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Instron 1000KPX-J3D, Operating Instructions Manual

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Instron 1000KPX-J3D Operating Instructions Manual Download Page 64

Chapter 4: Maintenance

64

M47-17035-EN

Ancillary parts

KPX systems are provided with several operating tools and other accessories that are either: required to 
complete installation of the frame; required for use or maintenance of frame; or required for set up of 
accessories on the frame.  These ancillary parts are included with the frame upon delivery.  Ancillary 
parts for the various KPX systems are listed in 

Table 14

.  Be sure to keep these ancillary parts in a safe 

place so they do not get misplaced.

Table 14.    Ancillary parts list.

Description

Location or Purpose

Frame Model

Part Number

1

Quantity

Hex-bit socket, 27 mm,
3/4 in square-drive

Loosen the clamp bolts during frame 
installation

600KPX-J3

300-8875-9429

1

Socket, 36 mm x 1 in drive 
6 point  impact

Loosen the clamp bolts during frame 
installation

1000KPX-J3
1500KPX-J3

300-8875-9362

1

Hex stock, 36 mm, 
100 mm (4 in) long

227535-1

1

Spanner wrench

Loosen the clamp bolts during frame 
installation

2000KPX-J3

300-8875-9390

1

Socket, 36 mm x 1 in drive 
6 point  impact

300-8875-9362

1

Hex stock, 36 mm, 
100 mm (4 in) long

227535-1

1

Socket, 8 mm,
3/8 in square-drive

Tighten and loosen jackbolts of 
Superbolt fasteners on crosshead

600KPX-J1

300-8875-9241

2

Ratchet wrench,
3/8 in square-drive

Loosen various fasteners

600KPX-J1

300-8875-9352

1

Socket, 10 mm,
1/2 in square-drive, deep impact

Tighten and loosen jackbolts of 
Superbolt fasteners on crosshead

1000KPX-J1
1500KPX-J1

300-8875-9416

2

Ratchet wrench,
1/2 in square-drive

Loosen various fasteners

1000KPX-J1
1500KPX-J1

300-8875-9376

1

Torque wrench, 
3/8 in square-drive
14-115.8 N-m (8.3-83.3 ft-lbs)

Tighten various fasteners

600KPX-J1
600KPX-J3

300-8875-9277

1

Torque wrench, 
1/2 in square-drive
47-210 N-m (30-150 ft-lbs)

Tighten various fasteners

1000KPX-J1
1000KPX-J3
1500KPX-J1
1500KPX-J3
2000KPX-J3

300-8875-9281

1

Hex-bit socket, 5/16 in,
3/8 in square-drive

Tighten and loosen the crosshead 
support collars

600KPX-J1
600KPX-J3

300-8875-9428

1

Hex-bit socket, 5/16 in,
1/2 in square-drive

Tighten and loosen the crosshead 
support collars

1000KPX-J1
1000KPX-J3

300-8875-9288

1

Hex-bit socket, 3/8 in,
1/2 in square-drive

Tighten and loosen the crosshead 
support collars

1500KPX-J1
1500KPX-J3
2000KPX-J3

300-8875-9287

1

Hex key set, 13 piece, 
0.050 - 3/8 in ball end

Tighten and loosen various fasteners

All

300-8875-1958

1

Summary of Contents for 1000KPX-J3D

Page 1: ...www instron com Industrial Products Group Model KPX Static Hydraulic Universal Testing System Operating Instructions M47 17035 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: ...cifications 19 Use limits 19 Frame 20 Hydraulic power supply physical dimensions 24 59 Series control unit 24 Environmental conditions 25 Heat load 25 Noise level 26 Chapter 3 Operation 27 Operation o...

Page 8: ...ylinders of J3 style crosshead 56 Clean the columns 57 Hydraulic power supply HPS 58 Check the oil cleanliness 58 Add oil to reservoir 58 Equipment and supplies required 58 Recommended procedure 58 Ch...

Page 9: ...ion Manual Your system 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...

Page 10: ...r provide users with great flexibility in the specimen size that can be tested and in the grips fixtures and extensometry that can be used for the test System components Model KPX systems consist of F...

Page 11: ...PX 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 cylinders...

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: ...ition 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 found on...

Page 14: ...nd Table 1 to identify components of the frame For proper operation of the system it is important to be able to identify and to understand the basic function of these components Figure 2 KPX frame com...

Page 15: ...tyle and J3 style crossheads The vertical opening of the test space can be adjusted Refer to Change height of test opening J1 style or J3 style crosshead on page 33 for more information For J4 style c...

Page 16: ...ses control components that receive and process data from the various system transducers communicate with the system s controlling software and provide feedback to the system s servo valve to operate...

Page 17: ...an Instron service engineer Eye protection Indicates that a flying debris hazard exists either from specimen failure or improper use of system components Wear eye protection or use protective shields...

