Models ESM303 & ESM303H User`s Guide - Mark-10
Contents
1. 32 INSTALLING THE TRAVEL INDICATION OPTION 33 INSTALLING A COLUMN EXTENSION 35 MAINTENANCE AND 38 TROUBLESHOOTING ee deut asc 39 SPECIFICATIONS een aps e bU eee ee eee eee 39 DIMENSIONS ceteris esr eee eee 40 MIA GIG Models ESM303 amp ESM303H Test Stands User s Guide 1 OVERVIEW 1 1 List of included items P Description Qt ESM308 Qty ESM30H Force gauge mounting adapter Indicator load cell mounting adapter Force gauge indicator mounting screws 6 32 x 1 2 Indicator mounting screws 6 32 x 1 2 Limit switch thumb screws 6 32 x 5 8 Limit switch thumb screws 6 32 x 5 8 1 Control panel Control panel Control panel 1 1 shipped installed Screw for mounting control panel bracket Screws for mounting control panel bracket to column 1 4 20 x 1 with lock washers to adapter 8 32 x 1 shipped installed Screws for mounting adapter to frame 10 32 x 1 shipped installed Screws for mounting control panel to Screws for mounting control panel to bracket 1 4 28 x 1 1 4 with lock bracket 1 4 28 x 1 1 4 with lock washers washers Accessories kit Accessories kit 10 32F small hook 10 32F small hook 10 32 medium hook 10 32 medium hook 10 32F 2 diamete2. O b jjSettravelunttoinches S ooo c Entercyclemode o A 43s d _ Move crosshead down or left 4 O oet speed Inch format eXX XX Two leading zeroes and two decimal places required Millimeter format eXXXX X Four leading zeroes and one decimal place required Set cycles Format fXXXX leading zeroes required f0500 500 cycles Set lower travel limit _ SS Inch format g XX XXX _ Negative sign if applicable two leading zeroes and three a decimal places required oM Millimeter format g XXX XX _ Negative sign if applicable three leading zeroes and two i 2M decimal places required ge i Set upper travel limit gt h pi NER n 0 02 85 2 85 0200 3 200 3 Inch format h XX XXX _ Negative sign if applicable two leading zeroes and three oS h01 258 1 258 in decimal places required Millimeter format h XXX XX Negative sign if applicable three leading zeroes and two decimal places required Set travel unit to millimeters h 007 52 7 52 mm h010 70 10 7 mm SS Set crosshead speed to maximum speed 1 11 1 Set crosshead speed to minimum speed 1 Entertravellimtmode 0 Enter manualmode Z 3 o Transmit travel and force readings o Set
3. gt lt x 1 gt eo 9 18 233 2 oy i 7 60 193 0 z ee E 14 09 358 6 4 MIA GIG Models ESM303 amp ESM303H Test Stands User s Guide 13 2 ESM303H 10 32 UNF 2B X 0 350 DEEP X24 0 50 12 7 TYP 3 26 82 8 2 80 71 1 5 16 18 UNC 2B X 0 350 DEEP 3 0 21 2 76 538 MAX 1 02 25 9 3 86 98 1 29 54 750 3 5 16 18 UNC 2B 0 750 X4 28 23 717 1 DA ESIZIDS ER ER 2 Models ESM303 amp ESM303H Test Stands User s Guide 13 3 ESM303 002 1 2 3 Double Column Extensions optional 18 90 480 1 x2 29 30 744 2 X2 A gt Me a M A M M ed 7 y 9 20 10 510 5 I 30 58 776 7 A B 8 79 6 00 ESM303 002 1 223 3 152 4 14 79 12 00 ESM303 002 2 375 7 304 8 26 79 24 00 ESM303 002 3 CET tS MIA GIG 0 40 10 2 0 65 16 5 5 16 18 UNC 2B X 0 75 DEEP DETAIL A SCALE 2 1 0 25 6 2 52 13 1 o di 8 48 215 4 3 98 101 1 6 98 177 3 9 98 253 5 11 48 291 6 12 98 329 7 16 48 418 6 SECTION A A Models ESM303 amp ESM303H Test Stands User s Guide NOTE
4. LOAD HOLDING off BREAK DETECTION off PROFILE DEFAULT CONTROL CONSOLE BAUD RATE 115200 STOP BITS amp PARITY 8 1n UNIT in min KEYS auto FOLLOWME off PASSWORD 0000 off If the PROFILES function is installed the test stand will revert to the profile named DEFAULT This profile contains the factory settings listed above and may not be edited If the PROFILES function is not installed the display appears as follows Description Cycles through yes or no selections Returns to the Test Function Setup menu Exits the function without saving changes MIA GIG Models ESM303 amp ESM303H Test Stands User s Guide 4 17 Password NEW PWORD If desired a password can be set to prevent unwanted changes to test functions The password can be set to any number between 0000 and 9999 The default setting of 0000 indicates that the password is disabled and that the user can freely enter the Test Function Setup menu If misplaced or forgotten the password may be reset through a code activation process Details on this may be found in the Function Activation section Default setting 0000 off Available settings 0000 9999 NEW PWORD ESC 5 OPERATING MODES 5 1 Overview The ESM303 can be operated in several modes including combinations of these modes 1 FollowMe Mode Crosshead movement responds to pushing or pulling on the force gauge shaft or load cell Increasing force produces greater speed
5. 10 32 holes are provided 4 The viewing angle may be adjusted by loosening the lever in the rear of the bracket positioning the control panel and re tightening the lever MIA GIG Models ESM303 amp ESM303H Test Stands User s Guide 2 3 Connections and Outputs The following connections and outputs are supplied in the rear of the test stand as shown in the illustration below and the other end into a PC s USB port Refer to the next sub section for driver installation information T USB connector ds Outputs force only or force and travel data optional via USB Also allows u for PC control optional Plug one end of the USB cable into this connector AUX LIMITS N lt Auxiliary limit switch connector 2 For interfacing an external limit switch such as interlock for a machine guard door A pin diagram is shown in the next sub section PANEL Control panel cable connector Plug the cable into this connector POWER RATING 100 240 VAC 50 60 Hz 300 W Power switch M Refer to the Connecting Power sub section for important safety information 7U Power plug receptacle Plug the power cord in here Refer to the Connecting Power sub section for important safety information FUSE 4A SLO BLO 250 VAC Ss P 2 3 1 Auxiliary limit switch pin diagram ORIENTATION MARKER UPPER LI
6. at an increasingly faster rate If 00000 is reached the next number will be 99999 and continue decrementing Press and hold and simultaneously ENTR Returns to the Test Function Setup menu Exits the function without saving changes 4 3 2 Dwell Times HI R DWELL and LO L DWELL This setting corresponds to the amount of time in seconds for which the crosshead stops at the limit during a cycle sequence Individually set dwell times can be applied to the upper and lower or right and left limits Note The dwell time setting is unavailable for an auto return sequence If pressed and held for 2 seconds or longer the number of cycles will change to O Default setting O no dwell time Available settings 0 9999 9 Description Increases dwell time in increments of 1 Holding down will increment at an increasingly faster rate If 9999 9 is reached the next number will be 0 and continue incrementing Decreases dwell time in increments of 1 Holding down will decrement at an increasingly faster rate If 0 is reached the next number will be 9999 9 and continue decrementing Returns to the Test Function Setup menu Exits the function without saving changes 4 4 Travel Limits HI LIMIT RIGHT LM and LO LIMIT LEFT LM Travel limits may be programmed as specified distances either as upper and lower limits or right and left limits The crosshead stops when the distance limits have been reached Default settin
