Mark-10 ESM1500 Instruction Manual

Model ESM1500

FORCE TEST STAND

User’s Guide

Model ESM1500 Test Stand User’s Guide

Thank you…

Thank you for purchasing a Mark-10 ESM1500 Force Test Stand, designed for
producing up to 1,500 lbF (6.7 kN) of tension and compression force. The
ESM1500 is an essential component of a force testing system, typically also
comprising a force gauge, or load cell with indicator, and grips.

With proper usage, we are confident that you will get many years of great
service with this product. Mark-10 test stands are ruggedly built for many
years of service in laboratory and industrial environments.

This User’s Guide provides setup, safety, and operation instructions.
Dimensions and specifications are also provided. For additional information or
answers to your questions, please do not hesitate to contact us. Our technical
support and engineering teams are eager to assist you.

Before use, each person who is to use the test stand 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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Model ESM1500 Test Stand User’s Guide

1 OVERVIEW

1.1 List of included items

Qty. Description

1 Load cell / indicator mounting bracket – ESM1500LC only

Force gauge mounting bracket – ESM1500FG only

1

Base eye end

2

Lock ring for eye end

2

Spanner wrench

4

Force gauge/indicator mounting screws, #6-32

4

Force gauge mounting screws, #10-32 – ESM1500FG only

1

Cable, instrument to test stand crosshead

1

Power cord
1 USB cable, A/B
1 Allen wrench set
1 Resource CD

1.2 Physical Features

Note the following physical features of the ESM1500. The user’s guide will reference this terminology.

Column cap

Limit
switches
(not visible)

Interface
cable

Indicator

Load cell /
force sensor /
force gauge

Upper grip

Test sample

Lower grip

Base plate

Base

Column

Bellows

Control panel

Crosshead

Emergency stop

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Model ESM1500 Test Stand 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 integrated levers.

To mount the controller to the bracket, fasten the two
provided screws through the bracket and into the
housing of the controller, 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 controller 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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Model ESM1500 Test Stand 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.
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:

When the +5V

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Model ESM1500 Test Stand 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 (ESM1500LC)

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 (ESM1500FG)

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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Model ESM1500 Test Stand User’s Guide

2.6 Safety / Proper Usage

Typical materials able to be tested by the ESM1500 include many raw materials and manufactured items,
such as springs, metals, plastics, electronic components, mechanical assemblies, packaging materials,
and many others. Items that should not be used with the ESM1500 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 ESM1500 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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Model ESM1500 Test Stand 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 those 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 the power is turned off to prevent accidental
engagement of any of the controls.

3.2 Controls
1

6

5

Label Function

1 SOFT KEYS

2 UP

3 STOP

4 DOWN

5 FollowMeTM

6 ZERO TRAVEL

3.2 Emergency Stop

Functions are determined by the corresponding text on the display.

Commences movement in the up direction.

Stops crosshead movement.

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.

2

3

4

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Model ESM1500 Test Stand User’s Guide

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 ESM1500 has three functional modes:

1. OPERATING MODE
This is the operating mode in which testing sequences can be started and stopped.

2. TEST FUNCTION SETUP
In this mode, test functions are configured, such as rate of speed, number of cycles, password
editing, and other functions.

3. FUNCTION ACTIVATION

Many test stand functions, such as cycling, auto return, distance measurement, and others are
ordered individually as options. The Function Activation menu provides a means of identifying
which functions were purchased. Through this menu, it is also possible to enable any functions
not originally purchased via an activation code. All functions are temporarily enabled for the first
160 hours of operation, as described below:

DEMO MODE

The ESM1500 is shipped in Demo Mode, during which time all available functions
are temporarily activated for 160 hours of operation. At power-up, a counter displays
the number of hours remaining, as follows:

R E MA I N I N G D E MO

T I ME : 1 6 0 HOUR 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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Model ESM1500 Test Stand User’s Guide

4 TEST FUNCTION SETUP

This section provides configuration instructions for each test function.