Page 18: ...any aspect of the product documentation Please email info_dev instron com with your comments System verification Caution System verification is vital to ensure the accuracy of your calibration Curren...

Page 19: ...injury and guard the equipment Instron offers safety rated guards for this purpose Please contact your local Instron representative for more information The system must not be used as a press The syst...

Page 20: ...xperience sections of this table should not have access to the system Table 4 Use limits of the testing system Continued Figure 3 KPX specification measurements G E A B F For legend refer to Table 5 C...

Page 21: ...1041 to 2540 mm 41 to 100 in 1626 to 3226 mm 64 to 127 in 1626 to 3226 mm 64 to 127 in 1295 to 3226 mm 51 to 127 in J4A N A N A N A N A 1608 to 2217 mm 63 3 to 87 3 in B Horizontal Test Width J1 J3 76...

Page 22: ...factory Cyclic Test and Frequency Limits Capable of tension tension or compression compression cyclic testing only Cyclic tests are limited to ramp type waveforms as defined within the materials testi...

Page 23: ...efer to the appropriate drawing for your model and its configuration 7 Weight does not include grips fixtures HPS or control equipment 8 C3 Hydraulic cylinder position Speed measurement high resolutio...

Page 24: ...al Signal Processor 32 bit floating point Self test diagnostics Real time closed loop control Real time data acquisition Data Transfer to Computer 1000 Hz Transducer Inputs Standard Instron rationaliz...

Page 25: ...ull load per hour Table 8 Recommended environmental conditions Operating Temperature 10 to 38 deg C 50 to 100 deg F Storage Temperature 40 to 66 deg C 40 to 150 deg F Humidity 10 to 90 non condensing...

Page 26: ...e does not exceed 63 Pa Since many variables such as room layout affect noise levels it can not be assumed that these readings will be equal to those in the field The noise level readings were taken a...

Page 27: ...and head protection Other types of personal protective equipment may also be needed You must perform your own risk assessment and take appropriate measures to protect yourself from harm Table 10 Cont...

Page 28: ...lling software If the display is showing live displays you must toggle back to show the soft key functions if you want to use a soft key button on the control panel For information on setting up the d...

Page 29: ...test once all test parameters are set Up and Down Arrow indicators show the type of test selected Up indicates tension and Down indicates compression If the hydraulic cylinder will not move AND the f...

Page 30: ...Chapter 3 Operation 30 M47 17035 EN Figure 5 User control panel...

Page 31: ...or accessory may be limited by the capacity of the bolt pattern being used Most bolt patterns can accommodate testing at full frame capacity Refer to the Note below Details of the bolt patterns provid...

Page 32: ...the controlling software 7 Open or create the desired test procedure in the controlling software 8 Check that the lights on the front of the 59 Series control unit are illuminated as follows T indicat...

Page 33: ...wrench supplied A ratchet wrench supplied Recommended procedure 1 Start the system see page 32 Start the HPS Always wear appropriate personal protective equipment when preparing operating and maintai...

Page 34: ...x bit socket and ratchet wrench Secure the crosshead support collars to the columns Tighten the cap screws to the torque specified in Table 11 use hex bit socket and torque wrench Figure 6 Superbolt t...

Page 35: ...cylinder until the crosshead is in the desired position 6 Tighten the crosshead Superbolts as follows a If the tensioners were removed from their studs for maintenance thread each tensioner onto a stu...

Page 36: ...View B Initial tightening of tensioners with 8 jackbolts View C Subsequent tightening of tensioners with 8 jackbolts View D Tightening of tensioners with 6 jackbolts Table 12 Crosshead jackbolt torque...

Page 37: ...is to be adjusted Turn knob counterclockwise to open and clockwise to close Procedures vary depending on frame model refer to the appropriate procedure for your model Caution Improper use of the cros...

Page 38: ...crosshead before you loosen the setscrews and remove the retaining rings Always reinstall the retaining rings as directed in this procedure Always close the RAISE and LOWER controls following an adjus...

Page 39: ...re the locks control valve is closed Open the RAISE valve for five seconds and then close it xi Loosen the setscrew 5 Figure 9 in each lift block 4 use 4 mm hex key xii Open the LOWER valve and allow...

Page 40: ...odily injury or damage to the frame Be sure that you understand and follow the directions given for placement of the crosshead support collars Be sure that the crosshead support collars are tightened...

Page 41: ...ation in the hydraulic components the cylinders will not retract at the same rate this is normal operation Close the LOWER valve xiii Remove each retaining ring 6 from its upper notch use 4 mm hex key...

Page 42: ...oning controls 1 Determine if it will be necessary to change the travel range of the crosshead to attain the desired test opening If the travel range does not need changed continue with step 2 If the...

