MARK-10 ESM1500SLC User's Guide

MARK-10 ESM1500SLC User's Guide
Series ESM
FORCE TEST STANDS
ESM1500
ESM1500S
ESM750
ESM750S
User’s Guide
Models ESM1500 / ESM750 Test Stands
User’s Guide
Thank you…
Thank you for purchasing a Mark-10 Force Test
Stand, designed for tension and compression
force measurement applications. The stands
are essential components of force testing
systems, 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 these
products. 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.
Before use, each person who is to use these test stands should be fully trained in appropriate
operation and safety procedures.
TABLE OF CONTENTS
OVERVIEW .......................................................................................... 3
SETUP AND SAFETY ......................................................................... 4
OPERATION BASICS ......................................................................... 7
TEST FUNCTION SETUP ........................................ …………………10
OPERATING MODES........................................................................ 21
COMMUNICATION ............................................................................ 27
FUNCTION ACTIVATION.................................................................. 29
TROUBLESHOOTING....................................................................... 30
MAINTENANCE AND SERVICE ....................................................... 31
SPECIFICATIONS ............................................................................. 37
DIMENSIONS .................................................................................... 38
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Models ESM1500 / ESM750 Test Stands
User’s Guide
1 OVERVIEW
1.1 List of included items
Qty.
1
1
1
1
2
2
4
4
1
1
1
1
1
Description
Load cell / indicator mounting bracket (-LC test stands only)
Force gauge mounting bracket (-FG test stands only)
Control panel
Control panel mounting bracket with hardware
Eye end kit for base
Lock ring for eye end
Spanner wrench
Force gauge/indicator mounting screws, #6-32
Force gauge mounting screws, #10-32 (-FG test stands only)
Cable, instrument to test stand crosshead
Power cord
USB cable, A/B
Allen wrench set
Resource CD
1.2 Physical Features
Note the following physical features of the test stands. The user’s guide will reference this terminology.
Model ESM1500LC is shown below.
Column cap
Limit
switches
(not visible)
Interface
cable
Column
Bellows
Control panel
Indicator
Load cell /
force sensor /
force gauge
Upper grip
Crosshead
Test sample
Lower grip
Base plate
Base
Emergency stop
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Models ESM1500 / ESM750 Test Stands
User’s Guide
2 SETUP AND SAFETY
2.1 Moving the stand into position
Place the stand on a sturdy, clean, and level work area
free from vibration. A recessed lifting hook is provided at
the top of the column for moving purposes, as shown in
the image at left.
2.2 Mounting the Control Panel
To avoid damage during shipment, the control panel is
packaged separately. The mounting bracket is preinstalled into a T-slot in the right side of the column. The
height and viewing angle can be adjusted by loosening
and tightening the two levers.
To mount the control panel to the bracket, fasten the two
provided screws through the bracket and into the
housing of the control panel, as shown in the image at
left.
2.3 Mounting other accessories
The column features four T-slots. Two of the slots are
used for the control panel and limit switches. Use any of
the slots to attach brackets or other accessories as
needed. To access a T-slot, remove its corresponding
cap by loosening the screw, as shown in the image at
left.
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Models ESM1500 / ESM750 Test Stands
User’s Guide
2.4 Connections and Outputs
The following connections and outputs are supplied in the lower rear section of the test stand’s column,
as shown in the illustration below:
3
2
4
1
5
1. Power plug receptacle
Plug the power cord in here. Refer to the Connecting Power sub-section for important safety
information.
2. Power switch
3. Control panel cable connector
Plug the cable into this connector.
4. Auxiliary limit switch connector
For interfacing an external limit switch, such as an interlock for a machine guard door. A pin
diagram is shown below:
Note that when pins 3 and 4 are not connected, the auxiliary limits are inactive. When the +5V
from pin 2 is connected to either pin 3 or pin 4, the respective limit becomes active and the
crosshead is prevented from movement in that direction. The hard-wired cable and connector, as
shown below, should remain in place if external limit switches are not used:
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Models ESM1500 / ESM750 Test Stands
User’s Guide
5. USB connector
Outputs force only or force and travel data via USB. Also allows for PC control. Plug one end of
the USB cable into this connector, and the other end into a PC’s USB port. 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.
Further instructions for configuring communication functions 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.
2.5 Installing a load cell with indicator or force gauge
Once the test stand is in a stable and secure position, install a load cell and indicator, or a force gauge,
with the hardware supplied. Grips and fixtures may be mounted to the load cell or force gauge and test
stand base, utilizing eye ends if desired.
2.5.1 Installing a sensor and indicator (-LC test stands)
Hardware to mount a Series R01 or Series R03 force sensor to the crosshead is included with the sensor.
Refer to the following illustration for installation instructions:
2.5.2 Installing a force gauge (-FG test stands)
A force gauge mounts directly to the mounting plate on the crosshead by aligning the dowel pin with the
blind hole in the rear of the gauge’s housing. Then, install the four thumb screws in the same fashion as
an indicator, as shown in the illustration above.