Function Standard / Optional
Speed - same setting applies to both directions Standard
Travel indication Optional
Independent up and down speeds Optional
High speed range extension Optional
Low speed range extension Optional
Auto return Optional
Cycling with dwell time Optional
Programmable travel limits Optional
Overload protection Optional
Preload Optional
Loadholding Optional
Break detection Optional
PC control Optional
FollowMeTM Optional
Profiles Optional
Communication settings Standard
Units of speed measurement Standard
Programmable button configuration Standard
Password protection Standard

All ESM1500 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 E D : 0 . 0 0

me n u m i n ma x S E T

After pressing menu, the initial Test Function Setup screen appears as follows:

S P E E D : 2 0 . 0 0

E S C < − − > E N T R

Label Description

ESC
< –
– >
ENTR

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.

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

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Model ESM1500 Test Stand 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

E S C + E D I T S A V E

Label Description

ESC
+

EDIT

SAVE

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:

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

S A V E C H A N G E S ?

N O Y E S

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: 10 in/min / 250 mm/min
Available settings: 0.001 – 90 in/min / 0.02 – 2,300 mm/min

U P S P E E D : 1 0 . 7 3

E S C − + E N T R

Label Description

+

–

ENTR

ESC

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.

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

Exits the function without saving changes

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Model ESM1500 Test Stand User’s Guide

Default setting: off
Available settings: off, on

A U T O R E T U R N o f f

E S C − + E N T R

Label Description

+ or –
ENTR

ESC

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

C Y C L E S : 0 0 0 0 0

E S C − + E N T R

Cycles through the available settings
Returns to the Test Function Setup menu

Exits the function without saving changes

Label Description

+

–

Press and hold
+ and –
simultaneously
ENTR

ESC

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

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

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Model ESM1500 Test Stand User’s Guide

H I D WE L L : 0 0 0 0 . 0

E S C − + E N T R

Label Description

+

–

ENTR
ESC

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 settings: +39.000 in, -39.000 in / +990 mm, -990 mm
Available settings: -39.000 to +39.000 in / -990 to +990 mm

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

H I L I M I T : 2 . 0 5 8

E S C − + E N T R

Label Description

+

–

ENTR
ESC

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 ESM1500 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

O V E R L D : MA R K - 1 0

E S C − + E N T R

4.5.2 Compression and Tension Overload Settings (COMP OVERLD and TEN OVERLD)

This setting corresponds to the percentage of full scale at which crosshead travel stops. For example, a
setting of 80% for a 1,000 lbF capacity load cell would stop crosshead travel when approximately 800 lbF
is reached.

Note:

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Model ESM1500 Test Stand User’s Guide

%

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% - 100% (10% increments)

C O MP O V E R L D : 1 0 0

E S C − + E N T R

Label Description

+ or –
ENTR
ESC

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 O A D : Z E R O , G O

E S C − + E N T R

Label Description

+ or –
STOP
STOP, ZERO
ZERO, GO
ENTR
ESC

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%

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

P R E L D %F S : 0 1 . 0

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Model ESM1500 Test Stand User’s Guide

E S C − + E N T R

Label Description

+ or –
ENTR
ESC

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 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 O A D H O L D I N G : O N

E S C − + E N T R

Label Description

+ or –
ENTR
ESC

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

B R E A K D E T E C T : O N

E S C − + E N T R

Increases or decreases the value, in increments of .1
Returns to the Test Function Setup menu
Exits the function without saving changes

Cycles through the available settings
Returns to the Test Function Setup menu
Exits the function without saving changes

Label Description

+ or –
ENTR
ESC

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)

Cycles through the available settings
Returns to the Test Function Setup menu
Exits the function without saving changes

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Model ESM1500 Test Stand User’s Guide

%

%

B R K T H R E S H : 8 0

E S C − + E N T R

Label Description

+ or –
ENTR
ESC

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)

B R E A K

Increases or decreases the value.
Returns to the Test Function Setup menu
Exits the function without saving changes

P E A K : 1 0

E S C − + E N T R

Label Description

+ or –
ENTR
ESC

Note:

When using an ESM1500 with a Series 7 instrument, enable Break Detection in either the test stand or
the instrument. 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:

Default setting: CONSOLE
Available settings: CONSOLE, PC

C O N T R O L : C O N S O L E

E S C − + E N T R

Increases or decreases the value.
Returns to the Test Function Setup menu
Exits the function without saving changes

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.

