14 - Brittle Fracture and Impact Testing

Dossier
Materials testing machine
Copyright 2010, Zwick GmbH & Co. KG D-89079 Ulm
Section 4:
2 3
5 6
8 9
Instruction manual
User manual
for materials testing machines
BRA370002000.1
Serial number:
Order confirmation number:
09.10 / 11315 / V5.4
Zwick technical documentation

Instruction manual
2481190
Document
2 3
5 6
8 9
Instruction manual
for materials testing machines
Section 4
General
This section contains information that is important on operating your
materials testing machine and the accessories.
There are short instructions on carrying out tests at the end of the
section. You could copy it and afix it to the materials testing machine.
Document:
User manual
Version:
Print date:
V 5.41
May 2015
Tips, notes and constructive criticism are always welcome. Please direct
these to:
Zwick GmbH & Co. KG
Technische Dokumentation
August-Nagel-Strasse 11
89079 Ulm
dokumentation@zwick.de

Instruction manual
09.10 / 11315 / V5.4
All rights reserved
List of contents
User manual
2 3
5 6
8 9
List of contents
List of contents .................................................................................................................. 3
Safety remarks ................................................................................................................... 7
Symbols on the testing systems ................................................................................... 7
Transport Sign ............................................................................................................. 9
System diagrams of the safety functions .................................................................... 10
Materials testing machine .......................................................................................... 11
EMERGENCY STOP linking ...................................................................................... 15
Operating modes ............................................................................................................. 17
Operating notes ......................................................................................................... 19
Test at speed (6,000 r.p.m.) ....................................................................................... 24
Specimen preparation ............................................................................................... 25
Fault rectification ....................................................................................................... 25
Relevant DIN standards ............................................................................................. 25
Load bearing with air cushion .................................................................................... 26
Operational controls ....................................................................................................... 29
Main switch unit ......................................................................................................... 29
Safety cover .............................................................................................................. 33
General description ................................................................................................... 35
Machines setup ........................................................................................................ 35
Operational controls on the electronics ....................................................................... 37
Commissioning of the materials testing machine ........................................................ 39
Shutdown the materials testing machine ...................................................................... 41
Recommissioning the materials testing machine ......................................................... 43
Types of operation .......................................................................................................... 45

Error messages ............................................................................................................... 47
Set free ..................................................................................................................... 47
Electronics error messages ....................................................................................... 49
Temperature monitoring ............................................................................................. 51
External devices ........................................................................................................ 52
Drive system .............................................................................................................. 53
Index ................................................................................................................................. 61
09.10 / 11315 / V5.4

Instruction manual
Safety
Testing system
2 3
5 6
8 9
Your safety
This user manual should make it easier for you to get acquainted with the
testing system and to use its range of applications.
This user manual contains important notes on using the testing system
safely, properly and economically. Paying attention to these notes helps
to avoid danger, to reduce repair costs and down times as well as to
increase reliability and the lifespan of the testing system.
Authorised persons
The user manual must be read and used by all persons authorised to
work at and with the testing system, such as
- Operating inclusive of setup work, interference rectification in the work
sequence
- Disposing of production waste, maintenance, and disposing of
operating and auxiliary material.
National regulations
Supplement the user manual with instructions from national regulations
on accident prevention and environmental protection.
Please observe and adhere to:

- Valid, binding regulations on accident prevention
- Recognised technical rules for safety and correct working
- Regulations on safety and health protection when preparing and using
working means
- User manuals
The entire user manual must always be available at the installation site of
the test system.
09.11 / 13324 / V5.3

Instruction manual
Safety
Testing system
2 3
5 6
8 9
Operator personnel
The testing system must be operated by qualified and authorised
operator personnel only.
The operator personnel must have knowledge of:
- Safe operation.
- Suitable safety clothing.
- Any potential risks emanating from the testing system.
A trained and authorised operator personnel knows
- Potentially dangerous zones, and keeps clear of them (neither
working nor grasping in the test area whilst the machine is running)
- dangerous specimens and either does not use them or provides
protection against them, e.g. with safety goggles, safety shield,
extraction hood, etc.
- risk of pinching/squashing by specimen grips and thus uses specimen
grippers/tongs when inserting specimens, and operates in inching
mode and with all necessary care
- the risk of injury through cuts caused by extensometer knife edges and
handles these accordingly (using safety gloves), manual attaching only
when the crosshead is stationary
- the risks posed by a laser extensometer and avoids direct eyecontact with the laser beam
- the risks emanating from temperature conditioning device and uses/
wears, for example, suitable safety gloves
For safety reasons only one operator is allowed to operate the

testing system at any one time.