7. crosshead speed to programmed speed 1 1 111 Requeststandstatus Z MIA GIG Models ESM303 amp ESM303H Test Stands User s Guide q Request number of cycles completed r Requestnumberofcyclesset s Stopcsshead JJ t JjResetoydecouterto zero u Movecrosshead up or right 0 v Request upper travel limit w QRequestlowertravelimit S o x Request position O o z Resetposiontozero _ j 17 5 The transmission of ASCII p will return the stand status The following are the return codes and their definitions upper case Command BDescription Ss Crosshead status D Crosshead moving down Operating mode 5 10 2 Force gauge indicator commands Limit switch status Mark 10 force gauge and indicator commands are compatible with the ESM303 To open this channel of communication use a forward slash no quotations followed by the commands followed by a back slash V to close the channel Refer to the instrument s user s guide for a complete list of commands The following gauge indicator commands upper case do not require slashes P Steps through Normal mode Tension Peak mode and Compression Peak mode R Zeroesthe instrument zeroes all modes The ESM303 is compatible with legacy Nexygen TCD software no
8. follows 1 The first digit of the request code will be flashing Press to increment the digit Pressing when the number 9 is displayed will cycle to O 2 Press gt to advance to subsequent digits and change them in the same manner 3 Press ENTR when complete If an incorrect code is entered the display will revert to the Function Activation menu without installing the function If this happens the above process must be repeated The Function Activation menu also includes a utility for disabling the password Scroll through the functions until the following is displayed DISABLE PASSWORD ESO Press ENTR to generate the request code then follow the authorization code procedure indicated above 6 3 Demo Mode All ESM303 test stands are shipped in Demo Mode which provides full functionality of all available functions for an evaluation period of 160 operating hours When this period has expired an additional 160 hours may be added via the authorization code procedure indicated above NAGI E ER S EJ Models ESM303 amp ESM303H Test Stands User s Guide 8 TRAVEL INDICATION OPTION RETROFIT Retrofitting an ESM303 test stand with the AF009 travel indication option requires hardware installation and entering an activation code The instructions below reference Model ESM303 however the process is similar with the ESM303H 8 1 Hardware installation 1 Power off the test stand and disconnect all cable
9. settings CONSOLE PC Description Cycles through the available settings Returns to the Function Setup menu xits the function without saving changes m 4 10 Baud Rate This setting corresponds to the baud rate setting of the computer program controlling the test stand Default setting 115200 Available settings 1200 2400 4800 9600 19200 38400 57600 115200 BAUD RATE 115200 Description Cycles through the available settings Returns to the Function Setup menu Exits the function without saving changes DA ESIZIDS ER Models ESM303 amp ESM303H Test Stands User s Guide 4 11 Stop Bits and Parity STOP amp PAR This corresponds to the stop bits and parity settings of the computer program controlling the stand Default setting 8 1n Available settings 8 1E 8 stop bits 1 stop bit even parity 8 10 8 stop bits 1 stop bit odd parity 8 1 8 data bits 1 stop bit no parity 8 2n 8 data bits 2 stop bits no parity 1E 7 data bits 1 stop bit even parity 10 data bits 1 stop bit odd parity 2E 7 data bits 2 stop bits even parity 20 data bits 2 stop bits odd parity 2n 7 data bits 2 stop bits no parity STOP amp PAR ESC 4 12 Units of Speed UNITS This setting corresponds to units of speed measurement Default setting in min Available settings in min mm min Description Cycles through the available settings Returns to the Test Function Setu
10. testing Extra bodily protection should be worn if a destructive failure of a test sample is possible Keep away from moving parts of the test stand Loose articles of clothing should not be worn Long hair should be covered to avoid a hazardous situation A Crush Hazard warning label is located on the base of the test stand It appears as follows WARNING CRUSH HAZARD KEEP CLEAR OF TEST AREA Definition Keep any body parts and clothing clear of the area between the base of the test stand and the moving crosshead In those applications where samples can shatter or other applications that could lead to a hazardous situation use of a machine guard is strongly recommended When the test stand is not in use ensure that the power is turned off to prevent accidental engagement of any of the controls Models ESM303 amp ESM303H Test Stands User s Guide 3 2 Controls EMERGENCY STOP DOCS GCs 4 EH SOFT KEYS Functions are determined by the corresponding text on the display 2 UP RIGHT Commences movement in the up ESM303 or right ESM303H direction 3 5 Stops crosshead movement 4 DOWN LEFT Commences movement in the down ESM303 or left ESM303H direction FollowMe Enables force activated crossh
11. their positions by loosening the thumb screws repositioning and re tightening the thumb screws as illustrated below GG TiTa 1 ESM303 ESM303H 5 4 3 Overload Protection The available interface cable is required for overload protection of a Mark 10 force gauge or load cell If overload protection is installed and enabled the crosshead will stop when the programmed percentage of full scale of the instrument has been reached When overload protection is installed if the cable is disconnected and or if the instrument is powered off an error message will appear Plug in the cable and or turn on the instrument to clear the message Note When the crosshead is moving in the tension direction only the tension overload setting is active When the crosshead is moving in the compression direction only the compression overload setting is active 5 5 Auto Return Mode In this mode the crosshead moves at the set speed to whichever limit it encounters first and stops Then the crosshead returns at maximum speed to the opposite limit whichever occurs first and stops Press either directional button to initiate an Auto Return sequence D ENEIES ER ER S Models ESM303 amp ESM303H Test Stands User s Guide The crosshead can be stopped at any time during an Auto Return sequence by pressing STOP To resume the test press either directional button Note If the crosshead has stopped at a soft limit the limit condition may be o
12. MIT 50 MAX LOWER LIMIT Note that when pins 1 and 2 are not connected the auxiliary limits are inactive When the 5 from pin 4 is connected to either pin 1 or pin 2 the respective limit becomes active and the crosshead is prevented from movement in that direction 2 3 2 USB driver installation To use this output install the USB driver provided on the Resource CD labeled Mark 10 USB Device Installation instructions may also be found on the CD or may be downloaded from www mark 10 com Caution Install the USB driver before physically connecting the tester to a PC with the USB cable MIA GIG Models ESM303 amp ESM303H Test Stands User s Guide Further instructions for configuring communication parameters may be found in the Test Function Setup section If PC control is used a full listing of available ASCII commands may be found in the Operating Modes section 2 4 Installing a force gauge or indicator with load cell 2 4 1 ESM303 Once the test stand is in a stable and secure position install a force gauge by mating the dowel pin in the force gauge mounting plate with the blind hole in the rear of the force gauge s housing Use the four thumb screws to secure the gauge Grips and fixtures may be threaded onto the force gauge and test stand base 2 4 2 ESM303H 1 Once the test stand is in a stable and secure position install an indicator via four thumb screws 2 Install a load cell to the crosshea
