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Chapter 4

Maintenance

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General maintenance recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

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Preventative maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

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Make daily checks of system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

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Remove and install console covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

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Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

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Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

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Hydraulic power supply (HPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

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Ancillary parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

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Consumable parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

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Spare and replacement parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Warning

General maintenance recommendations

Only the maintenance procedures 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 appropriate personal protective equipment when preparing, operating and

maintaining this equipment. Personal protective equipment should include, but is not

limited to, eye protection 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.

Содержание 1000KPX-J3D

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 69: ......

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

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