2.5.3 Installing the interface cable
If using a Series 5 or Series 7 instrument, connect the interface cable between the instrument’s connector
and the crosshead’s connector, as shown in the image below.
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Models ESM1500 / ESM750 Test Stands
User’s Guide
2.6 Safety / Proper Usage
Typical materials able to be tested include manufactured items such as springs, metals, plastics,
electronic components, mechanical assemblies, packaging materials, and many others. Items that should
not be tested 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.
2.7 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 connector).
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 test stand 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.
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. 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.
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Models ESM1500 / ESM750 Test Stands
User’s Guide
2. 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 testing. Extra bodily protection should be worn if a destructive
failure of a test sample is possible.
3. 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:
Definition: Keep any body parts and clothing clear of the area between the base of the test stand and the
moving crosshead.
4. In applications where samples can shatter, or other applications that could lead to a hazardous
situation, use of a machine guard is strongly recommended.
5. When the test stand is not in use, ensure that power is turned off to prevent accidental engagement
of any of the controls.
3.2 Controls
1
2
3
6
5
4
Label
Function
1
SOFT KEYS
Functions are determined by the corresponding text on the display.
2
UP
Commences movement in the up direction.
3
STOP
Stops crosshead movement.
4
DOWN
5
FollowMe®
6
ZERO TRAVEL
Commences movement in the down direction.
Enables force-activated crosshead 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
INSTALLED” flashes.
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Models ESM1500 / ESM750 Test Stands
User’s Guide
3.2 Emergency Stop
The Emergency Stop button is located on the base, adjacent to the lower
right corner of the column, as shown in the image at left.
Press this button at any time to stop test stand motion. Rotate clockwise to
release.
3.3 Modes Overview
The test stands have 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:
DEMO MODE
The stands are 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:
R E MA I N I N G D EMO
T I ME :
160
HO UR S
Press STOP to continue.
At the end of this period, any functions 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.
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Models ESM1500 / ESM750 Test Stands
User’s Guide
4 TEST FUNCTION SETUP
This section provides configuration instructions for each test function.
Function
Speed - same setting applies to both directions
Travel indication
Independent up and down speeds
High speed range extension
Low speed range extension
Auto return
Cycling with dwell time
Programmable travel limits
Overload protection
Preload
Loadholding
Break detection
PC control
FollowMe®
Profiles
Communication settings
Units of speed measurement
Programmable button configuration
Password protection
Standard / Optional
Standard
Optional
Optional
Optional
Optional
Optional
Optional
Optional
Optional
Optional
Optional
Optional
Optional
Optional
Optional
Standard
Standard
Standard
Standard
Test stands are shipped 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:
S P E ED :
0 . 00
me n u m i n ma x
SET
After pressing menu, the initial Test Function Setup screen appears as follows:
S PEED :
ESC
Label
ESC
<–
– >
ENTR
<−
20 . 0 0
−>
ENTR
Description
Exits Test Function Setup, reverts to Operating Mode
Scrolls to the previous function
Scrolls to the next function
Selects the function, allowing it to be modified
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.
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Models ESM1500 / ESM750 Test Stands
User’s Guide
If the PROFILES function is installed, the changes may be saved to the desired profile name. The screen
appears as follows:
S A V E A S : E X A MP L E 1
ESC
+
ED I T
SAVE
Label
ESC
+
EDIT
SAVE
Description
Exits Test Function Setup, reverts to Operating Mode
Scrolls to the next saved profile
Press to edit the profile name. The first character will be
flashing. Press + to change the character and –> to
advance to the next character.
Saves the settings under the specified profile name
Refer to the Profiles sub-section for further details on selecting and deleting profiles.
If the PROFILES function is not installed, the screen appears as follows:
S A V E C H A NG E S ?
NO
YES
Make the appropriate selection.
4.1 Speed, Up Speed, Down Speed (SPEED, UP SPEED, DOWN SP)
If the independent up and down speed option has not been installed, the up and down speeds will be the
same, and is programmed in the SPEED function. If the independent up and down speeds option is
installed, UP SPEED and DN SPEED functions will be present, and may be set individually.
Default setting:
Available settings:
10 in/min / 250 mm/min
ESM1500 / ESM1500S: 0.001 – 90 in/min / 0.02 – 2,300 mm/min
ESM750 / ESM750S: 0.001 - 60 in/min / 0.02 - 1,525 mm/min
UP SPEED :
ESC
Label
+
−
10 . 73
+
ENTR
ENTR
Description
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.
Returns to the Test Function Setup menu
ESC
Exits the function without saving changes
–
4.2 Auto Return (AUTO RETURN)
With this function, the crosshead moves to a limit switch or soft limit (force set point, distance limit,
preload, or break detection), whichever occurs first, and stops. Then, the crosshead returns to the other
limit and stops. The test speed is dictated by the SPEED setting or the UP SPEED and DOWN SP
settings. The return speed is always maximum speed. The maximum speed depends on whether or not
the optional high speed range has been installed.