13. Models ESM303 amp ESM303H FORCE TEST STANDS User s Guide MARKEE Models ESM303 amp ESM303H Test Stands User s Guide Thank you Thank you for purchasing a Mark 10 ESM303 ESM303H Force Test Stand designed for producing up to 300 IbF 1 5 KN of tension and compression force The ESM303 ESM303H is an essential component of a force testing system typically also comprising a force gauge or load cell with indicator and grips With proper usage we are confident that you will get many years of great service with this product Mark 10 test stands are ruggedly built for many years of service in laboratory and industrial environments This User s Guide provides setup safety and operation instructions Dimensions and specifications are also provided For additional information or answers to your questions please do not hesitate to contact us Our technical support and engineering teams are eager to assist you Note Except where otherwise indicated references to ESM303 include models ESM303 and ESM303H Before use each person who is to use the test stand should be fully trained in appropriate operation and safety procedures TABLE OF CONTENTS OE E m 3 SETUP AND SAFETY eene 5 OPERATION BASICS 1 eee 11 TEST FUNCTION SETUP 1 essem 13 OPERATING MODES seem 24 FUNCTION
14. S DA ESIZIDS ER M AGE Mark 10 Corporation has been innovator in the force and torque measurement fields since 1979 We strive to achieve 100 customer satisfaction through excellence in product design manufacturing and customer support In addition to our standard line of products we can provide modifications and custom designs for OEM applications Our engineering team is eager to satisfy any special requirements Please contact us for further information or Suggestions for improvement DO ZN G4 Ee aE Force and torque measurement engineered better Mark 10 Corporation 11 Dixon Avenue Copiague NY 11726 USA 1 888 MARK TEN Tel 631 842 9200 Fax 631 842 9201 www mark 10 com 5 info mark 10 com REV 1115
15. ad motion 2 Momentary The crosshead will move only if the button is pressed and held Releasing the button will stop movement immediately NAGI E ER S EJ Models ESM303 amp ESM303H Test Stands User s Guide 3 Auto default Holding down the button for more than 0 5 seconds will enter Momentary mode at which time an audible indicator will sound and the LED indicator on the button pushed will be illuminated A short tap on the button will operate the test stand in Maintained mode Pressing STOP during Maintained mode will stop crosshead motion To resume the test press UP or DOWN again Pressing EMERGENCY STOP will immediately stop crosshead motion in any mode To release twist the button clockwise until it assumes its original position To resume the test press either directional button for two seconds Crosshead movement will take place until a limit has been reached If the crosshead has stopped at a soft limit the limit condition may be overridden by pressing and holding either directional button for two seconds 5 4 1 Travel Indication If installed the position is displayed in the upper left corner of the display The unit of measurement is dictated by the UNITS function To zero the value press the Zero Travel key The position will be retained during power cycles 5 4 2 Limit Switch Operation Limit switches allow the operator to set a location along the column at which point the crosshead will stop moving Adjust
16. alue Default setting 196 Available settings 0 100 FS 01 0 ESC 4 7 Load Holding This setting directs the test stand to dynamically adjust the crosshead position to maintain a programmed force The force is programmed as a set point in a Series 5 or 7 instrument refer to the user s guide for details If the CYCLING option has been installed load holding will be active for the period of time as defined in dwell settings If CYCLING has not been installed load holding will continue indefinitely Pressing STOP will end load holding NAGI E ER S 18 Models ESM303 amp ESM303H Test Stands User s Guide Default setting OFF Available settings ON OFF Description Cycles through the available settings Returns to the Test Function Setup menu xits the function without saving changes m 4 8 Break Detection 4 8 1 Setting This setting directs the test stand to stop when a sample break has occurred The test stand stops when the force has decreased to a specified percentage of peak Default setting OFF Available settings ON OFF BREAK DETECT ON Description Cycles through the available settings Returns to the Test Function Setup menu xits the function without saving changes m 4 8 2 Activation Threshold This setting corresponds to the force threshold after which the break detection function is active The threshold is provided to prevent false activation of the f
17. apitalized as shown in the figure above The set speed can be changed in Test Function Setup If enabled independent directional speeds may be set 5 2 Menu navigation At power up the display will show the operation screen for whichever mode was used last The display will appear as one of the following 1 Basic amp Auto Return Modes travel indication option not installed SPEED 0 00 menu min max SET 2 Basic amp Auto Return Modes travel indication option installed POSITION SPEED 1 275 0 00 menu min max SET 3 Cycling Mode travel indication option not installed CYCLES 00024 menu min max SET Note The min and max keys will not appear when a password has been set 4 PC Control Mode Appears the same as in Basic and Auto Return modes MIA GIG Models ESM303 amp ESM303H Test Stands User s Guide Enters Test Function Setup Sets speed to minimum speed Will not appear when a password has been set Sets speed to maximum speed Will not appear when a password has been set Sets speed to the programmed value Pressing menu will enter Test Function Setup If a password has been programmed the display will prompt the following PASSWORD ESC The password is a four digit number Press or to increment or decrement the number Once the complete password has been entered press ENTR If correct the display will enter the Test Function Setup menu If the password is in
18. been completed by pressing STOP A soft key labeled RESET will appear as follows At this point there are two options 1 Cancel the cycle sequence Press RESET to stop and reset the cycle sequence The cycle counter will revert to the number of cycles originally programmed 2 Resume the cycle sequence Press either directional button to resume Once the sequence has been completed the screen will revert to the number of cycles programmed originally To begin another cycle test press either directional button NAGI E ER S EJ Models ESM303 amp ESM303H Test Stands User s Guide Travel indication and limit switch operation is the same as in Basic Mode 5 Preload Mode In this mode the crosshead moves at the set speed or no greater than 10 in min 250 mm min until the programmed preload value has been reached If moving in the tension direction a tension preload is required If moving in the compression direction a compression preload is required When the preload is reached the sequence of events programmed in the Preload function occurs If the ZERO GO setting is selected and if the set speed is greater than 10 in min 250 mm min the crosshead speed will revert to this setting after the travel indicator is zeroed Note 1 Before the start of a preload sequence the crosshead must be positioned at either of the physical limit switches Note 2 Preload and Load Holding cannot be enabled simultaneously 5 8 Loa
