www.instron.com
Industrial Products Group
Model KPX Static Hydraulic
Universal Testing System
System Concepts Manual
M47-17036-EN Revision A
The difference is measurable
®
Page 1: ...www instron com Industrial Products Group Model KPX Static Hydraulic Universal Testing System System Concepts Manual M47 17036 EN Revision A The difference is measurable...
Page 2: ...y 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 produc...
Page 3: ...e 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 preventio...
Page 4: ...ast 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 devi...
Page 5: ...head 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 b...
Page 6: ...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 possib...
Page 7: ...5 Chapter 2 Installation Notes 17 Existing transducer rationalization 17 Computer system ethernet card availability 17 Interconnections 18 Hydraulic interconnections 18 Electrical interconnections 20...
Page 8: ...42 Hydraulic power supply 42 Reservoir 42 Pump and motor 44 Manifold assemblies 45 Servo manifold assembly 45 Lifts and locks manifold assembly 46 Lock cylinder pressure switch 46 Pressure settings 46...
Page 9: ...ystem 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 t...
Page 10: ...es 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 Instr...
Page 11: ...000KPX 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 cylin...
Page 12: ...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...
Page 13: ...n 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 fou...
Page 14: ...lp 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...
Page 15: ...stem be calibrated when it is installed or when it is moved or relocated Instron calibrates the system at the factory and provides a record of readings for the load cell This frame may be verified on...
Page 16: ...Chapter 1 Introduction 16 M47 17036 EN This page is intentionally blank...
Page 17: ...This is often preferable because it will allow using the instrument on your existing system until the new system is installed Computer system ethernet card availability The system uses an Ethernet Fr...
Page 18: ...een the HPS and the frame Multiple connections may be necessary depending on system configuration or options purchased Table 1 provides the connection information Table 1 Hydraulic connections between...
Page 19: ...nections Product Support www instron com Figure 3 HPS connection panels Electric connections A through F Hydraulic connections 1 through 6 typical connections shown not all connections may be used by...
Page 20: ...S emergency stop cable male 6 pin HPS control box typically hardwired Connection F on HPS connection panel HPS cable male 14 pin Connection A on rear of 59 Series control unit Connection A on HPS conn...
Page 21: ...on rear of Expansion Channel Module box 1 If the position cable was not connected to the position encoder as stated in Chapter 4 of the System Pre Installation Manual supplied separately then the pos...
Page 22: ...system i In Windows XP it is found under Start Control Panel Select the network card associated with the EFI right click on it and select Properties The Properties window will open Select Internet Pro...
Page 23: ...23 Interconnections Product Support www instron com Figure 5 Local area connection properties Figure 6 Internet protocol properties Windows XP operating system Windows 7 operating system...
Page 24: ...verify the correct controller is selected Figure 7 vi Select Ethernet as the Interface type Figure 8 a third box appears for the MAC address vii In addition to an IP address the EFI uses a unique MAC...
Page 25: ...b For systems with Bluehill software perform the following i Start Bluehill ii Select the Admin button Ensure no methods are open iii On the Admin page select Configuration Figure 8 Partner interface...
Page 26: ...abel affixed to the front of the 59 Series control unit usually below the ethernet connection The first six digits 00 90 C2 indicate that the EFI is an Instron device The last six digits are unique to...
Page 27: ...he test space verify that the grip brackets have been removed from between the upper and lower grips 2 Locate the Operating Instructions that were supplied with the system You will be required to refe...
Page 28: ...l support the crosshead during this portion of the procedure and it is imperative that they are located as shown and are tightened to the required torque see Table 4 b For 2000KPX frames Remove the co...
Page 29: ...orm the System Startup procedure provided in Chapter 3 of the Operating Instructions that were supplied with the system 7 Check that the frame is enabled If the frame will not enable see Troubleshooti...
Page 30: ...the crosshead support collars to the columns Tighten the cap screws to the torque specified in Table 4 use hex bit socket specified in Table 4 and torque wrench 10 For frames with a J1 style crosshea...
Page 31: ...on the frame once the frame is in place and ready for operation Mounting hardware is supplied Slide the covers down over the ends of the crosshead from the top Secure in place with cap screws refer t...
Page 32: ...ost testing regardless of whether or not the accessory is being used for a given test The semi permanent mounting is typically done for accessories that are large enough to make continuous installatio...
