Instron 4400 Series Operator's Manual

Issue C April 1995

Instron

Model 4400

Universal Testing System

M10-94400-1

Operator’s Guide

This document and the information that it contains are the property of Instron
Corporation. Rights to duplicate or otherwise copy this document and rights to
disclose the document and the information that it contains to others and the right
to use the information contained therein may be acquired only by written
permissionsigned by a duly authorized officer of Instron Corporation.

Proprietory Rights Notice

© Copyright 1995 Instron Corporation

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Preliminary Pages

Materials testing systems are potentially hazardous.
Materials testing involves inherent hazards from high

forces, rapid motions and stored energy. You must be
aware of all moving and operating components which
are potentially hazardous, particularly the actuator in a
servohydraulic testing system or the moving crosshead
in an electromechanical testing system.

Whenever you consider that safety is compromised,
press the Emergency Stop button to stop the test and iso­late the testing system from hydraulic or electrical
power.

Carefully read all relevant manuals and observe all
Warnings and Cautions. The term Warning is used
where a hazard may lead to injury or death. The term
Caution is used where a hazard may lead to damage to
equipmentortolossofdata.

Ensure that the test set-up and the actual test you will
be using on materials, assemblies or structures consti­tutes no hazard to yourself or others. Make full use of
all mechanical and electronic limits features. These are
supplied for your safety to enable you to prevent move­ment of the actuator piston or the moving crosshead be­yond desired regions of operation.

The following pages detail various general warnings
that you must heed at all times while using materials
testing equipment. You will find more specific warn­ings and cautions in the t ext whenever a potential haz­ard exists.

Your best safety precautions are to gain a thorough un­derstanding of the equipment by reading your instruc­tion manuals and to always use good judgement.

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Preliminary Pages M10-94400-1

Warning

Disconnect the electrical power supply be­fore removing the covers to electrical equip­ment.

Disconnect the equipment from the electrical power sup­ply before removing any electrical safety covers or re­placing fuses. Do not reconnect the power source while
the covers are removed. Refit covers as soon as possible.

Disconnect power supplies before remov­ing the covers to rotating machinery.

Disconnect the equipment from all power supplies be­fore removing any cover which gives access to rotating
machinery. Do not reconnect any power supply while
the covers are removed unless you are specifically in­structed to do so in the manual. If the equipment needs
to be operated to perform maintenance tasks with the
covers removed, ensure that all loose clothing, long hair,
etc. is tied back. Refit covers as soon as possible.

Shut down the hydraulic power supply and
discharge hydraulic pressure before discon­necting any hydraulic fluid coupling.

Do not disconnect any hydraulic coupling without first
shutting down the hydraulic power supply and discharg­ing stored pressure to zero. Tie down or otherwise se­cure all pressurized hoses to prevent movement during
system operation and to prevent the hose from whipping
about in the event of a rupture.

vi

Warning

Do not release gas connections without first disconnect­ing the gas supply and discharging any residual pressure
to zero.

Use protective shields whenever a risk of injury to opera­tors and observers exists from the failure of a test speci­men, assembly or structure, particularly where explosive
disintegration may occur.Due to the wide range of speci­men materials, assemblies or structures that may be tested,
any hazard resulting from the failure of a test specimen, as­sembly or structure is entirely the responsibility of the
owner and the user of the equipment.

Preliminary Pages

Shut off the supply of compressed gas and
discharge residual gas pressure before dis­connecting any compressed gas coupling

Use protective shields or screens if any pos­sibility exists of a hazard from the failure of
a specimen, assembly or structure under
test.

Protect electrical cables from damage and
inadvertent disconnection.

The sudden loss of controlling and feedback signals
which can result from a disconnected or damaged cable
causes an open loop condition which may drive the ac­tuator or crosshead rapidly to its extremes of motion.
Protect all electrical cables, particularly transducer ca­bles, from damage. Never route cables across the floor
without protection, nor suspend cables overhead under
excessive strain. Use padding to avoid chafing where ca­bles are routed around corners or through wall openings.

vii

Preliminary Pages M10-94400-1

Warning

Wear protective clothing when handling
equipment at extremes of temperature.

