Mark-10 ESM303, ESM303H User Manual

Models ESM303 & ESM303H

FORCE TEST STANDS

User’s Guide

Models ESM303 & ESM303H Test Stands User’s Guide

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Thank you…

Thank you for purchasing a
Mark-10 ESM303 / ESM303H
Force Test Stand, designed
for producing up to 300 lbF
(1.5 kN) of tension and
compression force. The
ESM303 / ESM303H 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.

Note:
Except where otherwise indicated, references to “ESM303” include models ESM303 and ESM303H.

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 ......................................................................... 5

OPERATION BASICS ....................................................................... 11

TEST FUNCTION SETUP ................................................................. 13

OPERATING MODES ........................................................................ 25

COMMUNICATION ............................................................................ 31

FUNCTION ACTIVATION .................................................................. 33

INSTALLING THE SAFETY SHIELD OPTION ................................. 34

INSTALLING THE TRAVEL INDICATION OPTION ......................... 35

INSTALLING A COLUMN EXTENSION OPTION ............................ 37

MAINTENANCE AND SERVICE ....................................................... 40

TROUBLESHOOTING ....................................................................... 41

SPECIFICATIONS ............................................................................. 42

DIMENSIONS .................................................................................... 42

Models ESM303 & ESM303H Test Stands User’s Guide

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1 OVERVIEW

1.1 List of included items

Description

Qty.

ESM303

Qty.

ESM303H

1

Force gauge mounting adapter

1

Indicator / load cell mounting adapter

4

Force gauge / indicator mounting screws,
#6-32 x 1/2

4

Indicator mounting screws, #6-32 x 1/2

2

Limit switch thumb screws, #6-32 x 5/8

2

Limit switch thumb screws, #6-32 x 5/8

1

Control panel

1

Control panel

1

Control panel mounting bracket

1

Control panel mounting bracket

- - 1

Adapter, control panel bracket to frame
(shipped installed)

1

Screw for mounting control panel bracket
to column, 1/4-20 x 1”, with lock washers

2

Screws for mounting control panel bracket
to adapter, #8-32 x 1” (shipped installed)

- - 2

Screws for mounting adapter to frame,
#10-32 x 1” (shipped installed)

2

Screws for mounting control panel to
bracket, 1/4-28 x 1-1/4”, with lock
washers

2

Screws for mounting control panel to
bracket, 1/4-28 x 1-1/4”, with lock
washers

1

Accessories kit:

- #10-32F small hook

- #10-32M medium hook

- #10-32F 2” diameter comp. plate

- #10-32 M/F 2” extension rod

- #10-32 F/F coupler

- Adapter, 5/16-18M to #10-32F

- Set screw, #10-32 x 3/4" (3)

- Hex nut, #10-32 (3)

- Allen wrench set

1

Accessories kit:

- #10-32F small hook

- #10-32M medium hook

- #10-32F 2” diameter comp. plate

- #10-32 M/F 2” extension rod

- #10-32 F/F coupler

- Adapter, 1/2-20M to #10-32F

- Adapter, 1/4-28M to 5/16-18F

- Adapter, 5/16-18M to #10-32F (2)

- Set screw, #10-32 x 3/4" (3)

- Hex nut, #10-32 (3)

- Allen wrench set

1

Resource CD

1

Resource CD

1

Power cord

1

Power cord

Additional optional items are available, such as an adjustable base plate, connection cables, and column
extensions. Instructions for installing a column extension and retrofitting the test stand with the travel
indication option are provided later on in this user’s guide.

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1.2 Physical features

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

1.2.1 ESM303

Base

Base plate

Lower grip

Upper grip

Force gauge

Column

Control panel

Emergency stop

Limit
switch
(upper)

Test sample

Crosshead

Interface
cable

Column cap

Limit
switch
(lower)

Control panel

mounting bracket

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1.2.2 ESM303H

2 SETUP AND SAFETY

2.1 Mounting

Place the stand on a clean, flat and level work area free from vibration.
For the vertically oriented ESM303, It is suggested to mount the stand to a work bench via screws

fastened into the underside of the base. Failure to properly mount the test stand may make it more
vulnerable to tipping, especially if a column extension is used, causing a hazardous situation.