19. brication 1 Power off the test stand and disconnect all cables 2 Remove the left sheet metal and electronics support plate as described in previous sections 3 Using a brush apply a small amount of general purpose bearing grease to the screw as shown in the image below D ENEIES ER ER S Models ESM303 amp ESM303H Test Stands User s Guide 4 Cycle the crosshead several times until the newly applied grease has been spread evenly over the length of the screw 5 Re install the hardware Be sure to position the upper limit switch above the crosshead and the lower limit switch below the crosshead before installing to the electronics support plate 10 2 Check for loosened grips and attachments daily Check to ensure that the grips attached to the force gauge and base plate are firmly secured Looseness could result in a potentially hazardous situation 10 3 Check for loosened components once per month 1 Remove the test sample from the test stand 2 Attempt to loosen subcomponents of the test stand ex fasteners brackets etc All components should be firmly attached If any looseness is detected stop using the test stand and contact Mark 10 or a distributor for instructions 10 4 Removing and replacing the Electronics Support Plate As described earlier most electronics are mounted to a support plate located along the left side of the column It is designed for quick removal and replacement in the event of servic
20. correct the display flashes INCORRECT PASSWORD and then reverts to Operating Mode 5 3 FollowMe Mode Crosshead movement responds to manually pushing or pulling on the force gauge shaft or load cell Increasing force produces greater speeds Ideal for quick positioning during sample loading and unloading To arm FollowMe mode press the FollowMe key The display appears as follows SPEED 0 00 FollowMe Active CAUTION Exercise extreme caution when handling low capacity force gauges or load cells as overload can occur If no force is detected for 5 seconds after pressing the FollowMe key the function becomes inactive and the display flashes FOLLOWME OFF If the FollowMe function has not been enabled in Test Function Setup pressing the key will not arm the function The display will flash NOT ENABLED If the FollowMe function has not been installed in the test stand pressing the key will not arm the function The display will flash NOT INSTALLED 5 4 Basic Mode The crosshead moves upward when UP is pressed and downward when DOWN is pressed When the crosshead is in motion an LED indicator on the button pushed will be illuminated The KEYS setting controls how crosshead movement responds to the push of either of the directional buttons The three settings are 1 Maintained The crosshead will move continuously once the button has been pressed Subsequently pressing STOP will stop crosshe
21. d Holding Mode In this mode the crosshead moves until the set point value programmed in the force gauge or indicator is reached The crosshead position dynamically adjusts to maintain a programmed force The force gauge or load cell s capacity should be as close as possible to the intended load for best performance In the instrument both set points must be set The upper set point refers to a force limit in the tension direction The lower set point refers to a force limit in the compression direction The opposite set point must be set to any value in the opposite measuring direction For example for a test requiring load holding at 10 IbF of compression force set the upper set point to 30 IbF tension as an example and the lower set point to 10 IbF compression If the CYCLING option has been enabled load holding will be active for the period of time as defined in the Dwell Time settings If CYCLING has not been enabled load holding will continue indefinitely Note Before the start of a preload sequence the crosshead must be positioned at either of the physical limit switches 5 8 1 Adjusting speed for sample stiffness variations An appropriate speed should be chosen for a given sample Fine tuning may be necessary to ensure optimal crosshead dynamic behavior Stiff samples require a lower test speed softer samples can be tested at higher speeds If the speed of approach is too high for a given sample stiffness the crosshead may over
22. d using the supplied hardware and insert the Plug amp Test connector into the indicator as shown in the image below 2 5 Installing an indicator load cell mounting kit optional for ESM303 The optional AC1062 mounting kit is available to mount a Series R01 or Series load cell force sensor and an indicator onto the crosshead instead of a force gauge To install follow these instructions 1 Remove the force gauge mounting plate by loosening the two 5 16 18 flat head screws as shown below 2 Install the indicator bracket onto the side of the crosshead utilizing two 10 32 flat head screws as shown below NAGI E ER S Models ESM303 amp ESM303H Test Stands User s Guide 3 Install the L bracket with the same two flat head screws as shown below 5 Mount the indicator utilizing the four provided thumb screws and insert the Plug amp Test connector into the indicator Orient the housing of the indicator such that the connector is pointed downwards Refer to the indicator s user s guide for details MIA GIG Models ESM303 amp ESM303H Test Stands User s Guide 2 6 Installing the 09 1214 09 1252 interface cable If using test stand functions requiring communication between the force gauge indicator and test stand such as data output overload protection preload etc connect the interface cable between the instrument s connector and the crosshead s connector This cable may be use
23. d with a Series 4 5 or 7 instrument Refer to the image below Or 09 1214 ESM303 09 1252 ESM303H Note The 09 1214 and 09 1252 cables power the instrument When connected the instrument automatically powers on when the test stand is powered on The instrument s AC adapter is not necessary under these conditions 2 7 Safety Proper Usage Typical materials able to be tested by the ESM303 include many raw materials and manufactured items such as springs metals plastics electronic components mechanical assemblies packaging materials and many others Items that should not be used with the ESM303 include potentially flammable substances or products items that can shatter in an unsafe manner and any other components that can present an exceedingly hazardous situation when acted upon by a force Ensure that the grip or fixture is positioned to ensure axial load with respect to the load axis of the load cell or force gauge When using a grip ensure that it secures the sample in such a way that it is prevented from slipping out during a test preventing a potential safety risk to the operator and others in the vicinity If using a grip or fixture from a supplier other than Mark 10 ensure that it is constructed of suitably rugged materials and components 2 8 Connecting Power Plug one end of the power cord into its receptacle at the rear of the stand and the other end into a wall outlet with local earth ground 3 prong connect