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Model ESM1500 Test Stand User’s Guide

Label Description

+ or –
ENTR
ESC

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

B A U D R A T E : 1 1 5 2 0 0

E S C − + E N T R

Label Description

+ or –
ENTR
ESC

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:

8-1o 8 stop bits, 1 stop bit, odd parity
8-1n 8 data bits, 1 stop bit, no parity
8-2n 8 data bits, 2 stop bits, no parity
7-1E 7 data bits, 1 stop bit, even parity
7-1o 7 data bits, 1 stop bit, odd parity
7-2E 7 data bits, 2 stop bits, even parity
7-2o 7 data bits, 2 stop bits, odd parity
7-2n 7 data bits, 2 stop bits, no parity

S T O P & P A R : 8 - 1 n

E S C − + E N T R

Cycles through the available settings
Returns to the Function Setup menu
Exits the function without saving changes

Cycles through the available settings
Returns to the Function Setup menu
Exits the function without saving changes

8-1E 8 stop bits, 1 stop bit, even parity

Label Description

+ or –
ENTR
ESC

4.12 Units of Speed (UNITS)

This setting corresponds to units of speed measurement.

Default setting: in/min
Available settings: in/min, mm/min

U N I T S : i n / mi n

E S C − + E N T R

Increases or decreases the value.
Returns to the Test Function Setup menu
Exits the function without saving changes

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Model ESM1500 Test Stand User’s Guide

Label Description

+ or –
ENTR
ESC

4.13 Programmable Button Function (KEYS)

Three button function modes are available:

Default setting: maintained
Available settings: maintained, momentary, auto

Cycles through the available settings
Returns to the Test Function Setup menu
Exits the function without saving changes

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.

K E Y S : M A I N T A I N E D

E S C − + E N T R

Label Description

+ or –
ENTR
ESC

4.14 FollowMe

Crosshead responds to manually pushing or pulling on the force gauge shaft or load cell. Increasing force
produces greater speeds. Ideal for quick positioning during sample loading and unloading.

Default setting: OFF
Available settings: ON, OFF

Cycles through the available settings
Returns to the Test Function Setup menu
Exits the function without saving changes

TM

(FollowMe)

CAUTION!

Exercise extreme caution when handling low force load cells and gauges, as overload
can occur.

F O L L O WM E : O F F

E S C − + E N T R

Label Description

+ or –
ENTR
ESC

Cycles through the available settings
Returns to the Test Function Setup menu
Exits the function without saving changes

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Model ESM1500 Test Stand 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:

S a v e a s : - - -

E S C + E D I T S A V E

Press + until the profile name “ - - - “ is displayed. Then, press EDIT. The display appears as follows:

P R O F I L E : - - -

E S C + > S A V E

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 R O F I L E : P E E L T E S T

E S C − + E N T R

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

D E L . P R : P E E L T E S T

E S C − + E N T R

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: 10 in/min
UP SPEED: 10 in/min
DOWN SP: 10 in/min
AUTO RETURN: off
CYCLING: 00000 (off)

HI LIMIT: +39.000 in

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Model ESM1500 Test Stand User’s Guide

LO LIMIT: -39.000 in
OVERLD: off
PRELOAD: off
LOADHOLDING: off
BREAK DETECT: off
PROFILES: DEFAULT

CONTROL: CONSOLE

BAUD RATE: 115200

STOP & PAR: 8-1n

UNITS: in/min

KEYS: auto
FOLLOWME: off
PASSWORD: 0000 (off)

If the PROFILES function is installed, the test stand will revert to the profile named “DEFAULT”. This
profile contains the factory settings listed above, and may not be edited.