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Models ESM1500 / ESM750 Test Stands
User’s Guide
Default setting: off
Available settings: off, on
AU TO RE T URN
ESC
−
+
of f
ENTR
Label
+ or –
ENTR
Description
Cycles through the available settings
Returns to the Test Function Setup menu
ESC
Exits the function without saving changes
Note:
If 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 up and down speed function is not enabled, the speed will
be the same in both directions.
Default setting: 00000 (off)
Available settings: 00000 – 99999
CYCL E S :
ESC
−
Label
+
–
Press and hold
+ and –
simultaneously
ENTR
ESC
00000
+
ENTR
Description
Increases the number of cycles in 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 at an increasingly faster rate. If 00000 is reached
the next number will be 99999 and continue decrementing.
If pressed and held for 2 seconds or longer the number of cycles
will change to 0.
Returns to the Test Function Setup menu
Exits the function without saving changes
4.3.2 Upper and Lower Dwell Times (U DWELL and LO DWELL)
This setting corresponds to the amount of time, in seconds, for which the crosshead stops at the limit
during a cycle sequence.
Note:
The dwell time setting is unavailable for an auto return sequence.
Default setting: 0 (no dwell time)
Available settings: 0 – 9999.9
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Models ESM1500 / ESM750 Test Stands
HI
D WE L L :
ESC
−
Label
+
–
ENTR
ESC
User’s Guide
0000 . 0
+
ENTR
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 Upper and Lower Travel Limits (UPPER LM and LOWER LM)
This setting corresponds to the travel distance the crosshead moves before stopping or cycling. Upper
and lower limits are programmed individually. The programmed distances are relative to the zero position
of the crosshead. The travel indicator can be zeroed by pressing the ZERO TRAVEL key.
Default / available setting range:
HI
L IMI T :
ESC
−
2 . 058
+
ENTR
Label
+
–
ENTR
ESC
ESM1500 / ESM750: -39.000 to +39.000 in
ESM1500S / ESM750S: -15.000 to +15.000
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
4.5.1 Overload Protection (OVERLD)
The test stand 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
OV ER L D :
MA R K - 1 0
ESC
+
−
ENTR
4.5.2 Compression and Tension Overload Settings (COMP OVERLD and TEN OVERLD)
This setting corresponds to the percentage of full scale (in lbF units) at which crosshead travel stops. For
example, a setting of 80% for a 1,000 lbF capacity load cell would stop crosshead travel when
approximately 800 lbF is reached.
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Models ESM1500 / ESM750 Test Stands
User’s Guide
Note:
When the crosshead is moving in the UP direction, only the tension overload setting applies. When the
crosshead is moving in the DOWN direction, only the compression overload setting applies.
Default setting: 100%
Available settings: 20% - 120% (10% increments)
C OMP O V E R L D : 1 0 0 %
ESC
−
+
ENTR
Label
+ or –
ENTR
ESC
Description
Increases or decreases the value.
Returns to the Test Function Setup menu
Exits the function without saving changes
4.6.1 Preload (PRELOAD)
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 the upper or lower
physical limit switch.
Default setting: OFF
Available settings: STOP, STOP/ZERO, ZERO/GO, OFF
P R E L OA D :
Z E R O , GO
ESC
+
−
Label
+ or –
STOP
STOP, ZERO
ZERO, GO
ENTR
ESC
ENTR
Description
Cycles through the available settings listed below:
Crosshead stops when preload has been reached
Crosshead stops when preload has been reached, then zeroes the travel display
Travel display is zeroed when preload has been reached, crosshead does not stop
Returns to the Test Function Setup menu
Exits the function without saving changes
4.6.2 Preload Value (PRELD %FS)
This setting corresponds to a preload value, defined as a percentage of the load cell or force gauges’ full
scale, in lbF 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 value.
Default setting: 1%
Available settings: 0 – 100%
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Models ESM1500 / ESM750 Test Stands
P R E L D %F S :
01 . 0
ESC
ENTR
Label
+ or –
ENTR
ESC
−
+
User’s Guide
Description
Increases or decreases the value, in increments of .1
Returns to the Test Function Setup menu
Exits the function without saving changes
4.7 Loadholding
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 respective user’s
guide for details). If the CYCLING option has been installed, loadholding will be active for the period of
time as defined in the Upper Dwell and Lower Dwell settings. If CYCLING has not been installed,
loadholding will continue indefinitely. Pressing STOP will end loadholding.
Default setting: OFF
Available settings: ON, OFF
L OA D HO L D I NG :
ESC
Label
+ or –
ENTR
ESC
−
+
ON
ENTR
Description
Cycles through the available settings
Returns to the Test Function Setup menu
Exits the function without saving changes
4.8.1 Break Detection
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 DE T EC T :
ESC
Label
+ or –
ENTR
ESC
−
+
ON
ENTR
Description
Cycles through the available settings
Returns to the Test Function Setup menu
Exits the function without saving changes
4.8.2 Break Detection 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 function during sample handling. The threshold is
defined as a percentage of full scale of the load cell or force gauge. For example, for a 500 lbF capacity
load cell, a setting of 10% represents 50 lbF.