Instruction manual
09.11 / 13324 / V5.3
Workplace
The operators workplace is in front of the testing system during
operation.
Safety notes
2 3
5 6
8 9
Safety remarks
Safety devices are there to protect you and others in the vicinity.
Never ever manipulate safety devices Never carry out tests with
safety devices which have been made passive.
Always adhere to the notes on safety as per section 1.
WARNING
Danger to life and limb!
Non-compliance to the safety remarks
could lead to injury or mortal danger for yourself or
others.
Symbols on the testing systems
The following stickers with pictograms can be attached to the Zwick

testing system and the respective accessories. Please pay attention to
the pictogram and the related safety notes.
Risk of injury!
This part moves.
Caution: No automatic shutdown when touched!
Risk of pinching parts of the body!

This part is closed manually or automatically.
Caution: No automatic shutdown when touched!
11.10 / 11649 / V5.41

Instruction manual
Safety notes
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5 6
8 9
Risk of burning!
These parts can be/get extremely hot.
Risk of frostbite!
These parts can be/get extremely cold.
Dangerous electrical voltage!

Only qualified electricians are allowed to open the housing.
Laser beam!
Only correspondingly trained and qualified personnel may do any work on
the laser of the laser extensometer or bar code reader.

Instruction manual
11.10 / 11649 / V5.41
Safety notes
2 3
5 6
8 9
Transport Sign
A transport sign is to be found at the rear of the materials testing
machines load frame.
Source of danger!
Before transporting, please get informed about the potential sources of
danger.
kg
Heavy machine!
Transport the testing system only using a suitable fork lift truck, crane or
lift-truck. Use suitable lift bearing fixtures and suitable lifting devices.
Danger of tipping over!

Please note that the materials testing machine can tilt over during
transport. Please make sure that nobody is within the area of possible
direction of fall.
11.10 / 11649 / V5.41

Instruction manual
Safety notes
2 3
5 6
8 9
System diagrams of the safety functions

Overview of the safety functions.
Force
monitoring
EMERGENCY
STOP
electronics
Testing system
EMERGENCY
STOP
monitoring (OR
link)
Motor
Brake
(Type
dependent)
Travel
monitoring
EMERGENCY
STOP button
External
EMERGENCY
STOP link
MCE
Electronics
(MCE stands for measurement and control electronics)

Example drawing, not all elements are necessarily available in your testing system.
10

Instruction manual
11.10 / 11649 / V5.41
The testing system is stopped immediately if an event from the

EMERGENCY STOP monitoring is triggered.
Safety notes
Electronics
2 3
5 6
8 9

To enable you to use your materials testing machine safely and
effectively, you must be able to handle a few important safety devices.
This paragraph introduces you to these important safety devices, and
informs you how to operate them safely.
EMERGENCY STOP
In the event of danger, you can bring the materials testing machine to a
stop by pressing or hitting the <EMERGENCY STOP> button. This
disconnects the drive motor from its power supply and brakes it.
TEST
POS
<EMERGENCY
STOP>
ON
12.09 / 9979 / V5.4

Instruction manual
Safety notes
Electronics
2 3
5 6
8 9
Set free buttons

Attention: With the rotating bend fatigue test system, the set-free
speed is reduced to a minimum of 60 revolutions/minute, because
this function is not needed.
TEST
POS
ON
ATTENTION
Danger of irreparable damage!
The set free buttons are active as long as you keep them
pressed.