24. e 6 supplied screws as shown in the image below 4 Position the test stand vertically and reinstall the sheet metal covers as shown below DA ESIZIDS ER Models ESM303 amp ESM303H Test Stands User s Guide CAUTION Vertical column extensions present an increased tipping hazard It is strongly recommended that the base be fastened to a workbench Holes are supplied on the underside of the base Refer to the dimensional drawing for hole locations 9 3 Installing a double column extension optional Model ESM303 only The optional double column extension is shipped fully assembled To mount the test stand frame to the assembly locate the 6 thru holes match them up to the corresponding threaded holes on the underside of the frame and install the screws Refer to the image below 10 MAINTENANCE AND SERVICE The ESM303 should be operated in a dry and clean area Under these circumstances only a few periodic maintenance operations are required 10 1 Ball screw lubrication Periodic lubrication improves performance and increases the longevity of test stand components On average lubrication is recommended twice per year However the frequency should increase if the stand is operated in adverse environmental conditions including airborne dust temperature and humidity extremes and other factors Frequent test stand usage also necessitates more frequent lubrication Follow these instructions for proper ball screw lu
25. e or repair If instructed by Mark 10 or a distributor to remove and or replace this plate follow the instructions outlined in the Installing the Travel Indication Option section 11 TROUBLESHOOTING 1 The ESM303 displays several error messages as follows Error Message Description The force gauge or indicator is powered off not in the operating CHECK GAUGE mode or not connected to the stand Message appears when overload protection is turned on The stand is attempting to move the crosshead up or down but it cannot establish communication with the force gauge or indicator The communication settings in the instrument are not correct or the instrument is not in its normal operating mode The programmed overload percentage of the force gauge s or GAUGE OVERLOAD indicator s full scale has been reached Immediately reduce the force or adjust the overload settings M5 M7 V2 0 REQD A series 5 or 7 force gauge or indicator with firmware version 2 0 or later is required for proper operation of the selected functions GAUGE COMM ERROR DA ESIZIDS ER Models ESM303 amp ESM303H Test Stands User s Guide To clear any of the above errors press STOP The amber indicator in the STOP button will be blinking while the error message is displayed 2 The crosshead will move only in one direction or not at all Possible causes 1 Ensure all cables are plugged in properly as described in Setup and Safety section 2 Ensure t
26. ead positioning If this option is not installed the message NOT INSTALLED flashes Zeroes the travel display If this option is not installed the message NOT ZERO TRAVEL INSTALLED flashes EMERGENCY Press this button at any time to stop test stand motion Rotate clockwise to STOP release 3 3 Modes Overview The ESM303 has three functional modes 1 OPERATING MODE This is the operating mode in which testing sequences can be started and stopped 2 TEST FUNCTION SETUP In this mode test functions are configured such as rate of speed number of cycles password editing and other functions 3 FUNCTION ACTIVATION Many test stand functions such as cycling auto return distance measurement and others are ordered individually as options The Function Activation menu provides a means of identifying which functions were purchased Through this menu it is also possible to enable any functions not originally purchased via an activation code All functions are temporarily enabled for the first 160 hours of operation as described below MIA GIGI Models ESM303 amp ESM303H Test Stands User s Guide DEMO MODE The ESM303 is shipped in Demo Mode during which time all available functions are temporarily activated for 160 hours of operation At power up a counter displays the number of hours remaining as follows REMAINING DEMO TIME 160 HOURS Press STOP to continue At the end of this period any function
27. gs Upper Right 20 000 in Lower Left 20 000 in Available settings From 20 000 to 20 000 in MIA GIG Models ESM303 amp ESM303H Test Stands User s Guide Description Increments the travel limit setting by 001 in or 02 mm Holding down will increment at an increasingly fast rate Decrements the travel limit setting by 001 in or 02 mm Holding down will increment at an increasingly fast rate Returns to the Test Function Setup menu Exits the function without saving changes 4 5 Overload Protection OVERLD 4 5 1 Function The ESM303 protects a load cell or force gauge from overload by measuring incoming analog voltage and stopping crosshead travel when the programmed percentage of full scale has been reached The default setting is for Mark 10 instruments 1V full scale however the setting may be changed to 2V or 4V to accommodate other instruments Default setting OFF Available settings MARK 10 OTHER 2V OTHER 4V OFF OFF ENTR Returns to the Test Function Setup menu Exits the function without saving changes 4 5 2 Compression and tension overload settings COMP OVERLD and TEN OVERLD This setting corresponds to the percentage of full scale at which crosshead travel stops For example a setting of 80 for a 100 IbF capacity force gauge would stop crosshead travel when approximately 80 IbF is reached Note Overload protection is active only for forces applied in the same direction of tra
28. h the available settings Returns to the Test Function Setup menu xits the function without saving changes m 4 15 Profiles 4 15 1 Save a new profile Test Function settings may be saved by creating a new profile or by overwriting an existing profile Up to 50 profiles may be saved named and recalled Description Cycles through previously saved profiles Returns to the Test Function Setup menu xits without loading a new profile m MIA GIG Models ESM303 amp ESM303H Test Stands User s Guide 4 15 2 Delete a profile PR EXAMP LE1 ENTR Description Cycles through profiles Press to delete the selected profile The screen will prompt DELETE PROFILE Select yes or no Note the profile named DEFAULT cannot be deleted Exits without saving changes 4 15 3 Changing a profile name Profile names may be changed when exiting the Test Function Setup menu if settings have been changed The screen will prompt the user to save as and then allows the profile name to be edited Note that the profile named DEFAULT cannot be changed Refer to the beginning of the Test Function Setup section for details 4 16 Default Settings Revert to the following factory settings SPEED 10 in min UP RIGHT SPEED 10 in min DOWN LEFT SPEED 10 in min AUTO RETURN off CYCLING 00000 off HI RIGHT LIMIT 20 000 in LO LEFT LIMIT 20 000 in OVERLOAD PROTECTION off PRELOAD off