Default setting: 10%
Available settings: 1% - 95% (1% increments)
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Models ESM1500 / ESM750 Test Stands
BRK T HRE SH :
ESC
Label
+ or –
ENTR
ESC
−
+
User’s Guide
8 0%
ENTR
Description
Increases or decreases the value.
Returns to the Test Function Setup menu
Exits the function without saving changes
4.8.3 Break Detection 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 pulled to 500 lbF, then breaks. The break detection percentage setting is 60%.
After the sample breaks, the force rapidly decreases to 300 lbF (60% of peak), and causes the test stand
to stop.
Default setting: 80%
Available settings: 1% - 95% (1% increments)
BREAK % P EAK :
ESC
Label
+ or –
ENTR
ESC
−
+
10
ENTR
Description
Increases or decreases the value.
Returns to the Test Function Setup menu
Exits the function without saving changes
Note:
When using the test stand with a Series 7 instrument, enable Break Detection in either the test stand or
the instrument – not both. The function will not work if simultaneously enabled in both devices.
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 settings: CONSOLE, PC
CON T RO L :
CON S O L E
ESC
+
−
ENTR
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Models ESM1500 / ESM750 Test Stands
Label
+ or –
ENTR
ESC
User’s Guide
Description
Cycles through the available settings
Returns to the Function Setup menu
Exits the function without saving changes
4.10 Baud Rate (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 RA T E : 1 1 5 2 0 0
ESC
Label
+ or –
ENTR
ESC
−
+
ENTR
Description
Cycles through the available settings
Returns to the Function Setup menu
Exits the function without saving changes
4.11 Stop Bits and Parity (STOP & 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
8-1o
8-1n
8-2n
7-1E
7-1o
7-2E
7-2o
7-2n
8 stop bits, 1 stop bit, even parity
8 stop bits, 1 stop bit, odd parity
8 data bits, 1 stop bit, no parity
8 data bits, 2 stop bits, no parity
7 data bits, 1 stop bit, even parity
7 data bits, 1 stop bit, odd parity
7 data bits, 2 stop bits, even parity
7 data bits, 2 stop bits, odd parity
7 data bits, 2 stop bits, no parity
S TOP & PAR :
8 - 1n
ESC
ENTR
Label
+ or –
ENTR
ESC
−
+
Description
Increases or decreases the value.
Returns to the Test Function Setup menu
Exits the function without saving changes
4.12 Units of Speed (UNITS)
This setting corresponds to units of speed measurement.
Default setting: in/min
Available settings: in/min, mm/min
UN I T S :
ESC
i n / mi n
−
+
ENTR
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Models ESM1500 / ESM750 Test Stands
Label
+ or –
ENTR
ESC
User’s Guide
Description
Cycles through the available settings
Returns to the Test Function Setup menu
Exits the function without saving changes
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.
Default setting: maintained
Available settings: maintained, momentary, auto
KE Y S : MA I N T A I NED
ESC
Label
+ or –
ENTR
ESC
−
+
ENTR
Description
Cycles through the available settings
Returns to the Test Function Setup menu
Exits the function without saving changes
4.14 FollowMe® (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!
Exercise extreme caution when handling low force load cells and gauges, as overload
can occur.
Default setting: OFF
Available settings: ON, OFF
F O L L OWM E :
ESC
Label
+ or –
ENTR
ESC
−
OFF
+
ENTR
Description
Cycles through the available settings
Returns to the Test Function Setup menu
Exits the function without saving changes
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Models ESM1500 / ESM750 Test Stands
User’s Guide
4.15 Profiles
4.15.1 Save a new profile
To save a new profile, configure the menu settings as required, then exit the menu. When prompted to
save changes, press YES. The display appears as follows:
Save as : - - ESC + E D I T
SAVE
Press + until the profile name “ - - - “ is displayed. Then, press EDIT. The display appears as follows:
P RO F I L E : - - ESC
+
>
SAVE
Press + to increment the flashing character, and > to advance to the next character. The profile name can
consist of up to 8 characters. When complete, press SAVE. Up to 50 profiles may be saved. Press ESC
to exit without saving changes.
4.15.2 Load a previously saved profile
P RO F I L E : P E E L T E ST
ESC
−
+
ENTR
Press + and – to cycle through the profiles, then press ENTR. Press ESC to exit without saving changes.
4.15.3 Change a profile name
Refer to the instructions in the Save a new profile sub-section. Scroll to the appropriate profile, then
press ENTR and follow the same procedure.
4.15.4 Delete a profile
DE L .
ESC
P R : P E E L T E ST
−
+
ENTR
Press ESC to exit without saving changes.
Press + and – to cycle through the profiles, then press ENTR to delete. The screen will prompt, “DELETE
PROFILE?” Select YES or NO.
Note: the profile “DEFAULT” cannot be deleted, and will not appear in the list.