Instruction manual
12.09 / 9979 / V5.4
Safety notes
Electronics
2 3
5 6
8 9
Safety recommendations
Normal safety devices can only provide protection for the foreseen
application. Protection for any other types of test is the users
responsibility.
Corresponding to the test arrangement we recommend the use of:
- Safety boots
- Ear protectors
+
- Safety goggles
0
-
- Safety gloves
Special safety measures

Use a safety device for any potentially dangerous test requirements. This
is especially true for:
- Specimens with high potential energy and resilience properties, such
as
springs, ropes, belts
- Specimens which splinter at break

- Positioning at high crosshead speeds
- Using hardened or ceramic jaw inserts
All materials testing machines can be equipped with a safety device
(also subsequently).
12.09 / 9979 / V5.4

Instruction manual
Safety notes
Electronics
2 3
5 6
8 9
Disconnecting unneeded peripheral devices

Unneeded peripherals must be unplugged directly from the electronics.
Never disconnect peripheral devices from couplings or other plugs.
Why?
The electronics do not receive any data when test leads are
disconnected. The electronics then outputs an error message about this
peripheral device, and does not permit further testing.
Never here
Attention!
X15
module slots
IV
III
safety device
electrostatic
sensitive
devices
II
I
COM1 PC
COM2 debug
X16
Peripheral device
Always here
Symbolic diagram
All devices connected to the testing system are equipped with uniform
connectors. The retaining screws of the device connectors can be
screwed in/unscrewed by hand.
Tools are not generally needed.
Use a size PH0 or PZ0 screwdriver to unscrew the lock screws if it is not
possible to unscrew them by hand.
Tighten the retaining
screws by hand only

Instruction manual
12.09 / 9979 / V5.4
Device connector
Safety notes
Electronics
2 3
5 6
8 9
EMERGENCY STOP linking
X(NA-OUT)
external emergency off
X (NA-IN)
Electronics
Plug-in the terminator

here
Controllable Zwick components are linked to the materials testing

machine via the EMERGENCY STOP linking Only Zwick components
may be connected to the EMERGENCY STOP chain. These
components must be connected in series.
The EMERGENCY STOP linking belongs to the materials testing
machines safety system.
All components connected via the EMERGENCY STOP linking are shut
down should an event which is contained in the EMERGENCY STOP
monitoring occur.
The terminator must be plugged into the electronics plug X(NA-OUT) if
no controllable components are connected to the materials testing
machine.
Electronics
X(NA-OUT)
X
X(NA-OUT)
X(NA-IN)
X(NA-IN)
X(NA-IN)
X(NA-OUT) X
Connection of several Zwick components

These components must be connected in series. The last components of
the EMERGENCY STOP linking must be closed with a termination plug.
Please pay attention to the following example.
Terminating plug
Last component with

terminator
04.08 / Sicherh / V5.2

Instruction manual
15
Safety notes
Electronics
2 3
5 6
8 9
Check the EMERGENCY STOP linking

You must check the EMERGENCY STOP linking:
- Once a month
- For each alteration to the EMERGENCY STOP linking
Sequence
- Press the <EMERGENCY STOP> on the materials testing machine
=> The ON button at the materials testing machine must extinguish
- Release the <EMERGENCY STOP>
Press the materials testing machines <ON> button.
- Press the <EMERGENCY STOP> at the first component
=> The <ON> button at the materials testing machine must
extinguish
- Release the <EMERGENCY STOP> at the first component
Press the materials testing machines <ON> button.
Check all <EMERGENCY STOP> buttons of all connected Zwick
components in the same manner
No further tests may be run if you have activated an <EMERGENCY
STOP> button and when the <ON> button still illuminates
- At the materials testing machine
and/or
- At a controllable Zwick component
=>
=>
Check all of the plug connections of the entire EMERGENCY

STOP linking
Check that the terminator is plugged into the last component in
the chain
16

Instruction manual
04.08 / Sicherh / V5.2
Please contact ZwickService if you cannot establish the correct

EMERGENCY STOP function in this manner. The address is to be found
in the appendix.
Operating modes
testControl electronics
2 3
5 6
8 9
Operating modes
The materials testing machine can only be operated via a PC with the
corresponding program.
User manual
+
0
-
Information on preparation of test tools can be obtained from chapter