If the PROFILES function is not installed, the display appears as follows:

D E F A U L T ? : N O

E S C − + E N T R

Label Description

+ or –
ENTR
ESC

4.17 Password (NEW PWORD)

If desired, a password can be set to prevent unwanted changes to test functions. The password can be
set to any number between 0000 and 9999. The default setting of 0000 indicates that the password is
disabled, and that the user can freely enter the Test Function Setup menu. If misplaced or forgotten, the
password may be reset through a code activation process. Details on this may be found in the Function
Activation section.

Default setting: 0000 (off)
Available settings: 0000 – 9999

N E W P WO R D 0 0 0 0

E S C − + E N T R

Label Description

+ or –
ENTR
ESC

Cycles through “yes” or “no” selections
Returns to the Test Function Setup menu
Exits the function without saving changes

Increases or decreases the value.
Returns to the Test Function Setup menu
Exits the function without saving changes

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Model ESM1500 Test Stand User’s Guide

5 OPERATING MODES

5.1 Overview

The ESM1500 can be operated in several modes, including combinations of these modes:

1. FollowMe

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 E D : 0 . 0 0

me n u m i n ma x S E T

If the travel indication option is installed, the screen appears as follows:

TRAVEL

1 . 2 7 5 0 . 0 0

me n u m i n ma x S E T

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.

TM

Mode

SPEED

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Model ESM1500 Test Stand User’s Guide

m

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 E D : 0 . 0 0

me n u m i n ma x S E T

2. Basic & Auto Return Modes (travel indication option installed):

TRAVEL

SPEED

1 . 2 7 5 0 . 0 0

me n u m i n ma x S E T

3. Cycling Mode (travel indication option not installed):

C Y C L E S : 0 0 0 2 4

Note:
The min and max keys will not appear when a password has been set.

e n u mi n ma x S E T

4. PC Mode

Appears the same as in Basic and Auto Return modes.

Label

menu
min

max

set

Pressing menu will enter Test Function Setup. If a password has been programmed, the display
will prompt the following:

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

Description

P A S S WO R D 0 0 0 0

E S C − + E N T R

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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Model ESM1500 Test Stand User’s Guide

5.3 FollowMe

TM

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

TM

mode, press the FollowMeTM key. The display appears as follows:

S P E E D : 0 . 0 0

F o l l o w M e A c 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

TM

key, the function becomes inactive,

and the display flashes “FOLLOWME OFF”.

If the FollowMe

TM

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

TM

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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Model ESM1500 Test Stand 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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Model ESM1500 Test Stand 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:

C Y C L E S 0 0 0 2 4

me n u m i n ma x S E T

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 : 0 0 0 1 . 5

me n u m i n ma x S E T

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:

C Y C L E S : 0 0 0 2 4

R E S E 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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Model ESM1500 Test Stand 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.

Before the start of a load holding sequence, the crosshead must be positioned at either the upper limit
switch to begin compression load holding or at the lower limit switch to begin tension load holding.

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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Model ESM1500 Test Stand User’s Guide

6 COMMUNICATION

6.1 Setup

The ESM1500 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

- 115,200 baud rate

ESM1500 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 Description Example

a Request speed
b Set travel units to inches
c Enter cycle mode
d Move crosshead down

Set speed
Inch format: eXX.XXX

e

f Set cycles. Format: fXXXX (leading zeroes required) f0500 = 500 cycles

g

h

i Set travel units to millimeters
j Set crosshead speed to maximum speed

k Set crosshead speed to minimum speed

l Enter travel limit mode

Leading zeroes and three decimal places required.
Millimeter format: eXXXX.XX
Leading zeroes and two decimal places 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.

e02.850 = 2.85 in/min

e0200.30 = 200.3 mm/min

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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Model ESM1500 Test Stand User’s Guide

m Enter manual mode

n Transmit travel and force readings

o Set crosshead speed to programmed speed
p Request stand status*
q Request number of cycles completed

r Request number of cycles set

s Stop crosshead

t Reset cycle counter to zero
u Move crosshead up
v Request upper travel limit

w Request lower travel limit

x Request travel value

z 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

6.2.1 Force gauge / indicator commands

Mark-10 force gauge and indicator commands are compatible with the ESM1500. 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 Description

A Displays current unit
F Toggles between Normal and Data Collect modes
P Steps through Normal mode, Tension Peak mode, and Compression Peak mode

R Zeroes the instrument (zeroes all modes)

S Sends current mode (Normal, Tension Peak, Compression Peak, or Data Collect)

U Steps through units

X or ?