4.16 Return to Default Settings (DEFAULT SETTINGS)
This setting provides a quick return to factory settings, as follows:
SPEED:
UP SPEED:
DOWN SP:
AUTO RETURN:
CYCLING:
HI LIMIT:
10 in/min
10 in/min
10 in/min
off
00000 (off)
+39.000 or +15.000 in (depending on test stand model)
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Models ESM1500 / ESM750 Test Stands
LO LIMIT:
OVERLD:
PRELOAD:
LOADHOLDING:
BREAK DETECT:
PROFILES:
CONTROL:
BAUD RATE:
STOP & PAR:
UNITS:
KEYS:
FOLLOWME:
PASSWORD:
User’s Guide
-39.000 or -15.000 in (depending on test stand model)
off
off
off
off
DEFAULT
CONSOLE
115200
8-1n
in/min
auto
off
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:
D E F AUL T ? :
ESC
Label
+ or –
ENTR
ESC
−
NO
+
ENTR
Description
Cycles through “yes” or “no” selections
Returns to the Test Function Setup menu
Exits the function without saving changes
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 corresponds to no password (off).
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
N E W P WO R D
E SC
Label
+ or –
ENTR
ESC
−
0000
+
ENTR
Description
Increases or decreases the value
Returns to the Test Function Setup menu
Exits the function without saving changes
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Models ESM1500 / ESM750 Test Stands
User’s Guide
5 OPERATING MODES
5.1 Overview
The test stand 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 speeds. 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. Loadholding 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.
7. Break Detection
Crosshead stops when a sample break has been detected. An auto-return or cycle/dwell time
sequence may follow.
8. PC Control Mode
See Communications section.
The Operating Mode home screen appears as follows:
S P E ED :
me n u m i n ma x
0 . 00
SET
If the travel indication option is installed, the screen appears as follows:
TRAVEL
SPEED
1 . 275
0 . 00
me n u m i n ma x
SET
The item selected will be capitalized, as shown in the figure above. The set speed can be changed in
Test Function Setup. If enabled, the up and down speeds can be configured independently of each other
(UP SPEED and DN SPEED). Otherwise, the SPEED setting corresponds to crosshead speed in both
directions.
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Models ESM1500 / ESM750 Test Stands
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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 & Auto Return Modes (travel indication option not installed):
S P E ED :
0 . 00
me n u m i n ma x
SET
2. Basic & Auto Return Modes (travel indication option installed):
TRAVEL
SPEED
1 . 275
0 . 00
me n u m i n ma x
SET
3. Cycling Mode (travel indication option not installed):
CYCL ES :
00024
me n u m i n ma x
SET
Note:
The min and max keys will not appear when a password has been set.
4. PC Mode
Appears the same as in Basic and Auto Return modes.
Label
menu
min
max
set
Description
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 SPEED, UP SPEED, or
DOWN SP setting
Pressing menu will enter Test Function Setup. If a password has been programmed, the display
will prompt the following:
P A S S WO R D
ESC
−
0000
+
ENTR
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 incorrect, the display flashes “INCORRECT
PASSWORD”, and then reverts to Operating Mode.
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Models ESM1500 / ESM750 Test Stands
User’s Guide
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:
S P E ED :
0 . 00
F o l l o wM e
Ac t i v e
CAUTION!
Exercise extreme caution when handling low force load cells
and gauges, as overload can occur.
If no force is detected for five 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 the UP and DOWN buttons. The three
settings are:
1.
Maintained (default)
The crosshead will move continuously once the button has been pressed. Subsequently
pressing STOP will stop crosshead motion.
2.
Momentary
The crosshead will move only if the button is pressed and held. Releasing the button will
stop movement immediately.
3.
Auto
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 UP or DOWN.
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 UP or DOWN for two seconds.
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Models ESM1500 / ESM750 Test Stands
User’s Guide
5.4.1 Travel Indication
If installed, travel indication is displayed in the upper left corner of the display. The displayed units are the
same as programmed in the UNITS function. Indicated travel is a relative value. To zero the value, press
the Zero Travel key.
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. Limit switches are located on the left side
of the test stand column, as shown in the image to the left. Adjust their
positions by loosening the thumb screws, repositioning, and re-tightening the
thumb screws.
5.4.3 Overload Protection
The included instrument-test stand interface cable is required for overload protection of a Mark-10
instrument. 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 UP direction, only the tension overload setting is active. When the
crosshead is moving in the DOWN direction, only the compression overload setting is active.
5.5 Auto Return Mode
In this mode the crosshead moves to whichever limit it encounters first, and stops. Then, the crosshead
returns at maximum speed to the opposite limit, whichever occurs first, and stops. The speed at which the
crosshead travels is dictated by the SPEED setting or UP SPEED and DN SPEED settings (if the
independent up and down speeds option is installed). Press UP or DOWN to initiate an Auto Return
sequence.
The crosshead can be stopped at any time during an Auto Return sequence by pressing STOP. To
resume the test, press UP or DOWN.