Retrofit, section Specimen grips.
A word about temperature
The testControl electronics is a high quality measuring electronics. To
enable the electronics to work to its utmost capabilities, you must
1. Keep to the warm-up time of approx. one hour for the electronics
2. Ensure a constant ambient and test temperature.
Why?
Tests to standards require constant temperatures for both the electronics
and for the vicinity. Only in this way can relevant statements on your
specimen be made.
Topic 1.
The internal temperature of the testControl electronics stabilizes after
approx. one hour.
Copyright 2002, Zwick GmbH & Co. D-89079 Ulm
Topic 2.
The testControl electronics will inform you if it has detected ambient
temperature deviations that happen to be too high. Tests will not be
cancelled.
05.10 / Betrieba / V5.0

Instruction manual
Operating modes
2 3
5 6
8 9
Inspection after each test

The collet chucks being used must be in a first class condition. Please
check the condition of the jaw inserts before each test. Should wear or
damage to the jaw inserts become apparent, then the inserts must be
exchanged for some in perfect working order.
0
-

Instruction manual
05.10 / Betrieba / V5.0
Attention! When handling specimens:

Danger of burns!
The motor, the specimen and the specimen grips can
become very hot over an extended test duration.
Never ever leave hot specimens lying around unprotected.
Only work with heat-resistant protective gloves.
Operating modes
2 3
5 6
8 9
Operating notes
The following procedure is practical for daily use:
01. Switch the machine on via the main switch on the testControl
electronics below the machine tabletop.
02. Switch on and boot the PC. Start the testXpert software
and UBM500.ZPV.
03. Open the safety cover. If necessary, first unlock it via the software
using the Safety door button.
04. Select a suitable collet chuck for the specimen diameter.
05. Slide specimen into the collet chuck. Only specimens as per
DIN 50113 are permissible
06. Insert the supplied metal rod into the handwheel and use it
to tighten both collet chucks while countering with the hook
spanner.
07. Close the safety cover.
08. Set approx. 100...200 mbar with the pressure control valve
of the pneumatic supply unit, so that the load bearing floats on the
air cushion.
09. Produce air cushions by opening the ON/OFF valve. If
vibrations occur, reduce the air pressure by turning the valve.
09. The load application weight m required for a certain flexural stress
sB (sigma)
is calculated according to the following
formula:
For notched specimens, the resisting moment of the core or remaining

cross section is used (according to DIN 50113).
Further specimens can be found in testXpert under Help testXpert Info
about rotating bar bending fatigue test.
05.10 / Betrieba / V5.0

Instruction manual
Operating modes
2 3
5 6
8 9
Bending moment result module:

The bending moment is calculated from the load application mass, the
gravitational acceleration and the lever length. On the rotating bend
fatigue test system UBM200, this lever is 1 m long.
M=mxgxl
M: Bending moment in Nm
m: Load application mass in kg
g: Gravitational acceleration in m/s
l: Lever length in m
M is calculated from the effective force at the start of test and the lever
length of 1 m if a load cell is connected.
Resisting moment:
For a solid shaft (un-notched specimen)
W = x d3 / 32
d: Diameter of the specimen
Static flexural stress result module:
The static flexural stress is calculated as follows:
s (sigma) = M / W
s (sigma): Static flexural stress

W: Resisting moment
The load application mass is calculated as follows:
m=
s (sigma) x W
lxg

Instruction manual
05.10 / Betrieba / V5.0
Operating modes
Table for UBM bars:
According to DIN 50113

r:B>=3
05.10 / Betrieba / V5.0

Instruction manual
2 3
5 6
8 9
Operating modes
2 3
5 6
8 9
10. Tare the load application weight (steel balls measuring around
3 - 5 mm in diameter (ball bearings) have proven to be useful for
this purpose).
Standard weights are also available as an option.
The load application weight can be tared either via an external scale or
using the load cell option.
The user can now proceed as follows, via the testXpert application
button Load application mass:
a) Zero the force using the corresponding icon on the tool bar
b) Hang in the bucket
c) Fill in steel balls until the determined load application weight is
reached. The force can be read off in N or in kg on the running display.
d) The load application weight is adopted as the load application mass
parameter using the Flexural load button.
e) Hang in the bucket on the load unit again.
The further parameter assignment of the test sequence, e.g. the
specimen data, test r.p.m., limit cycle and break detection parameters,
etc., is performed via the testXpert software.