Materials testing is often carried out at non-ambient tem­peratures using ovens, furnaces or cryogenic chambers.
Extreme temperature means an operating temperature ex­ceeding 60 °C (140 °F) or below 0 °C (32 °F). You must
use protective clothing, such as gloves, when handling
equipment at these temperatures. Display a warning no­tice concerning low or high temperature operation when­ever temperature control equipment is in use. You
should note that the hazard from extreme temperature
can extend beyond the immediate area of the test.

Take care when installing or removing a
specimen, assembly or structure.

Installation or removal of a specimen, assembly or struc­ture involves working inside the hazard area between the
grips or fixtures. Keep clear of the jaws of a grip or fix­ture at all times. Keep clear of the hazard area between
the grips or fixtures during actuator or crosshead move­ment. Ensure that all actuator or crosshead movements
necessary for installation or removal are slow and,
where possible, at a low force setting.

viii

Warning

The actuator or crosshead will immediately respond to
manual control settings when the system is placed off­line from computer control. Before transferring to man­ual control, make sure that the control settings are such
that unexpected actuator or crosshead movement cannot
occur.

The robot in an automated testing system presents a haz­ard because its movements are hard to predict. The robot
can go instantly from a waiting state to high speed opera­tion in several axes of motion. During system operation ,
keep away from the operating envelope of the robot. De­activate the robot before entering the envelope for any
purpose, such as reloading the specimen magazine.

Preliminary Pages

Do not place a testing system offline from
computer control without first ensuring that
no actuator or crosshead movement will oc­cur upon transfer to manual control.

Keep clear of the operating envelope of a
robotic device unless the device is de-acti­vated.

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Preliminary Pages M10-94400-1

Table of Contents

Chapter Page

1 Introduction

Outline .........................................................................1-1

Introduction..................................................................1-2

About this Manual...............................................1-3

Product Support..................................................1-3

General Characteristics...............................................1-4

Console Components..................................................1-7

Front Panel..................................................................1-8

Main Panel Section.............................................1-8

Display Panel Section.........................................1-10

Limits Panel Section ...........................................1-10

Crosshead Control Section.................................1-11

Internal Status Indicators ....................................1-12

Recorders ...........................................................1-12

Console Internal Functions..........................................1-14

Central Processing Unit (CPU) ...........................1-14

Crosshead Control Function ...............................1-14

Load Sensor Conditioner....................................1-14

Strain Sensor Conditioner...................................1-15

IEEE-488 Interface .............................................1-15

2 Specifications

Introduction..................................................................2-2

Specifications...............................................................2-3

3 Installation

Outline .........................................................................3-1

General Considerations...............................................3-2

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Preliminary Pages

Table of Contents (continued)

Chapter Page

3 Installation

(continued)

Console Connections...................................................3-3

Mounting the Console.........................................3-3

Attaching the Console...................................3-3

Mounting the Console Bracket......................3-4

Connector Panel.................................................3-5

Installing Cables .................................................3-7

Cabling for Optional Equipment..........................3-9

Cables...........................................................3-9

Analog Output Connector .............................3-9

Opening the Console...................................................3-11

4 Function Of Controls

Outline .........................................................................4-1

Preliminary Considerations..........................................4-2

Function Of Controls....................................................4-3

Main Panel..........................................................4-3

Display Section...................................................4-12

Limits Section .....................................................4-14

Data Storage ...............................................................4-16

Nonvolatile Memory............................................4-16

System Reset .....................................................4-16

Volatile Memory ..................................................4-16

Resident Test Program Overview................................4-20

Self Test Routine .........................................................4-23

Self Test - Part 1 .................................................4-23

Self Test - Part 2 .................................................4-24

Self Test Result - No Failures .............................4-24

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Preliminary Pages M10-94400-1