Note:
If the crosshead has stopped at a force set point, the limit condition may be overridden by pressing and
holding UP or DOWN 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. If the crosshead is
at a limit, however, cycling can only be started in the opposite direction. To initiate a cycle sequence,
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Models ESM1500 / ESM750 Test Stands
User’s Guide
press UP or DOWN. During a cycle sequence, a counter will be displayed, indicating the number of cycles
remaining, as shown below:
CYCL ES
00024
me n u m i n ma x
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 UP or DOWN.
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:
D WE L L :
0001 . 5
me n u m i n ma x
SET
If the DWELL U and/or DWELL L 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 been completed by pressing STOP. A soft key
labeled RESET will appear as follows:
CYCL ES :
00024
RESE T
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 UP or DOWN 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 UP or DOWN.
Travel indication and limit switch operation is the same as in Basic Mode.
5.7 Preload Mode
In this mode, the crosshead moves at the set speed (10 in/min [250 mm/min] maximum) until the
programmed preload value has been reached. If moving in the up direction, a tension preload is required.
If moving in the down 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, 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 the upper or lower
physical limit switch.
Note 2:
Preload and Load Holding cannot be enabled simultaneously.
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Models ESM1500 / ESM750 Test Stands
User’s Guide
5.8 Load Holding Mode
In this mode, the crosshead moves until the set point value programmed in the instrument is reached.
The crosshead’s position is dynamically adjusted to maintain a programmed force. The load cell or force
gauge’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 up
(tension) direction. The lower set point refers to a force limit in the down (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 lbF of compression force, set the upper set point to 30 lbF tension (as an
example), and the lower set point to 10 lbF 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.
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 overshoot 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 1:
Before the start of a load holding sequence, the crosshead must be positioned at either of the physical
limit switches.
Note 2:
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
force decreases to a specified percentage of peak, as illustrated below:
If enabled, an auto-return sequence or single-cycle sequence may follow break detection.
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Models ESM1500 / ESM750 Test Stands
User’s Guide
6 COMMUNICATION
6.1 Setup
The test stand can transmit force and travel (optional) data to a PC. The following settings are required
for proper functioning of all test stand functions and data output:
Force gauge / indicator (Series 5 / 7 only):
- RS-232 communication enabled
- 115,200 baud rate
Test stand menu:
- CONTROL: CONSOLE (this menu is only shown if the PC Control function is installed; PC
Control is not required for data output)
- STOP & PAR (stop bits and parity): 8-1n (8 data bits, one stop bit, no parity)
Connection cables:
- Gauge / indicator to test stand: Part no. 09-1214
- Test stand to PC (USB): Part no. 09-1158
If not using Mark-10 data collection software, ensure that the software’s communication settings match. A
number of data collection commands are available, highlighted in blue in the following section.
6.2 PC Control Mode
Motion control and data collection functions may be sent by an external device via user-developed
applications. A list of supported ASCII commands is provided below.
PC Control is required for all commands, except those highlighted in blue.
Command
a
b
c
d
e
f
g
h
i
j
k
l
Description
Request speed
Set travel units to inches
Enter cycle mode
Move crosshead down
Set speed
Inch format: eXX.XXX
Leading zeroes and three decimal places required.
Millimeter format: eXXXX.XX
Leading zeroes and two decimal places required.
Set cycles. Format: fXXXX (leading zeroes required)
Set lower travel limit
Inch format: g-XX.XXX
Negative sign (if applicable), leading zeroes, and three
decimal places required.
Millimeter format: g-XXX.XX
Negative sign (if applicable), leading zeroes, and three
decimal places required.
Set upper travel limit
Inch format: h-XX.XXX
Negative sign (if applicable), leading zeroes, and three
decimal places required.
Millimeter format: h-XXX.XX
Negative sign (if applicable), leading zeroes, and three
decimal places required.
Set travel units to millimeters
Set crosshead speed to maximum speed
Set crosshead speed to minimum speed
Enter travel limit mode
Example
e02.850 = 2.85 in/min
e0200.30 = 200.3 mm/min
f0500 = 500 cycles
g-00.550 = -0.55 in
g01.258 = 1.258 in
g-007.52 = -7.52 mm
g010.70 = 10.7 mm
h-00.550 = -0.55 in
h01.258 = 1.258 in
h-007.52 = -7.52 mm
h010.70 = 10.7 mm
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Models ESM1500 / ESM750 Test Stands
m
n
o
p
q
r
s
t
u
v
w
x
z
User’s Guide
Enter manual mode
Transmit travel and force readings
Set crosshead speed to programmed speed
Request stand status*
Request number of cycles completed
Request number of cycles set
Stop crosshead
Reset cycle counter to zero
Move crosshead up
Request upper travel limit
Request lower travel limit
Request travel value
Reset travel to zero
* The transmission of ASCII “p” will return the stand status. The following are the return codes and their
definitions (upper case):
Crosshead status
Operating mode
Limit switch status
Command
U
D
S
C
L
M
UL
DL
Description
Crosshead moving up
Crosshead moving down
Crosshead stopped
Cycle mode
Limit mode
Manual mode
Crosshead at upper limit
Crosshead at lower limit
6.2.1 Force gauge / indicator commands
Mark-10 force gauge and indicator commands are compatible with the test stand. To open this channel of
communication, use a forward slash “ / “ (no quotations), followed by the commands, followed by a back
slash “ \ “ 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:
Command
A
F
P
R
S
U
X or ?