Instruction manual
05.10 / Betrieba / V5.0
Operating modes
2 3
5 6
8 9
After complete parameter assignment and application of the load, press

the ON button on the testControl unit.
Start the test in testXpert via Start.
If the specimen should slip in the collet chuck, the test will be aborted if
the break detection parameters are set accordingly.
The specimen r.p.m. is continuously monitored during the test via the
active and passive r.p.m. if the break detection parameters are set
accordingly.
If the assigned parameters are correct, the specimen break or the
fulfillment of the test end criteria is detected automatically.
The selected results are logged in testXpert.
Additional operating notes for the testing software are available via the
Online Help of testXpert or can be found in chapter 7 of this instruction
manual.
05.10 / Betrieba / V5.0

Instruction manual
Operating modes
2 3
5 6
8 9
Test at speed (6,000 r.p.m.)

A warm-up run must take place prior to daily operation at max. speed of
6,000 r.p.m.
For this purpose, the machine should be operated for approx. 5 minutes
with installed, unloaded specimen at a speed of approx. 1,000 r.p.m.
Acceleration to the rated speed of 6,000 r.p.m. takes place in approx. 5
seconds.

Instruction manual
05.10 / Betrieba / V5.0
Operating modes
2 3
5 6
8 9
Specimen preparation
The cylindrical shafts must be at least 45 mm long and must have a
diameter tolerance class of h9.
The specimens must be produced according to DIN 50113.
True running must be better than 2/100 mm.
Fault rectification
If the machine cannot be switched on using the ON button on the
testControl unit, this may be caused by the following:
a) The main switch is off or the mains plug is unplugged:
Establish connection with the mains.
b) The EMERGENCY STOP button is actuated or activated.
Pull the EMERGENCY STOP button out again.
c) Fuses tripped in the testControl electronics.
Please contact the Zwick hotline (see chapter 15 in this manual
for contact information)
d) Machine has mechanically blocked: Manually
check the machine for smooth operation. If necessary, remedy
the blockage while observing the applicable safety notes.
If the machine produces unusual noises, either

true running of the clamped specimens is inadequate or one of the
rolling-contact bearings is faulty.
Please contact the Zwick hotline (see chapter 15 of this manual
for contact information).
e) Safety cover not closed properly.
Relevant DIN standards

DIN 50113Rotating bar bending fatigue test
DIN 50100Dynamic fatigue test
We unfortunately cannot include copies of these standards due to legal
reasons (copyright).
However, they are available from:
Beuth Verlag GmbH, Berlin, Cologne
05.10 / Betrieba / V5.0

Instruction manual
Operating modes
2 3
5 6
8 9
Load bearing with air cushion

INSTRUCTIONS FOR HANDLING THE AIR CUSHION PNEUMATICS
The load bearing and the load lever are supported by four air cushions.
Two each of the four air chambers are interconnected by bores in the
plate. The throttle valve reduces the air pressure on the side facing away
from the load lever until the weight asymmetry is compensated.
Procedure
1. The guide rail for the break limit switch is lowered parallel until the
roller on the end of the load lever no longer touches this rail (around 23 mm clearance).
2. After connection to the usual laboratory or workshop compressed air
supply, the cut-off valve is opened.
3. Approx. 100...200 mbar is set with the air pressure control valve.
4. The throttle valve is set so that the weight asymmetry produced by the
load lever is compensated. This can be easily checked by pushing the
load lever slightly.
5. Using the same checking method, the pressure is reduced with the air
pressure control valve until the load bearing can still just slide freely.
6. This free sliding state can now be used to facilitate specimen gripping.

Instruction manual
05.10 / Betrieba / V5.0
7. After gripping the specimen, check true running by turning manually.