Table of Contents (continued)

Chapter Page

4 Function Of Controls

(continued)

Self Test Result - Failures...................................4-25

Self Test Result Display......................................4-25

Version Number...........................................................4-31

Selecting Operating Units............................................4-32

Switching Units ...................................................4-32

Operating Units for Self Identified Load Cells

and Load Frames................................................4-33

Operating Units for Non-Self Identified Load

Cells and Load Frames.......................................4-34

Area...................................................................4-35

Energy Units .......................................................4-35

5 System Operation

Outline .........................................................................5-1

Operating Considerations............................................5-2

Pretest Procedures......................................................5-3

Turn Instrument On: Warm-up.....................................5-4

Self Test Routine At Power Up ....................................5-5

System Reset At Initial Power Up................................5-7

Load Calibration ..........................................................5-8

Overview ............................................................5-8

Electrical Calibration of Self Identifying

Load Cells ..........................................................5-9

Manual Calibration of Self Identifying

Load Cells ..........................................................5-10

Electrical Calibration of Non-Self Identifying

Load Cells...........................................................5-12

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Preliminary Pages

Table of Contents (continued)

Chapter Page

5 System Operation

(continued)

Manual Calibration of Non-Self Identifying

Load Cells..........................................................5-13

Load Weighing System Balance ........................5-15

Calibration And Balance Errors...........................5-16

Strain Calibration.........................................................5-18

Overview.............................................................5-18

Strain Operating Mode........................................5-18

Strain Gauge Extensometers..............................5-20

Electrical Calibration of Self Identifying Strain

Gauge Extensometers ......................................5-22

Manual Calibration of Strain Gauge

Extensometers...................................................5-22

Extensometers - Operating Notes.......................5-25

Display Panel...............................................................5-26

Description..........................................................5-26

Operation............................................................5-26

Establish Gauge Length ..............................................5-28

Electronic Limits...........................................................5-30

Operating Notes - Limits Panel...........................5-30

Operation............................................................5-31

Set Crosshead Travel Limit Stops...............................5-34

Set Crosshead Speed .................................................5-35

Crosshead Jog Control................................................5-37

Area Compensation.....................................................5-38

Install Specimen ..........................................................5-42

Set Testing Area ..........................................................5-43

Run a Test ...................................................................5-45

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Preliminary Pages M10-94400-1

Table of Contents (continued)

Chapter Page

6 System Options

Overview......................................................................6-1

Introduction..................................................................6-2

Strip Chart Recorder....................................................6-3

Description..........................................................6-3

Specifications......................................................6-4

Power Requirements ....................................6-6

Installation...........................................................6-7

Operation............................................................6-8

Pen Scaling...................................................6-8

Pen Calibration .............................................6-9

X-Y Recorder...............................................................6-12

Description.........................................................6-12

Specifications......................................................6-13

Installation...........................................................6-15

Power Requirements ....................................6-15

Signal Input Connection................................6-15

Operation............................................................6-16

Initial Setup...................................................6-16

Calibration.....................................................6-19

Time Base Operation....................................6-22

Normal Operation..........................................6-23

Printer..........................................................................6-24

Description..........................................................6-24

Installation...........................................................6-24

Operation............................................................6-25

Printout Format...................................................6-25

Printer Units........................................................6-26

xiv

Preliminary Pages

Table of Contents (continued)

Chapter Page

6 System Options

(continued)

AC/DC Strain Conditioner............................................6-30

Specifications......................................................6-31

Installation...........................................................6-31

Operation............................................................6-32

Preset Points ...............................................................6-34

Description..........................................................6-34

Operation............................................................6-35

Energy .........................................................................6-37

Description..........................................................6-37

Operation............................................................6-37

Cycle Counter..............................................................6-39

Pip Control...................................................................6-41

Air Kit Option ...............................................................6-44