Y
Z
Description
Displays current unit
Toggles between Normal and Data Collect modes
Steps through Normal mode, Tension Peak mode, and Compression Peak mode
Zeroes the instrument (zeroes all modes)
Sends current mode (Normal, Tension Peak, Compression Peak, or Data Collect)
Steps through units
Sends currently displayed reading
Enables RS-232 output and sends continuous data stream when in Data Collect mode
Zeroes the peak values
The test stand is compatible with legacy Nexygen TCD software, which also utilizes the above
commands. Baud rate, stop bits and parity must be programmed 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.
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Models ESM1500 / ESM750 Test Stands
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7 FUNCTION ACTIVATION
This menu displays the list of available functions and indicates which ones are installed, indicated by
“ON” or “OFF”. Those that are not installed can be installed in the field.
7.1 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:
C Y C L I NG :
OF F
E SC
<−
−>
ENTR
Label
<–
– >
ENTR
ESC
Description
Scrolls to the previous function
Scrolls to the next function
Selects the function
Exits Function Activation menu
7.2 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:
C Y C L I NG :
E SC
+
0139027
−>
ENTR
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 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 0.
2. Press –> 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.
7.3 Resetting the Password
Scroll through the functions until the following is displayed:
D I S A B L E P A S S WOR D
E SC
<−
−>
ENTR
Press ENTR to generate the request code, then follow the authorization code procedure indicated above.
7.4 Demo Mode
The test stand is 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. Scroll to the function labeled DEMO MODE.
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Models ESM1500 / ESM750 Test Stands
User’s Guide
8 TROUBLESHOOTING
1. The test stand displays several error messages, as follows:
Error Message
CHECK GAUGE
GAUGE COMM ERROR
GAUGE OVERLOAD
M5/M7 V2.0+ REQD
Description
The instrument is powered off, not in the operating 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 instrument. The
communication settings in the instrument are not correct or the gauge
is not in the operating mode.
The programmed overload percentage of the force gauge’s or load
cell’s full scale has been reached. Immediately reduce the force or
adjust the overload settings.
A Series 5 or 7 instrument with firmware version 2.0 or later is
required for proper operation of the selected functions.
To clear any of the above errors, press STOP. The amber light in the STOP button will be blinking
when 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 that the force value has not exceeded the overload limits configured in the stand.
3. Ensure that instrument’s set points have been configured properly.
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.
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Models ESM1500 / ESM750 Test Stands
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9 MAINTENANCE AND SERVICE
The test stand should be operated in a dry and clean area. Under these circumstances only a few
periodic maintenance operations are required:
9.1 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 lubrication:
1. Remove the upper and lower bellows to expose the ball screw, by separating the Velcro strips at
each end of the crosshead. Velcro locations are identified in the image below:
2. Using a brush, apply a small amount of general purpose bearing grease to the screw, as shown
in the image below:
3. Cycle the crosshead up and down several times until the newly applied grease has been spread
evenly over the length of the screw.
4. Re-install the bellows.
9.2 Slider lubrication
As with the ball screw, periodic lubrication of the slider improves performance and increases the longevity
31
Models ESM1500 / ESM750 Test Stands
User’s Guide
of test stand components. Frequency depends on environmental conditions and usage.
Follow these instructions for proper slider lubrication:
1. Lay the test stand on its side on a flat and secure working surface. Exercise caution while doing
so, as the test stand is heavy.
2. Remove the upper and lower bellows to expose the slider, as per the instructions above.
3. Locate the grease receptacle on the slider, identified in the below image:
4. Using a grease gun, add general purpose bearing grease to the inside of the slider until full. Wipe
clean any spillage. Refer to the image below:
5. Cycle the crosshead up and down several times until the newly applied grease has been spread
evenly over the length of the slide.
6. Re-install the bellows.
9.3 Bearing lubrication
As with the ball screw and slider, periodic lubrication of the bearings improves performance and increases
the longevity of test stand components. Frequency depends on environmental conditions and usage.
Follow these instructions for proper lubrication:
Lay the test stand on its side on a flat and secure working surface. Exercise caution while doing so, as
the test stand is heavy.
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Models ESM1500 / ESM750 Test Stands
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9.3.1 Upper bearing lubrication
1. Remove the large, round plastic cover in the top of the end cap to expose the bearing, identified
in the image below:
2. Apply general purpose bearing grease along the perimeter of the bearing. Wipe clean any excess
grease.