The compressed air is then switched off briefly by closing of the cut-off
valve while the machine is accelerating. The compressed air is
switched on again once the desired speed has been reached. This
method offers the advantage of damping the vibrations when passing
through any resonant speeds.
Operating modes
2 3
5 6
8 9
8. If readily perceptible vibrations should occur at operating speedafter

the air cushions are switched on again, they can be damped by
reducing the air cushion pressure. A slight residual vibration should
still be perceptible, so that the vibration-compensating effect of friction
does not begin to falsify the load.
If the damping effect of reducing the air pressure is inadequate, the
limit-switch rail can be additionally raised again.
05.10 / Betrieba / V5.0

Instruction manual
Operational controls
Drive/electronics
2 3
5 6
8 9
The materials testing machine is controlled and monitored via a PC and
a modern, convenient program system.
This reduces the operational controls on the machine itself to a minimum.
Main switch unit
Main switch
The main switch is to be found at the side of or behind the materials

testing machines measurement and control electronics console.
Switch on the materials testing machine. A 1 can be seen in the
switchs view window when the machine is switched on.
EMERGENCY STOP
In the event of danger, you can stop the machine movement immediately
by hitting or pressing the <EMERGENCY STOP> button. The drive motor
is thus disconnected from the power supply, and is eventually stopped
via a brake resistor.
The <EMERGENCY STOP> button remains in the Off position once it
has been activated. Turn the <EMERGENCY STOP> button to release it.
The <EMERGENCY STOP> button then goes into the released position.
Released
<EMERGENCY
STOP>
<EMERGENCY
STOP> in the Off
position
05.10 / Schalt / V5.0
The drive remains at zero potential even after you have reactivated the
<EMERGENCY STOP> button. You must press the <ON> button.
STOP
Instruction manual
Turn until it is released
Drive/electronics
2 3
5 6
8 9
Temperature
The electronics constitute a high-quality measuring system. To enable
the electronics to work to their utmost capability, you must
+
0
-
- Adhere to the warm-up time of approx. one hour for the electronics
- Ensure a constant ambient and test temperature.
Why?
Tests to standards require constant temperatures for both the electronics
and for the vicinity. Only in this way can relevant statements on your
specimen be made.
Heating up time
The internal temperature of the electronics stabilizes after approx. one
hour.
Stable ambient and test temperatures

The electronics will inform you of excessive deviations in ambient
temperature. Tests will not be cancelled.

Instruction manual
05.10 / Schalt / V5.0
Safety notes
2
13
Safety cover
The safety cover is interlocked automatically at a certain minimum speed
or at the start of the test. The cover can be opened only when the speed
is below the minimum speed.
Danger of injury through rotating parts.
The emergency stop circuit is always switched off when the safety cover
is opened, thus reliably preventing the motor from turning.
When the safety cover is closed again, the ON button must be confirmed
again on testControl.
Caution: parts continue to coast after the safety cover is opened.
Do not perform any work in the test area until the drive, motor and
clamping device have come to a complete stop.
A triangle socket key is supplied for the key-operated switch for
emergency release of the safety cover.
The mechanical interlock must always be in the interlocked position for
normal operation.
The key must be kept by the safety officer.
Temperature
Danger of burns.
The motor, the specimen and the specimen grips can become very hot
over an extended test duration.
Never ever leave hot specimens lying around unprotected.
Only work with heat-resistant protective gloves.
Laser pointer/temperature measuring device

Safety goggles arent necessary.
However, avoid looking at the laser light
directly or with the aid of optical instruments.
Work on the laser must must be performed by trained service personnel
only.
05.10 / Sicherh_UBM / V5.0

Instruction manual
General description
2 3
5 6
8 9
General description
The rotating bend fatigue test system produces a sinusoidal load
characteristic by superimposing a free bending moment on the
specimen rotation. The absolute value of the upper and lower stresses is
identical, but the mathematical sign differs. The bending moment is
constant over the entire specimen length because four-point bending is
used. The max. permissible bending moment is 200 Nm.
Machines setup
A lead screw supported by a fixed bearing is located on the right side of
the machine bed. This lead screw is driven by an electric motor behind it.
Opposite the lead screw on the left side, the load bearing that introduces
the bending moment into the specimen via a non-driven shaft can move
freely on a horizontal sliding surface.
The specimen shafts are positively connected with the lead screw or the
shaft of the load bearing with the aid of standard collet chucks.
The bending moment is produced by a larger or smaller weight
according to the magnitude of the bending moment. This weight acts on
a 1,000-mm-long horizonal lever arm via a cable and a deflection roller.
The absolute value of the max. tensile or compressive stress arising in
the edge fiber results from the following relationship for unnotched,
rotationally symmetrical specimens:
MB
m 9.81 1,000 32 N
s (sigma) = =
W
d3 P (Pi) mm
Whereby: MB =
W
=
m
=
d
=
Bending moment
Resisting moment of the specimen
Load application weight (kg)
Specimen diameter (mm) in the test cross-section
The force acting on the lever arm produces an axial load stress in the
specimen, but this stress is less than 0.2% of the flexural stress in the
edge fiber and is thus negligible.
05.10 / 10810 / V5.0