Overview.............................................................6-44

Description..........................................................6-44

Operation............................................................6-45

Manual Operation .........................................6-46

Grip Control Function Operation ...................6-47

Pretension and Excess Tension Operation...6-47

Automatic Start Operation.............................6-48

Automatic Release Operation .......................6-49

Set pretension Level .....................................6-49

Set Excess Tension Level .............................6-50

Time Delays ..................................................6-50

Continuous Pretension Testing.....................6-50

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Preliminary Pages M10-94400-1

Table of Contents (continued)

Chapter Page

7 Test Check List
8 Maintenance

Overview......................................................................8-1

Introduction..................................................................8-2

General...............................................................8-2

Special Maintenance Considerations..................8-2

Preventive Maintenance ..............................................8-3

Cleaning - Control Console.................................8-3

Error Messages ...........................................................8-4

Overview.............................................................8-4

Displaying Error Messages.................................8-4

Rear Panel Indicators ..................................................8-10

Rear Panel Indicators .........................................8-10

General.........................................................8-10

Power Supply Condition Indicators...............8-11

Green Test LEDs...........................................8-11

Red Activity LEDs .........................................8-12

Red Latch Indicator LEDs.............................8-13

IEEE-488 Interface Indicators.......................8-14

Summary of Operating Sequence for

Rear Panel Indicators ..................................8-15

Fault Indications ..........................................................8-16

Appendix A Test Planning

Applications .................................................................A-2

Load Requirements .....................................................A-4

Selection Of Grips........................................................A-5

xvi

Preliminary Pages

Table of Contents (continued)

Chapter Page

Appendix A Test Planning (continued)

Establishing Gauge Length..........................................A-7

Selection Of Testing Speed .........................................A-8

Strain Rate...................................................................A-9

Area Compensation.....................................................A-10

Description..........................................................A-10

Determining Stress Range..................................A-11

Limitations Due To Load Cell Capacity ...............A-12

Chart Magnification......................................................A-14

Appendix B Glossary

xvii

Preliminary Pages M10-94400-1

List of Illustrations

Figure Page

1-1. Functional Block Diagram............................................1-5

1-2. Control Console Front Panel ......................................1-9

3-1. Console Rear Panel Connectors .................................3-6

3-2. Rear Panel Cable Arrangement...................................3-8

3-3. Access to Interior of Console.......................................3-12

4-1. Main Panel...................................................................4-3

4-2. Display Section............................................................4-12

4-3. Limits Section ..............................................................4-14

4-4. Console Section Numbers Assigned to

Main Panel Display for Self Test Result......................4-26

4-5. Coding of Display Results for Self Test Result ............4-27

4-6. Characters Displayed in Self Test Result....................4-27

6-1 Model 4400 X-Y Recorder Panel.................................6-17

6-2. Typical Test Curve with Preset Points..........................6-34

8-1. Rear Panel Indicators .................................................8-12

8-2. Closeup Detail of Console Status and

Fault Indicators............................................................8-13

xviii

Preliminary Pages

List of Tables

TablePage

3-1. Series 4400 Console Option Cables............................3-9

3-2 Analog Output Connector Pin Assignments ................3-10

4-1. Main Panel Functions..................................................4-3

4-2. Display Section Functions ...........................................4-12

4-3. Limits Section Functions..............................................4-14

4-4. Variables and Functions in Nonvolatile

Memory........................................................................4-17

4-5. Control Console Sections ............................................4-26

4-6. Characters Possible in Self Test Result for

Each Digit of Main Panel Display.................................4-29

4-7. Operating Units for Self-Identified Load

Cells 4-33

5-1. Low Capacity Load Cells Calibration Data ..................5-13

5-2. Transducer Calibration/Balance Errors........................5-17

6-1. Strip Chart Recorder Supplies.....................................6-6

6-2. Recorder Line Voltage Selection .................................6-7

6-3. Calibration Signal for Load Cells .................................6-10

6-4. Recorder Supplies.......................................................6-14