Page 33: ...scription of crosshead styles see Crosshead on page 33 For procedures on crosshead adjustment refer to information provided in the System Operating Instructions supplied separately Crosshead The cross...
Page 34: ...pport collar 7 Base 8 Flexible track 9 Crosshead clamping mechanism see Figure 15 for specific styles 10 Rod 11 Pre load device 12 Guide plate 13 Bearing and wiper assembly 14 Load cell 15 Frame manif...
Page 35: ...it that is mounted to the frame The hydraulic lift and lock cylinders receive hydraulic pressure from the HPS A separate manifold directs the flow of oil to the cylinders from the HPS For more informa...
Page 36: ...s it is a direct force measurement Caution The controlling software is equipped with overload protection for the load transducer The overload protection should prevent damage to the load transducer du...
Page 37: ...otation linear guidance device to maintain load train alignment and to reduce the effects of torsion and bending on the specimen The anti rotation device consists of a guide plate 12 Figure 14 on page...
Page 38: ...em provides high temperature testing capability The furnace system includes a mounting bracket for mounting to the frame typically on the base The mounting bracket permits rotation of the furnace so t...
Page 39: ...or card transducer signal conditioning cards a frame interface board a 24 VDC power supply for the frame interface board a fused power entry module a relay board and an optional analog outputs card wh...
Page 40: ...en conditions are normal the T indicator is green and the A indicator is blinking red HPS A A female 14 pin interface that connects the HPS to the control unit Position H A female 9 pin interface that...
Page 41: ...ter system please refer to the computer manufacturer s literature that was provided with the system For more information on the controlling software refer to the software s On line Help system or to t...
Page 42: ...electric motor When the HPS is on the hydraulic cylinder should be positioned so that the piston is neither fully retracted nor fully extended When the hydraulic cylinder is in either of these conditi...
Page 43: ...should never exceed 80 deg C 176 deg F Consult factory for operating conditions that result in oil temperatures that exceed 80 deg C 176 deg F Oil temperature is monitored by a temperature switch ins...
Page 44: ...voir through the high pressure hydraulic hoses and into the hydraulic cylinder As the controller directs the frame to place load on a specimen the HPS builds pressure in the system and the piston is a...
Page 45: ...Oil filter A high pressure 3 micron oil filter is mounted on the manifold to provide the necessary filtration for the high performance hydraulic components in the system Oil passes through this filte...
Page 46: ...to the controller that the crosshead is unclamped When this is the case the system controls will not permit operation of the frame to jog the hydraulic cylinder or run a test until the crosshead is lo...
Page 47: ...ling software Frame and or 59 Series control unit are not receiving power Check incoming power supply for both frame and control unit A fuse could be blown Check all system fuses refer to Replacement...
Page 48: ...shead the lock cylinders are unclamped Be sure the locks control switch is set to CLAMP 5 Software posts an error message stating Control Panel Watchdog Timeout Communication has been lost with the us...
Page 49: ...e indicates a Hard Stop or other error for no apparent reason Disconnect switch not ON or customer s power supply not ON Turn the disconnect switch to ON Turn the customer s power supply to ON Set spe...
Page 50: ...stem Operating Instructions supplied separately The HPS was not able to build enough pressure to clamp the crosshead lock cylinders before the Jog controls were used Refer to information provided in t...
Page 51: ...51 Frame Product Support www instron com Figure 20 Controlling software error messages Figure 21 Internet protocol properties Partner Software Bluehill Software...
Page 52: ...Chapter 3 Additional System Details 52 M47 17036 EN This page is intentionally blank...
Page 53: ...ms require minimal parts replacement If a part does require replacement only the following parts can or should be replaced by the customer Fuses All other parts replacement should be done by an Instro...
Page 54: ...ructions supplied separately 2 Check the indicators on the SERVICE display of the 59 Series control unit see page 40 they should be lit If the indicators are not lit then the power entry module fuses...
Page 55: ...d self identifying and rationalized Approximate resistances can be provided to allow confirmation of a possible broken gauge or a faulty connector or cable If a strain gauge in a cell has been badly o...
Page 56: ...Chapter 4 Parts Replacement 56 M47 17036 EN This page is intentionally blank...
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