Instruction manual
Electronics
2 3
5 6
8 9
Operational controls on the electronics

The materials testing machine is operated with a PC. First of all we
would like to get you acquainted with the electronics operation.
System overview
<STOP> button
Power indicator lamp

<TEST> button
is not required
<Drive> buttons
are not required
POS
TEST
ON
<POS> button
is not required
<ON> button
<EMERGENCY STOP>
button
<Set free> buttons
are not required
The power indicator lamp lights up when the electronics is switched on. It
indicates that the electronics is switched on.
ON button
ON
OU T
TES T
PO S
IN
ON
OUT
Press the <ON> button to switch the drive system on. The button must be
activated if:
- You have switched the materials testing machine on via the main
switch, or
- a fatal error has occurred in the control electronics.
IN
The <ON> button lights up when the machine is on. The lamp in the
<ON> button is off if the drive system is off.
05.10 / Bedien / V5.0

Instruction manual
Electronics
2 3
5 6
8 9
Control buttons
POS
TEST
The materials testing machine can be driven with the control buttons.
Selected and active buttons indicate this state with illuminated or blinking
button lamps.
TEST
POS
ON
The following control buttons are available:

STOP
POS
TEST
<Up>
<Down>
- The <STOP> button. This closes all of the materials testing machines
drive functions.
- The <POS> button is not used.
- The <TEST> button is not used.
The <EMERGENCY STOP> button and the <SET FREE> buttons have
already been described in this manual under Safety notes.

Instruction manual
05.10 / Bedien / V5.0
- The drive buttons These drive buttons have functions that differ
depending upon whether the <POS> or <TEST> button has been
activated:
<Pos>
button is not used.
<Test>
button is not used.
Commissioning
Drive
2 3
5 6
8 9
Commissioning of the materials testing machine

You must make the following checks before commissioning:
- Has the EMERGENCY STOP been released?
Yes,
then proceed with the next topic.
No,
release it by turning the <EMERGENCY OFF> button.
EMERGENCY STOP
Installation manual
- Are the mechanical limit switches set correctly?

Yes,
No,
slacken the corresponding stops screw (upper and/or lower).
Set the correct switch off point.
Re-tighten the stops screw.
- Is the correct load cell installed?
Yes,
No,
please pay attention to the following when changing/replacing
the load cell:
- Never place the load cell data cable direct on the motor
- Never let transverse forces act on the load cell
Further, more detailed information is contained in the
installation manual under sections Installation/Mounting the
load cell
and
Dismantling/Dismantling the load cell
Please carry out the necessary work.
- Have the correct test tools been mounted?
Yes,
No,
changing test tools is described under paragraph Retrofit in
this manual. Please go to the corresponding page and
adhere to these instructions.
User manual
04.08 / Inbetr / V5.01
- If all preparations are finalised, and, if all listed points have been
answered with Yes, continue on the next page.
If no, re-check all of the topics on this page.

Instruction manual
39
Commissioning
Drive system
2 3
5 6
8 9
Switch the materials testing machine on

Rear view of the
electronics
Switch the materials testing machine on. The MC electronics now runs a
system check. The control buttons illuminate during this period of time.
The operating state of the electronics displays the digit 1.
Switch the PC on, call-up the user program and a test program. The
operating state of the electronics is indicated by the digit 5 after the test
program has been loaded.
Operational state
The system test is finalised in the meantime. This is indicated if the

control buttons do not illuminate.
Now press the ON button <ON> button.
The lamp in the <ON> button illuminates.
The materials testing machine is prepared. The PC has taken over

control of the materials testing machine.
40

Instruction manual
04.08 / Inbetr / V5.01
Shutdown
Drive system
2 3
5 6
8 9
Shutdown the materials testing machine