6-5. Chart Speed Conversions............................................6-22

6-6. Strain Units Printout.....................................................6-26

6-7. Energy Units Printout...................................................6-27

6-8. Printout with Strain as Independent

Variable........................................................................6-28

6-9. Printout with Extension as Independent

Variable........................................................................6-28

xix

Preliminary Pages M10-94400-1

List of Tables (continued)

Table Page

6-10. Example Pip Delay Values vs Test Speeds.................6-43

6-11. Air Kit Functions ..........................................................6-46

8-1. Sections of the Control Console..................................8-5

8-2. Error Messages ...........................................................8-7

8-3. LED Error Codes for IEEE-488 Section Tests .............8-14

8-4. Fault Indications ..........................................................8-16

A-1. Gripping Techniques....................................................A-6

A-2. Typical Testing Speed Ranges for Various

Materials......................................................................A-8

xx

Preliminary Pages

xxi

Preliminary Pages M10-94400-1

Frontispiece.Series 4400 Universal Testing System

xxii

Outline

Chapter 1

Introduction

Introduction

• Introduction ........................Page 1-2

• General Characteristics ...............Page 1-4

• Console Components .................Page 1-7

• Front Panel.........................Page 1-8

• Console Internal Functions ............Page 1-14

The Instron Series 4400 Universal Testing Instruments are
electromechanical systems employing the latest printed cir­cuit board technology to provide a small, light and efficient
testing system. This manual describes the functions and op­eration of the Control Console. Other manuals include
Load Frame operating instructions for each of the Series
4400 systems and an IEEE Interface User’s Guide.

This chapter describes:

• The features and functions of the Series 4400

Systems

• The physical layout of the system

• Some of the optional accessories available for the

system

1-1

Introduction M10-94400-1

Introduction

The Instron Series 4400 Universal Testing Instrument is
a materials testing instrument designed to test the
strength of a wide variety of materials. The system is
made up of a load frame, in which a specimen of the
test material is mounted, that applies a tension or com­pression load to the specimen, and a control console that
provides the calibration, test setup, and test operating
controls. The control console is compact enough to
mount directly on the load frame, eliminating the need
for a separate support table or workbench.

The Series 4400 Control Console includes an operator’s
front panel with controls that offer complete communica­tions with the system through a numeric keypad, push­button selection switches and Liquid Crystal Displays
(LCDs).

The Console front panel is divided into sections according
to functional groupings of controls. For example, a Main
section contains a numeric keypad and digital display for
data input, a Limits section sets up the electronic limits,
and a Display section contains LCD displays of real-time
values of test parameters. These panel sections are de­scribed more fully later in this chapter.

1-2

Optional interfacing is available for an X-Y or a strip chart
recorder, a printer, and a programmable computer. These
options may be specified with your initial order or added
later to expand the capabilities of your testing system.

About this Manual

The purpose of this manual is to provide a basic under­standing of the Control Console and its principles of op­eration. It contains specifications, cable installation,
component and control descriptions, operating details
for both basic and optional features, and maintenance.
Appendices contain an introduction to materials testing
and a glossary of terms related to materials testing.

In addition to this manual, there is also a manual cover­ing the installation, maintenance, and parts list for the
load frame. Accessories, such as the strip chart and X-Y
recorders, printer, and most grips and extensometers,
come with their own separate instruction manuals.

Product Support

If you encounter any problems with using or maintain­ing your testing instrument, or if you want to order ac­cessories or parts, you can obtain answers to your
questions or place orders by calling Instron Service, us­ing the list below:

Introduction

Introduction

In the United States: 1-800-473-7838
In Canada: 1-800-461-9123
In all other regions of the world: Nearest Instron

Service Office

A listing of international Instron Sales and Service of­fices, including addresses and telephone numbers, can
be found on the back cover of this manual.