2.2 Mounting the control panel

To avoid damage during shipment, the control panel and mounting bracket are packaged separately.
Follow these installation instructions:

2.2.1 ESM303

1. Install the mounting bracket to the column utilizing one 1/4-20 screw.

Control panel

mounting bracket

Control panel

Control panel

bracket adapter

Frame cap

Interface
cable

Indicator

Crosshead, indicator / load

cell mounting kit

Load cell

Right limit switch

Alternate control
panel mounting
location

Base plate

Base

Left grip

Test sample

Right grip

Emergency stop

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2. Install the control panel to the mounting bracket utilizing two #8-32 screws.

3. The viewing angle may be adjusted by loosening the lever, positioning the control panel, and re­tightening the lever.

2.2.2 ESM303H

1. Install the control panel to the mounting bracket utilizing two 1/4-28 screws.

2. Install the mounting bracket to the bracket adapter with two #8-32 screws.

3. Install the bracket adapter to the edge of the test frame with two #10-32 screws. This may be
done on either the right end or the left end of the frame, where sets of #10-32 holes are provided.

4. The viewing angle may be adjusted by loosening the lever in the rear of the bracket, positioning
the control panel, and re-tightening the lever.

2.3 Limit switches

Upper and lower limit switches are supplied to stop travel in both directions. The limit switch thumb
screws are shipped banded together, as illustrated below:

Remove the rubber band and instructional tag before use. Refer to later sections for more detailed
information about limit switches.

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2.4 Connections and outputs

The following connections and outputs are supplied in the rear of the test stand, as shown in the
illustration below:

USB connector

Outputs force only or force and travel data (optional) via USB. Also allows
for PC control (optional). Plug one end of the USB cable into this connector,
and the other end into a PC’s USB port. Refer to the next sub-section for
driver installation information.

Auxiliary limit switch connector

For interfacing an external limit switch, such as an interlock for a machine
guard door. A pin diagram is shown in the next sub-section.

Control panel cable connector

Plug the cable into this connector.

Power switch

Refer to the Connecting Power sub-section for important safety
information.

Power plug receptacle

Plug the power cord in here. Refer to the Connecting Power sub-section

for important safety information.

2.4.1 Auxiliary limit switch pin diagram

Note that when pins 3 and 4 are not connected, the auxiliary limits are inactive. When the +5V from pin 2
is connected to either pin 3 or pin 4, the respective limit becomes active and the crosshead is prevented
from movement in that direction.

2.4.2 USB driver installation

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.

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Further instructions for configuring communication parameters 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 force gauge or indicator with load cell

2.5.1 ESM303

Once the test stand is in a stable and secure position, install a force gauge by mating the dowel pin in the

force gauge mounting plate with the blind hole in the rear of the force gauge’s housing. Use the four

thumb screws to secure the gauge. Grips and fixtures may be threaded onto the force gauge and test
stand base.

2.5.2 ESM303H

1. Once the test stand is in a stable and secure position, install an indicator via four thumb screws.

2. Install a load cell to the crosshead using the supplied hardware, and insert the Plug & TestTM
connector into the indicator, as shown in the image below:

2.6 Installing an indicator / load cell mounting kit (optional for ESM303)

The optional AC1062 mounting kit is available to mount a Series R01 or Series R03 load cell (force
sensor) and an indicator onto the crosshead, instead of a force gauge. To install, follow these
instructions:

1. Remove the force gauge mounting plate by loosening the two 5/16-18 flat head screws, as shown
below:

2. Install the indicator bracket onto the side of the crosshead, utilizing two #10-32 flat head screws,
as shown below:

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3. Install the L-bracket with the same two flat head screws, as shown below:

4. Mount the load cell to the L-bracket utilizing the included hardware, as shown below.

5. Mount the indicator utilizing the four provided thumb screws, and insert the Plug & TestTM
connector into the indicator. Orient the housing of the indicator such that the connector is pointed
downwards. Refer to the indicator’s user’s guide for details.