Y Enables RS-232 output and sends continuous data stream when in Data Collect mode

Z Zeroes the peak values

The ESM1500 is compatible with legacy Nexygen
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.

Sends currently displayed reading

Command Description

U Crosshead moving up
D Crosshead moving down
S Crosshead stopped
C Cycle mode

L Limit mode

M Manual mode
UL Crosshead at upper limit
DL Crosshead at lower limit

TM

TCD software, which also utilizes the above

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Model ESM1500 Test Stand User’s Guide

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 N G : O F F

E S C < − −> E N T R

Label Description

< –
– >
ENTR
ESC

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 N G : 0 1 3 9 0 2 7

E S C + − > E N T R

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:

The Function Activation menu also includes a utility for disabling the password. Scroll through the
functions until the following is displayed:

D I S A B L E P A S S WO R D

E S C < − − > E N T R

Press ENTR to generate the request code, then follow the authorization code procedure indicated above.

7.3 Demo Mode

All ESM1500 test stands are shipped in Demo Mode, which provides full functionality of all available
functions for an evaluation period of 160 operating hours. When this period has expired, an additional 160
hours may be added via the authorization code procedure indicated above.

Scrolls to the previous function
Scrolls to the next function
Selects the function
Exits Function Activation menu

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.

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Model ESM1500 Test Stand User’s Guide

8 TROUBLESHOOTING

1. The ESM1500 displays several error messages, as follows:

Error Message Description

The instrument is powered off, not in the operating mode, or not

CHECK GAUGE

GAUGE COMM ERROR

GAUGE OVERLOAD

M5/M7 V2.0+ REQD

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.

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.

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Model ESM1500 Test Stand User’s Guide

9 MAINTENANCE AND SERVICE

The ESM1500 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
of test stand components. Frequency depends on environmental conditions and usage.

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Model ESM1500 Test Stand User’s Guide

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.

9.3.1 Upper bearing lubrication

32

Model ESM1500 Test Stand User’s Guide

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:

33

Model ESM1500 Test Stand 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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Model ESM1500 Test Stand User’s Guide

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 ESM1500’s electronics, and is designed for quick
removal and replacement in the event of service or repair. If instructed 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:

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:

35

Model ESM1500 Test Stand User’s Guide

5. Reinstall in the same fashion.

CAUTION!

The MDU is not field serviceable. Do not attempt to open it.

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Model ESM1500 Test Stand User’s Guide

10 SPECIFICATIONS

Load capacity:
< 60 in [1,525 mm]/min:
> 60 in [1,525 mm]/min:

Standard speed range: 0.5 – 24 in/min [10 – 600 mm/min]

Optional speed range: 0.001 – 90 in/min [0.02 – 2,300 mm/min]

Maximum travel: 32 in [813 mm]

Speed setting accuracy: ±0.2%

Speed variation with load: ±0% [Stepper motor driven]

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: Universal input 80-240 VAC, 50/60 Hz

Fuse type: 4A, 3AG, SLO BLO
Weight:
Test stand:
Shipping weight:

Environmental Conditions:

1,500 lbF [6.7 kN]
1,000 lbF [4.5 kN]

198 lb [90 kg]
248 lb [113 kg]

40 - 100°F [5 - 40°C], max. 96% humidity, non-condensating

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Model ESM1500 Test Stand User’s Guide

11 DIMENSIONS

11.1 ESM1500LC

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Model ESM1500 Test Stand User’s Guide

11.2 ESM1500FG

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Model ESM1500 Test Stand 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: [phone]
Fax: [phone]
www.mark-10.com
[e-mail]

32-1179

REV 0217

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