29. hat the force value has not exceeded the overload limits configured in the stand 3 Ensure that instrument s set points have been configured properly Both set points must be enabled regardless of test direction with upper limit in the tension direction and lower limit in the compression direction 3 Certain menu items are no longer displayed All test stand functions are temporarily enabled for 160 hours of operation in Demo Mode When demo mode has expired any functions and their associated menus not originally purchased will no longer be displayed 12 SPECIFICATIONS lt 24 in 610 mm min 300 IbF 1 5 kN gt 24 in 610 mm min 200 IbF 1 kN 0 5 13 in min 13 330 mm min 0 02 45 in min 0 5 1 100 mm min 18 0 n H57 mm 0 2 0 Stepper motor driven 0 002 in 0 05 mm per 10 in 25 4 mm 0 001 in 0 02 mm 0 001 in 0 03 mm Universal input 80 240 VAC 50 60 Hz Fuse type 1 2 A 250V 3AG SLO BLO ESM303 56 5 Ib 25 6 kg ESM303H 62 5 Ib 28 4 kg Environmental Conditions 40 100 F 5 40 C max 96 humidity non condensating Weight without options 13 DIMENSIONS 13 1 ESM303 MIA GIG Models ESM303 amp ESM303H Test Stands User s Guide 10 32 UNF 2B X 0 350 DEEP X24 0 50 12 7 TYP 0 50 12 7 TYP 5 16 18 UNC 2B X 0 350 DEEP 5 16 18 UNC 2B X 0 750 DEEP X4 1 7 19 9 43 505 C do e N 1 Y c 0 yA
30. ivation code cycle the crosshead up and down to ensure that the position indicator is incrementing and decrementing properly 9 SEPARATING THE COLUMN FROM THE BASE COLUMN EXTENSION INSTALLATION The column may be separated from the base to accommodate alternative mounting arrangements for considerations such as safety increased sample clearance integration into existing equipment etc The instructions below reference Model ESM303 however the process is similar with the ESM303H 9 1 Removing the base from the column To remove the base follow these instructions 1 Power off the test stand and disconnect the power cable 2 Laythe test stand on its side and remove the 6 screws from the underside of the base Carefully remove the base from the frame Refer to the image below 9 2 Retrofitting a Mark 10 single column extension optional If a single column extension is ordered upfront it is pre installed at the factory and shipped assembled It may also be retrofitted in the field Follow these instructions NALIN Models ESM303 amp ESM303H Test Stands User s Guide 1 Remove the two sheet metal covers from the column extensions by loosening the 16 screws as identified in the images below 2 Using the 6 screws removed from the test stand base reinstall the base onto the lower flange of the column extension as shown in the image below 3 Attach the top flange to the bottom of the test stand column utilizing th
31. l Memes Interface Crosshead indicator load cable cell mounting kit Left grip Test sample Right grip NC Frame cap Indicator 2 SETUP AND SAFETY 2 1 Mounting Place the stand on a clean flat and level work area free from vibration For the vertically oriented ESM303 It is suggested to mount the stand to a work bench via screws fastened into the underside of the base Failure to properly mount the test stand may make it more vulnerable to tipping especially if a column extension is used causing a hazardous situation 2 2 Mounting the control panel To avoid damage during shipment the control panel and mounting bracket are packaged separately Follow these installation instructions 2 2 1 ESM303 1 Install the mounting bracket to the column utilizing one 1 4 20 screw MIA GIG Models ESM303 amp ESM303H Test Stands User s Guide 2 Install the control panel to the mounting bracket utilizing two 8 32 screws 3 The viewing angle may be adjusted by loosening the lever positioning the control panel and re tightening the lever 2 2 2 ESM303H ee SEE SSS USA ee 1 Install the control panel to the mounting bracket utilizing two 1 4 28 screws 2 Install the mounting bracket to the bracket adapter with two 8 32 screws 3 Install the bracket adapter to the edge of the test frame with two 10 32 screws This may be done on either the right end or the left end of the frame where sets of
32. or Before turning on power the following safety checks and procedures should be performed 1 Never operate the test stand if there is any visible damage to the power cord or the test stand itself The ESM303 is powered by 110V 220V Any contact with this high voltage can cause serious injury or even death 2 Ensure that the test stand is kept away from water or any electrically conductive liquids at all times 3 Make sure the electrical outlet powering the test stand has local earth ground 3 prong connector 4 The test stand should be serviced by a trained technician only Power must be disconnected before the column covers are removed NAGI E ER S Models ESM303 amp ESM303H Test Stands User s Guide After the above safety checks and procedures have been performed the test stand may be powered on and is ready for operation 3 OPERATION BASICS 3 1 Operational Safety The following safety checks and procedures should be performed before and during operation 1 DA ESIZIDS ER Always consider the characteristics of the sample being tested before initiating a test A risk assessment should be carried out beforehand to ensure that all safety measures have been addressed and implemented Wear eye and face protection when testing especially when testing brittle samples that have the potential to shatter under force Be aware of the dangers posed by potential energy that can accumulate in the sample during
33. p menu xits the function without saving changes m 4 13 Programmable Button Function KEYS Three button function modes are available 1 Maintained The crosshead will move continuously once the button has been pressed and held Subsequently pressing STOP will stop crosshead motion 2 Momentary The crosshead will move only if the button is held down Releasing the button will stop movement immediately 3 Auto Holding down the button for more than 0 5 second will enter momentary mode at which time an audible indicator will sound and the LED indicator on the button pushed will be illuminated A short tap on the button will operate the test stand in maintained mode Pressing STOP during maintained mode will stop crosshead motion NAGI E ER S EJ Models ESM303 amp ESM303H Test Stands User s Guide Default setting auto Available settings maintained momentary auto MAINTAINED ENTR Description Cycles through the available settings Returns to the Test Function Setup menu xits the function without saving changes m 4 14 FollowMe Crosshead responds to manually pushing or pulling on the force gauge shaft or load cell Increasing force produces greater speeds Ideal for quick positioning during sample loading and unloading CAUTION N Exercise extreme caution when handling low capacity force gauges as overload can occur Default setting OFF Available settings ON OFF Description Cycles throug