1-3

General Characteristics M10-94400-1

General Characteristics

The Series 4400 control system is made up of two major
subsystems: a crosshead drive and control system, that
applies tensile or compressive loading to a specimen;
and a highly sensitive load weighing system, that meas­ures the loading of a specimen. Figure 1-1 is a functional
block diagram showing the interfacing of these two sys­tems, and the signal flow within the overall instrument.
During a test, results occur as tracked (instantaneous)
values of load, extension and strain or, after a test, as
stored break and peak values of these parameters. Total
energy and load and energy values at preset points are
also available as stored parameters. Several choices of
analog and digital output devices are available as op­tions for viewing and recording test results.

The control console provides control, data acquisition
and data readout functions for the load frame. All opera­tions are directed by a microprocessor-based central
processing unit (CPU). The crosshead control network
allows programmable crosshead speeds and provides
digital control of the crosshead position. The operating
mode of the console data entry and readout functions
can be in English, metric or SI units, as selected by a
switch. A status indicator on the main panel shows the
system of units selected.

1-4

The action of the moving crosshead during a test - stop,
return, or cycle - can be controlled manually by pushbut­ton switches, or automatically by the functions provided
by the Limits feature. These functions may be based on
the applied load, extension or strain, or to a detected
specimen break.

General Characteristics

Introduction

Figure 1-1. Functional Block Diagram

1-5

General Characteristics M10-94400-1

A CPU-controlled sensor conditioner in the load weigh­ing system allows calibration and balance procedures to
be performed automatically, after you initiate them at
the front panel. The sensor conditioner provides both an
unranged analog and an automatically ranged digital
load signal output suitable for several types of optional
readout devices.

Optional readouts for test results include interfacing for
an X-Y recorder, a strip chart recorder, and an 80 charac­ter-width printer.

The console also has provisions for an IEEE-488 inter­face. This is a General Purpose Instrument Bus (GPIB)
which allows remote supervisory control of test proce­dures through a programmable computer.

1-6

Console Components

The Series 4400 Control Console contains a single
printed circuit board on which are mounted all of the
electrical components, including the front panel
switches and displays, and rear panel connectors.

The console printed circuit board is the interface for all
connections to the console. The interconnecting cables
from the load frame and load cell, and cabling from op­tional recorders, printers, and strain measuring devices
plug into connector locations on the rear of the board.

Since the console receives its electrical power from a
d.c. power supply in the load frame, there is no need for
bulky power supplies and cooling fans, and thus a com­pact size has been achieved.

The Console itself is mounted on the load frame by
means of a special bracket. A friction locking device on
the bracket rides in grooves in the crosshead column cov­ers on the load frame, allowing the console to be moved
to any convenient working height. The bracket is sym­metrical, allowing the console to be mounted on either
the right-hand or left-hand column on the frame.

Console Components

Introduction

The main components of the control console are shown
in Figure 1-2. Access to the interior of the console is de­scribed in Chapter 4.

1-7

Front Panel M10-94400-1

Front Panel

The Front Panel (Figure 1-2) is divided into four major
sections. The Main section contains a numeric keypad
for data entry of system setup parameters, an LCD dis­play for the numeric input, pushbuttons for such func­tions as crosshead speed selection, and gauge length
setting, among others. The Display section contains
LCD displays of real-time values of Load, Extension,
and Strain, while the Limits section sets electronic limits
for the system. The last section is the Crosshead Control
section, in which manual controls for crosshead position­ing are located.

Main Panel Section

The Main Panel section consists of test function entry
keys, a numeric keypad and a 4-digit LCD display.
Status indicators on the left-hand side of the panel, when
lit, signify that a fault has occurred. The current units
(S.I., English, metric) in use by the testing system are
also shown in this area. The panel provides the follow­ing functions:

• Load cell calibration

• Crosshead speed selection

• Gauge length

1-8

• Area compensation

• Testing area definition

• Strain transducer calibration

• Printer operation

• IEEE bus enable/disable

• Special Software - Diagnostics