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2.7 Installing the 09-1214 / 09-1252 interface cable

If using test stand functions requiring communication between the force gauge / indicator and test stand,
such as data output, overload protection, preload, etc., connect the interface cable between the
instrument’s connector and the crosshead’s connector. This cable may be used with a Series 4, 5, or 7
instrument. Refer to the image below:

or

09-1214 (ESM303)

09-1252 (ESM303H)

Note:
The 09-1214 and 09-1252 cables power the instrument. When connected, the instrument automatically
powers on when the test stand is powered on. The instrument’s AC adapter is not necessary under these
conditions.

2.8 Safety / proper usage

Typical materials able to be tested by the ESM303 include many raw materials and manufactured items,
such as springs, metals, plastics, electronic components, mechanical assemblies, packaging materials,
and many others. Potentially flammable substances or products should not be used with the ESM303. For
samples which can shatter or otherwise present a physical danger to the operator, a safety shield is
required, such as model no. ESM303-003. Refer to the Safety Shield section for installation instructions.

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.

A safety shield is recommended

2.9 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 ESM303 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).

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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.

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.

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3.2 Controls

Label

Function

1

SOFT KEYS

Functions are determined by the corresponding text on the display.

2

UP / RIGHT

Commences movement in the up (ESM303) or right (ESM303H) direction.

3

STOP

Stops crosshead movement.

4

DOWN / LEFT

Commences movement in the down (ESM303) or left (ESM303H) direction.

5

FollowMeTM

Enables force-activated crosshead positioning. If this option is not installed, the
message “NOT INSTALLED” flashes.

6

ZERO TRAVEL

Zeroes the travel display. If this option is not installed, the message “NOT
INSTALLED” flashes.

7

EMERGENCY
STOP

Press this button at any time to stop test stand motion. Rotate clockwise to
release.

3.3 Modes overview

The ESM303 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:

2

3 4 1

5

6

7

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DEMO MODE

The ESM303 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:

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.

R E M A I N I N G D E M O T I M E : 1 6 0 H O U R S

4 TEST FUNCTION SETUP

This section provides configuration instructions for each function.

Function

Standard / Optional

Travel indication

Optional

Speed - same setting applies to both directions

Standard

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

Speed / distance unit of measurement

Standard

Directional button configuration

Standard

Password protection

Standard

All ESM303 test stands are supplied 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 m e n u m i n m a x S E

T

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

Label

Description

ESC

Exits Test Function Setup, reverts to Operating Mode

< –

Scrolls to the previous function

– >

Scrolls to the next function

ENTR

Selects the function, allowing it to be modified

When the functions have been configured and are ready to be saved, press ESC to exit Test Function
Setup.

Note:

Changes can be made to an unlimited number of settings before saving.

If the PROFILES function is installed, the changes may be saved to the desired profile name. The screen
appears as follows:

Label

Description

ESC

Exits Test Function Setup, reverts to Operating Mode

+

Scrolls to the next saved profile

EDIT

Press to edit the profile name. The first character will be
flashing. Press + to change the character and –> to
advance to the next character.

SAVE

Saves the settings under the specified profile name

Refer to the Profiles sub-section for further details on selecting and deleting profiles.
If PROFILES is not installed, the screen appears as follows:

Make the appropriate selection.

4.1 Speed

If the Independent Speeds option has not been installed, both directional speeds will be the same, and is
programmed via the SPEED function. If the Independent Speeds option is installed, UP SPEED / RIGHT
SP and DN SPEED / LEFT SP functions will be present, and may be set individually.

Default setting: 10 in/min / 250 mm/min
Available settings: 0.02 – 45 in/min / 0.5 – 1,100 mm/min

S P E E D : 2 0 . 0 0 E S C < − − > E N T R S A V E A S : E X A M P L E 1 E S C + E D I T S A V E S A V E C H A N G E S ? N O Y E

S