34. r comp plate 10 32F 2 diameter comp plate 10 32 M F 2 extension rod 10 32 M F 2 extension rod 10 32 F F coupler 10 32 F F coupler Adapter 5 16 18M to 10 32F Adapter 1 2 20M to 10 32F Set screw 10 32 x 3 4 3 Adapter 1 4 28M to 5 16 18F Hex nut 10 32 3 Adapter 5 16 18M to 10 32F 2 Allen wrench set Set screw 10 32 x 3 4 3 Hex nut 10 32 3 Allen wrench set Additional optional items are available such as an adjustable base plate connection cables and column extensions Instructions for installing a column extension and retrofitting the test stand with the travel indication option are provided later on in this user s guide MIA GIG Models ESM303 amp ESM303H Test Stands User s Guide 1 2 Physical features Note the following physical features The user s guide will reference this terminology 1 2 1 ESM303 Column cap Limit Column swith P n upper Interface cable oom d Crosshead Force gauge Emergency stop Upper grip EE ee IE Control panel Limit aH switch a lower Test sample E Lower grip NC Base plate c S S Control panel Base A mounting bracket MIA GIG Models ESM303 amp ESM303H Test Stands User s Guide Emergency stop Control panel 1 2 2 ESM303H Left limit switch Right limit switch panel mounting location Base plate Base gt Load cel
35. rofile Press to edit the profile name The first character will be EDIT flashing Press to change the character and gt to advance to the next character SAVE Saves the settings under the specified profile name Refer to the Profiles sub section for further details on selecting and deleting profiles lf PROFILES is not installed the screen appears as follows SAVE CHANGES NO YES Make the appropriate selection 4 1 Speed If the Independent Speeds option has not been installed both directional speeds will be the same and is programmed via the SPEED function If the Independent Speeds option is installed UP SPEED RIGHT SP and DN SPEED LEFT SP functions will be present and may be set individually Default setting 10 in min 250 mm min Available settings 0 02 45 in min 0 5 1 100 mm min MIA GIG Models ESM303 amp ESM303H Test Stands User s Guide Increments the speed setting Holding down will increment at an increasingly faster rate Decrements the speed setting Holding down will decrement at an increasingly faster rate ENTR Returns to the Test Function Setup menu Exits the function without saving changes 4 2 Auto Return With this function the crosshead moves to a limit switch or soft limit force set point distance limit preload or break whichever occurs first and stops Then the crosshead returns to the other limit and stops The test speed is dictated by the set
36. s 2 Remove the upper and lower limit switch thumb screws then remove the left sheet metal cover The limit switches and screws are identified in the image below 3 The electronics support plate contains most of the test stand s electronics and must be removed to access the required area First remove the 6 screws identified in the image below Do not pull the plate away from the column yet as additional steps are required for removal Electronics support plate MIA GIG Models ESM303 amp ESM303H Test Stands User s Guide 4 Carefully tilt the plate back slightly then disconnect the 3 connectors as identified in the images below Then remove the plate 5 Note the components below Then attach the encoder strip to the plate with 7 screws Encoder strip assembly 6 Install the encoder assembly to the crosshead with 2 screws as shown in the image below D ENEIES ER ER S Models ESM303 amp ESM303H Test Stands User s Guide 7 Re install all hardware and components in reverse order Be sure to position the upper limit switch above the crosshead and the lower limit switch below the crosshead before installing to the electronics support plate 8 2 Entering the activation code Access the Function Activation menu and locate the function labeled TRAVEL Obtain the request code and enter the activation code a process described in the Function Activation section After inputting the act
37. s Useful for quick positioning during setup and sample loading unloading 2 Basic Mode Manual control of crosshead motion 3 Auto Return Mode Crosshead moves to a limit switch or force set point travel distance preload or sample break referred to as soft limits whichever occurs first Then it reverses and moves at maximum speed to the other limit whichever occurs first 4 Cycling Mode Crosshead cycles between limits at the selected speed s and pauses at each limit or set point for a selected period of time 5 Preload Mode Crosshead moves until the preload has been reached and performs the action programmed in the setting An auto return cycle dwell time or break detection sequence may follow 6 Load holding Mode Crosshead moves to a force set point stops then dynamically adjusts position to maintain the programmed force An auto return or cycle dwell time sequence may follow T Break Detection Mode Crosshead stops when a sample break has been detected An auto return or cycle dwell time sequence may follow 8 PC Control Mode 203213 E ER S 24 Models ESM303 amp ESM303H Test Stands User s Guide Test stand is controlled through a USB connection with a PC The Operating Mode home screen appears as follows SPEED 0 00 menu min max SET If the travel indication option is installed the screen appears as follows POSITION SPEED 1 275 0 00 menu min max SET The item selected will be c
38. s not originally purchased will be deactivated and will no longer be accessible from the Test Function Setup menu Demo Mode can be suspended at any time by pressing and holding STOP while turning on power to the test stand This mode can be re enabled in the same manner and will be active for the remaining time period Refer to the Function Activation section for instructions for field activation 4 TEST FUNCTION SETUP This section provides configuration instructions for each function Function Standard Optional _ All ESM303 test stands are supplied in Demo Mode as explained in the Overview section After Demo Mode expires only installed functions will be displayed in Test Function Setup To access Test Function Setup menu press menu from the Operating Mode home screen which appears as follows SPEED 0 00 menu min max SET MIA GIG Models ESM303 amp ESM303H Test Stands User s Guide After pressing menu the initial Test Function Setup screen appears as follows When the functions have been configured and are ready to be saved press ESC to exit Test Function Setup Note Changes can be made to an unlimited number of settings before saving If the PROFILES function is installed the changes may be saved to the desired profile name The screen appears as follows SAVE AS EXAMPLE 1 ESC EDIT SAVE Label ESC Exits Test Function Setup reverts to Operating Mode Scrolls to the next saved p
39. shoot the set point value requiring an adjustment sequence where the crosshead reverses then moves again in the original direction multiple times before settling at the set point value A high enough speed may cause this correction cycle to repeat indefinitely For softer samples the amplitude of oscillation will be smaller but could still be present for the duration of the load holding period This is typical for samples which may relax such as rubber foam etc Lowering the test speed will reduce the oscillation For minimally relaxing materials such as metal springs the oscillation should stop shortly after the holding force is reached Load holding may be interrupted at any time by pressing STOP Note Preload and Load Holding cannot be enabled simultaneously 5 9 Break Detection Mode In this mode the crosshead will stop when a sample break has occurred This action occurs when the NAGI E ER S EJ Models ESM303 amp ESM303H Test Stands User s Guide force decreases to a specified percentage of peak as illustrated below PEAK PERCENTAGE THRESHOLD DETECTION DETECTED If enabled an auto return sequence or single cycle sequence may follow break detection 5 10 PC Mode The ESM303 can be controlled by a PC via the USB port A list of supported ASCII commands is provided below 5 10 1 Motion control commands lower case Command Description Exampe a QgRequstsped