The following measures should (Must) be taken should the materials
testing machine be shut down for a lengthy period of time:
- Please make sure that the materials testing machine is switched off.
- Disconnect the materials testing machine from the power supply.
- Unplug all cables going from the materials testing machine to an
external device.
- Roll the cable up and store it with the materials testing machine.
- Create a pack list containing all of the accessories.
Make a copy and keep it with your own paperwork.
Please observe the storage requirements. These are described in the

technical manual.
Technical manual
Cover the materials testing machine with a dust cover, e.g. plastic foil.
Make sure there is sufficient ventilation and place a dehumidifying agent
to the equipment.
Store the accessories, the instruction manual and the pack list in a safe,
clean, dust free place, such as in a tool cabinet.
11.04 / Ausser / V5.0

Instruction manual
41
Recommissioning
2 3
5 6
8 9
Recommissioning the materials testing machine

If the materials testing machine has been idle for a lengthy period of
time, you must take the following measures.
- Check the materials testing machines cabling.
The cabling is described in register 3 of the installation manual under
chapter Assembly, electrical connections for the materials testing
machine.
- The materials testing machins must be clean, i.e. free of any visible
dirt and dust. At the same time remove any old grease from the lead
screw(s).
WARNING
Danger of injury
on rotating shafts
and
when working in the test area while the machine is
running!
Long hair, jewelry or loose clothing (e.g. sleeves) could

get caught up in rotating shafts.
Please take the following precautions:
Wear closely fitting clothing
Do not wear jewelry
Use a hairnet if necessary
Please make sure that there is enough room for the
required travel.
05.10 / Wieder / V5.0

Instruction manual

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Materials testing machine

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Zwick technical documentation

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09.10 / 11315 / V5.4

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All rights reserved

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Types of operation .......................................................................................................... 45

09.10 / 11315 / V5.4

Zwick technical documentation

Copyright 2011, Zwick GmbH & Co. KG D-89079 Ulm

Please observe and adhere to:

09.11 / 13324 / V5.3

Zwick technical documentation

For safety reasons only one operator is allowed to operate the

Zwick technical documentation

09.11 / 13324 / V5.3

Copyright 2011, Zwick GmbH & Co. KG D-89079 Ulm

Symbols on the testing systems

Copyright 2010, Zwick GmbH & Co. KG D-89079 Ulm

The following stickers with pictograms can be attached to the Zwick

Risk of pinching parts of the body!

11.10 / 11649 / V5.41

Zwick technical documentation

Dangerous electrical voltage!

Copyright 2010, Zwick GmbH & Co. KG D-89079 Ulm

Zwick technical documentation

11.10 / 11649 / V5.41

Copyright 2010, Zwick GmbH & Co. KG D-89079 Ulm

Danger of tipping over!

11.10 / 11649 / V5.41

Zwick technical documentation

System diagrams of the safety functions

(MCE stands for measurement and control electronics)

Zwick technical documentation

11.10 / 11649 / V5.41

Copyright 2010, Zwick GmbH & Co. KG D-89079 Ulm

The testing system is stopped immediately if an event from the

Materials testing machine

Copyright 2009, Zwick GmbH & Co. KG D-89079 Ulm

12.09 / 9979 / V5.4

Zwick technical documentation

Set free buttons

Copyright 2009, Zwick GmbH & Co. KG D-89079 Ulm

Zwick technical documentation

12.09 / 9979 / V5.4

Special safety measures

Copyright 2009, Zwick GmbH & Co. KG D-89079 Ulm

- Specimens which splinter at break

12.09 / 9979 / V5.4

Zwick technical documentation

Disconnecting unneeded peripheral devices

Zwick technical documentation

12.09 / 9979 / V5.4

Copyright 2009, Zwick GmbH & Co. KG D-89079 Ulm

EMERGENCY STOP linking

external emergency off

Plug-in the terminator

Controllable Zwick components are linked to the materials testing

Copyright 2008, Zwick GmbH & Co. KG D-89079 Ulm

Connection of several Zwick components