3. Reinsert the plastic cover, as per above.
9.3.2 Lower bearing lubrication
1. Remove the base from the column by removing the six screws, as identified in the image below:
Exercise caution, as the base plate is heavy.
The underside of the column appears as follows:
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Models ESM1500 / ESM750 Test Stands
User’s Guide
2. The drive belt must be removed. To do so, the motor mount screws must be loosened to permit
the motor to be moved, reducing tension on the belt. Access to the motor is located in the back of
the column. Remove the lower sheet metal cover to expose the motor and MDU. Then, remove
the MDU. The motor will now be clearly accessible. Refer to the image below for locations of the
motor mounting screws:
The other two screws are out of view, behind the motor.
3. Remove the belt. The underside of the column now appears as follows:
4. Remove the pulley from the ball screw, identified above, by loosening two set screws. The
underside of the column now appears as follows:
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Models ESM1500 / ESM750 Test Stands
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5. Apply grease to the bearing identified above in the same fashion as the upper bearing.
6. Reassemble, as per above.
9.4 Check for loosened grips and attachments - daily
Check to ensure that the grips attached to the force measuring instrument and base plate are firmly
secured. Looseness could result in a potentially hazardous situation.
9.5 Check for loosened components – once per month
1. Remove the test sample from the test stand.
2. Turn off power to the test stand and disconnect the power cord. 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.
9.6 Removing and replacing the Motor Drive Unit (MDU)
The MDU is the self-contained location of most of the test stand’s electronics, and is designed for quick
removal and replacement in the event of service or repair. If requested by Mark-10 or a distributor to
remove and/or replace the MDU, follow these instructions:
1. Disconnect power to the test stand.
2. Remove the screws from the lower rear panel.
3. When the MDU is accessible, disconnect the four connectors and ground wire identified in the
image below:
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Models ESM1500 / ESM750 Test Stands
User’s Guide
4. Partially loosen the four screws securing the MDU to the frame, lift the MDU up slightly, and pull
out, as shown in the image below:
5. Reinstall in the same fashion.
CAUTION!
The MDU is not field serviceable. Do not attempt to open it.
36
Models ESM1500 / ESM750 Test Stands
User’s Guide
10 SPECIFICATIONS
ESM1500
Load capacity:
Maximum travel:
32.0 in [813 mm]
ESM750
14.2 in [360 mm]
32.0 in [813 mm]
0.001 - 90 in/min
[0.02 - 2,300 mm/min]
14.2 in [360 mm]
0.001 - 60 in/min
[0.02 - 1,525 mm/min]
±0.2%
Speed setting accuracy:
Travel accuracy:
±0.002 in. per 10 in. [±0.05 mm per 250 mm]
Travel resolution:
0.001 in [0.02 mm]
Limit switch repeatability:
±0.001 in [0.03 mm]
Power:
ESM750S
750 lbF [3.4 kN] at
< 35 in [900 mm]/min
500 lbF [2.3 kN] at
> 35 in [900 mm]/min
0.5 - 24 in/min [10 - 600 mm/min]
Standard speed range:
Optional speed range:
ESM1500S
1,500 lbF [6.7 kN] at
< 60 in [1,525 mm]/min
1,000 lbF [4.5 kN] at
> 60 in [1,525 mm]/min
Universal input 80-240 VAC,
50/60 Hz, 450W
Fuse type:
Universal input 80-240 VAC,
50/60 Hz, 120W
4A, 3AG, SLO BLO
Weight (test stand only):
198 lb [90 kg]
160 lb [72 kg]
185 lb [84 kg]
150 lb [68 kg]
Shipping weight:
248 lb [113 kg]
206 lb [93 kg]
236 lb [107 kg]
196 lb [88 kg]
Environmental
conditions:
40 - 100°F [5 - 40°C], max. 96% humidity, non-condensating
37
Models ESM1500 / ESM750 Test Stands
User’s Guide
11 DIMENSIONS in [mm]
11.1 -LC Models
A
ESM1500LC
51.35
[1304.3]
ESM1500SLC
33.89
[860.9]
B
8.13 - 40.13
[206.4 - 1019.2]
8.13 - 22.33
[206.4 - 567.1]
ESM750LC
50.85
[1291.6]
8.13 - 40.13
[206.4 - 1019.2]
ESM750SLC
33.39
[848.1]
8.13 - 22.33
[206.4 - 567.1]
38
Models ESM1500 / ESM750 Test Stands
User’s Guide
11.2 -FG Models
ESM1500SFG
33.89
[860.9]
B
5.25 - 37.25
[133.4 - 946.2]
5.25 - 19.45
[133.4 - 494.0]
ESM750FG
50.85
[1291.6]
5.25 - 37.25
[133.4 - 946.2]
ESM750SFG
33.39
[848.1]
5.25 - 19.45
[133.4 - 494.0]
ESM1500FG
A
51.35
[1304.3]
39
Models ESM1500 / ESM750 Test Stands
User’s Guide
Mark-10 Corporation has been an 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.
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
info@mark-10.com
32-1179
REV 0118
40
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