40. t available from Mark 10 which also utilizes the above commands Baud rate stop bits and parity must be configured in the stand to correspond with the PC software s settings While in PC control if any functions are changed on the front panel these settings will be ignored except if Auto Return or Cycling are turned on If so PC control will be turned off automatically DA ESIZIDS ER ER 2 Models ESM303 amp ESM303H Test Stands User s Guide 6 FUNCTION ACTIVATION This menu displays the list of available functions and indicates which ones are installed indicated by or OFF Those that are not installed can be installed in the field 6 1 Accessing the Function Activation menu While in Operating Mode press and hold STOP then press menu simultaneously and release both buttons The display will appear as follows 6 2 Activating Functions Functions not originally purchased can be activated with an authorization code To activate the function scroll through the menu until the desired function is displayed then press ENTR If the function is already installed indicated by ON pressing ENTR has no effect If the function is off pressing ENTR will generate a request code on the display as shown below The request code must be supplied to Mark 10 or a distributor who will then provide a corresponding authorization code to activate the function The process for entering the authorization code is as
41. ting described in the previous section The return speed is locked to maximum speed The maximum speed depends on whether or not the optional high speed range has been installed Default setting off Available settings off on Description Cycles through the available settings Returns to the Test Function Setup menu Exits the function without saving changes lf AUTO RETURN is turned on CYCLING is automatically turned off and the KEYS function is automatically set to MAINTAINED mode See following pages for details on the CYCLING and KEYS functions 4 3 1 Cycling CYCLES This setting allows the user to configure the number of up and down cycles through which the crosshead will sequence One cycle consists of the crosshead moving to a limit switch or soft limit whichever occurs first at the specified speed stopping for the specified amount of dwell time and returning to the other limit at the specified speed If the Independent Speeds function is not enabled the speed will be the same in both directions Default setting 00000 off Available settings 00000 99999 MIA GIG Models ESM303 amp ESM303H Test Stands User s Guide Increases the number of cycles increments of 1 Holding down will increment at an increasingly faster rate If 99999 is reached the next number will be 00000 and continue incrementing Decreases the number of cycles in increments of 1 Holding down will decrement
42. unction during sample handling The threshold is defined as a percentage of full scale of the load cell or force gauge For example for a 50 IbF capacity force gauge a setting of 10 represents 5 IbF Default setting 1096 Available settings 196 9596 196 increments BRK THRESH 80 ESC 4 8 3 Percentage of Peak This setting corresponds to the force trigger for break detection defined as a percentage of peak force For example A sample is tensioned and breaks at 50 IbF The break detection percentage setting is 60 After the sample breaks the force rapidly decreases to 30 IbF 60 of peak and the stand stops 203213 ER S 19 Models ESM303 amp ESM303H Test Stands User s Guide Default setting 80 Available settings 1 95 1 increments Description Increases or decreases the value Returns to the Test Function Setup menu Exits the function without saving changes 4 9 Control Source CONTROL This setting corresponds to the source of test stand control as follows CONSOLE The test stand is controlled either from the control panel or from MESURgauge Plus software running on a PC PC The test stand is controlled from a custom written PC application not MESURgauge Plus If any functions are changed on the front panel these settings will be ignored except for Auto Return or Cycling If either of these functions is turned on PC control will be turned off Default setting CONSOLE Available
43. vel Default setting 100 Available settings 20 100 10 increments COMP OVERLD 100 Increases or decreases the value Returns to the Test Function Setup menu Exits the function without saving changes DA ESIZIDS ER Models ESM303 amp ESM303H Test Stands User s Guide 4 6 Preload 4 6 1 Function This setting corresponds to the test stand s response to an initial load referred to as a preload The crosshead can stop and or zero the travel display when the preload has been reached This function is useful for applications such as spring testing elongation testing and tensile and compression testing of various materials In effect it establishes a reference point It is also sometimes referred to as a touch Note Before the start of a preload sequence the crosshead must be positioned at either physical limit switch Default setting OFF Available settings STOP STOP ZERO ZERO GO OFF ZERO GO Travel display is zeroed when preload has been reached crosshead does not stop 4 6 2 Preload Value PRELD FS This setting corresponds to a preload value defined as a percentage of the instrument s full scale in IbF units The test stand s response as described in the previous section occurs when this value has been reached Note In low force applications consider test stand vibration and crosshead acceleration as they can be significant enough to produce a force exceeding the preload v
44. verridden by pressing and holding either directional button for two seconds 5 6 Cycling Mode This mode cycles the crosshead between limits whichever occurs first One cycle consists of the following steps 1 Crosshead moves to a limit at the specified speed 2 Crosshead stops for the specified amount of dwell time 3 Crosshead reverses direction returns to the other limit at the specified speed and stops for the specified amount of dwell time A cycling sequence can be initiated from any position and can start in either direction To initiate a cycle sequence press either directional button During a cycle sequence a counter will be displayed indicating the number of cycles remaining as shown below menu min max SET As in Basic Mode the min max and set soft keys are active during crosshead movement When the cycling sequence and the crosshead has stopped at a soft limit the limit condition may be overridden by pressing and holding either directional button 5 6 1 Dwell time Dwell time is the amount of time in seconds for which the crosshead stops at a limit during a cycle sequence When the crosshead has reached a limit a counter will be displayed shown as follows DWELL 0001 5 menu min max SET If the dwell settings are set to 0 the crosshead will immediately reverse direction upon reaching the corresponding limit and no counter will be displayed The cycle sequence may be interrupted before it has
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