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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