report The logo must exist as a bitmap file in a USB flash drive in the root directory and hav...

Page 57: ...An example of a report printout is provided below 1 Headlines 2 Company logo 3 Test method conversion limits 4 Statistical trend line bar chart statistical analysis 5 Result list 6 Footer with signatu...

Page 58: ...ork administrator for information Network menu 5 7 Printer A printer can either be connected directly to the hardness testes via USB or if the printer has a fixed IP address via a network Please conta...

Page 59: ...of damage Always perform calibration in unclamped state otherwise there is already a force that acts on the load cell Place a workpiece on the load cell as an intermediate layer and set the display of...

Page 60: ...ed just above the measuring device approximately 0 5 mm Select the Start menu Depth probe menu After the set load has been reached a text message appears below the progress bar prompting you to perfor...

Page 61: ...values can be output as a csv file or be generated as a report and subsequently be saved as a PDF file or be printed The contents of the report can be defined in the Settings menu at Report Next assi...

Page 62: ...ouch to delete the measured value After you have deleted a value all subsequent values are re numbered Touch the button to delete the entire list of measured values Touch the button The following mess...

Page 63: ...t idle for a long period of time ensure that it is protected from dust and dirt and lightly oil the anvil before moving the test unit down the next time it is used NOTE Risk of damage Damaging the tou...

Page 64: ...Various USB devices can be connected to the USB port 1 USB flash disk USB stick USB printer USB hub USB RS232 adapter Bar code QR code scanner with USB connection accessory Contact your supplier for d...

Page 65: ...d Nose cone clamped are provided The intended field of application for this option is for example the integration of a DuraJet G5 into a production plant If this option is ordered the shipment additio...

Page 66: ...ition the the standard scope of supply of a DuraJet G5 the following parts are enclosed 1x activation plug 1x blank plug Instructions for wiring and cable routing The 24VDC power supply line pin 1 is...

Page 67: ...With a minimum cross section of 1 5mm the maximum length of the cable is 100m Cable length of more than 100m are not permitted The power applied at the interface connector must never be used to feed o...

Page 68: ...re applicable at the location where the machine is operated The external machine control system EMERGENCY STOP and Z axis downward or clamping must satisfy at least PL d to EN 13849 1 Safely de energi...

Page 69: ...terface must be installed in the machine For this option the DuraJet G5 is equipped with an additional interface at the rear of the machine stand The foot switch can be connected via this interface Th...

Page 70: ...ies DuraJet 10 7 7 The fuse cover 1 sits between the main switch with the green indicator lamp and the mains connection Turn the main switch to OFF Unplug the power cable Carefully pry out the fuse co...

Page 71: ...verse sequence of the removal Ensure that the two fuse clips are slightly pressed together when you insert them into the housing Plug the power cable into the mains connection Turn the main switch to...

Page 72: ...Hardness Tester Startup and Retooling with Optional Accessories DuraJet 10 7 9 Tester without the test anvil provided Mounting a new test anvil...

Page 73: ...Hardness Tester Startup and Retooling with Optional Accessories DuraJet 10 7 10 Insert the new test anvil into the space provided on the machine...

Page 74: ...t 10 7 11 Unit with new test anvil and round component 7 6 Test Methods and Indenters HRA 120 V HR15N 120 V HRB 1 16 HR30N 120 V HRC 120 V HR45N 120 V HRD 120 V HR15T 1 16 HRE 1 8 HR30T 1 16 HRF 1 16...

Page 75: ...30 HBT 2 5 31 25 HBT 2 5 62 5 HBT 2 5 187 5 HBT 5 125 HRZ HR 2 10 HR 2 20 HRY HR 2 40 HR 2 120 HRX 1 49N 5 mm 2 132N 5 mm 3 358N 5 mm 4 961N 5 mm The results are displayed in N mm 2 Explanation of sy...

Page 76: ...f the error list the software version and the measured value count to your service partner Touch OK to open the error list Alternatively you can open the error list in the settings via the General men...

Page 77: ...Hardness Tester Messages and Problems DuraJet 10 8 2 Many error messages can be eliminated by restarting the machine Contact your supplier if the error persists after you have restarted the machine...

Page 78: ...en appears on the touch screen monitor Touch Info The current software version and the serial number are shown here Use the main switch to turn the machine off The green pilot light switches off Wait...

Page 79: ...ow step Testing Upper end position reached if the Nose cone up does not work Change to the workflow step Testing to activate the measuring mode Lower the test unit with the Nose cone down button The s...

Page 80: ...unit up Upper Position reached Move Down Test Unit Use the Nose Cone Down button on the control unit to move the test unit down No Results in Measurement List Data Export not possible Proceed with te...

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