Page 43: ...e and allow the lift cylinder extensions 1 Figure 10 on page 44 to drift down until the height adjustment pins can be inserted in the high range position Insert the height adjustment pins and close th...

Page 44: ...linders are fully retracted and then close the LOWER valve viii Open the RAISE valve to raise the crosshead approximately 12 mm 0 5 in from the fully retracted position and then close the RAISE valve...

Page 45: ...close it This fills the lift cylinders with oil 6 Loosen the crosshead support collars so that they can slide along the columns use hex bit socket and ratchet wrench Allow them to rest either on the t...

Page 46: ...sion Compression switch is in the correct position for the direction of the test 7 Determine the required test opening and stroke needed to complete the desired test Be sure to take into consideration...

Page 47: ...adjusting the crosshead be sure the crosshead is secured in place once it is positioned as desired When the frame is equipped with a J1 style crosshead be sure all Superbolt tensioners are tightened...

Page 48: ...FRAME button in the controlling software to shut down the HPS 3 Engage the Emergency Stop button 4 Exit the controlling software and any other software that is running Shut down the Windows Operating...

Page 49: ...seen if system power remains off over an extended period i e several days Even with this very slow drift rate multiple pinching hazards may exist on the frame depending on accessories mounted in the...

Page 50: ...Chapter 3 Operation 50 M47 17035 EN This page is intentionally blank...

Page 51: ...dures outlined in these instructions should be performed by the customer or their representative All other maintenance and repairs should be performed by Instron Service personnel only Always wear app...

Page 52: ...eanliness see page 58 HPS Clean the air filter see page 63 2 Electronics Clean the fans see page 55 2 Annually or once every 2000 hrs of operation 1 System Verify Calibrate system HPS Change the air b...

Page 53: ...too bright or too dim and that they don t flicker If any of these conditions exist this could indicate a problem with the power supply in the 59 Series control unit or with system main power customer...

Page 54: ...e the seven M6 button head cap screws 2 Figure 11 from the rear cover 1 Be careful of the electrical wires to the fan If necessary the wires can be disconnected at their connections When installing th...

Page 55: ...department as directed on page 18 for immediate assistance Frame Warning Inspect the hydraulic cylinder The hydraulic cylinder should be inspected at the frequency stated in the Preventative maintena...

Page 56: ...ch high loads contact your local Instron Services department as directed on page 18 for replacement parts 4 Inspect the hardened washer for damage or deformation Depressions in the washer surface of 0...

Page 57: ...ey are in contact with the bottom of the crosshead use hex bit socket and ratchet wrench Secure the crosshead support collars to the columns Tighten the cap screws to the torque specified in Table 11...

Page 58: ...d amount required depends on how much is needed to sufficiently fill reservoir for fluid specifications see Oil type and quantity on page 63 Recommended procedure Refer to Figure 12 on page 59 for ide...

Page 59: ...all the air breather filter onto the reservoir fill hole 9 Start the HPS and cycle the hydraulic cylinder through its full stroke a few times Fully retract the hydraulic cylinder Press the DISABLE FRA...

Page 60: ...Oil type and quantity on page 63 New oil filter element for Instron part number see Table 15 on page 66 New air breather filter for Instron part number see Table 15 on page 66 Recommended procedure Re...

Page 61: ...own b Put towels around the base of the oil filter to absorb leaking oil c Start the HPS and monitor the flow of oil from the vent plug Watch for air bubbles in the oil Run the HPS until there are no...

Page 62: ...2 Clean the area around the fill hole and air breather filter 7 and 6 to remove all dust dirt and grime 3 Remove the air breather filter from the reservoir fill hole push down and turn counterclockwis...

Page 63: ...rs Oil type and quantity The International Standards Organization ISO viscosity designation for oil appropriate to use in the reservoir is ISO VG 32 An ISO VG 32 grade oil was used to fill the hydraul...

Page 64: ...4 in long 227535 1 1 Socket 8 mm 3 8 in square drive Tighten and loosen jackbolts of Superbolt fasteners on crosshead 600KPX J1 300 8875 9241 2 Ratchet wrench 3 8 in square drive Loosen various fasten...

Page 65: ...rious fasteners All 300 8875 9290 1 1 Part numbers are listed for reference only Some parts can not be ordered using these numbers contact your local Instron Services department as directed on page 18...

Page 66: ...rts for your system In the event that your system requires replacement parts or if you choose to keep spare parts in stock please contact your local Instron Services department as directed on page 18...

Page 67: ...EN ISO 13849 1 2008 Safety of machinery Safety related parts of control systems Part 1 General principles for design BS EN 61326 1 2006 Electrical Equipment for Measurement Control and Laboratory Use...

Page 68: ...Appendix CE Certificate 68 This page is intentionally blank...

Page 69: ......

Page 70: ...Product Support www instron com...

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