Tensile Tester

Acceptance report
Dossier no.: 702161
Copyright 2008, Zwick GmbH & Co. KG D-89079 Ulm
Order confirmation no.: 2142429
BT1-FB005TN.D14
Thank you for the trust shown in us by the purchase of one of our testing systems.
Please sign the acceptance report overleaf following successful commissioning and
acceptance of the system, and then fax it to Zwick, FAX ++49 (0)7305 / 10 261.
Doc.-No. F12-002 Ref. V12-006
Zwick technical documentation

Instruction manual
07.08 / Abn / V5.2
Acceptance report
2/25/2009
dated:
for machines and instruments
Abnahmeprotokoll
fr Maschinen und Gerte
Contractor:
Purchaser:
Auftragnehmer:
Auftraggeber:
Zwick GmbH & Co. KG

August-Nagel-Str. 11
D-89079 Ulm
Bereich: US
Fax: 07305/10 261
BSW Bag Solutions Worldwide s.r.o.

Hj 357
CZ-798 12 Kralice na Han
Phone:
Fax:
702161
Product type:
Produkt, Typ:
2142429
The above machine / system has been

accepted
accepted, but with small faults/defects that
still have to be rectified
not accepted
BT1-FB005TN.D14
Die oben genannte Maschine / Anlage wurde

bernommen
mit geringen Beanstandungen, die noch zu
beseitigen sind, bernommen
nicht bernommen.
Notes:
Bemerkungen:
Wichtig!
Important!
Die Lieferung und/oder die Leistung wurde gem den

Vertragsbedingungen erfllt. Wir bitten Sie das
Abnahmeprotokoll unserem Servicetechniker mitzugeben. Sollte keine Inbetriebnahme durch einen Servicetechniker stattgefunden haben, bitten wir Sie das
Abnahmeprotokoll innerhalb 10 Tage per Post oder
Fax zurckzuschicken.
Nur bei termingerechter Besttigung und Rcksendung
des Protokolls kann die in der Rechnung ausgewiesene Skontofrist angerechnet werden und beginnt
fr unsere Kunden eine kostenlose Hotline zur
schnellen Hilfe bei Fehlfunktionen.
Please note that a missing confirmation on the part of

the customer does not mean that the machine has not
been successfully installed and commissioned. We
will assume that the equipment has been correctly
installed and commissioned if it is used in a
satisfactory manner by the customer.
Wir weisen daraufhin, dass eine fehlende kundenseitige Besttigung nicht bedeutet, dass die Maschine
nicht erfolgreich in Betrieb genommen wurde. Mit dem
Einsatz der Maschine und ihrer zufriedenstellenden
Nutzung durch den Kunden gehen wir von einer
erfolgreichen Maschinen-Inbetriebnahme aus.
Doc.-No. F12-002 Ref. V12-006
Date
Datum
Zwick department and signature

Abteilung und Unterschrift von Zwick
Name and address of the customer

Name und Unterschrift des Kunden

Instruction manual
07.08 / Abn / V5.2
The consignment and/or performance has been fulfilled

compliant to the contractual conditions. We request
our customers to acknowledge this fact by
countersigning the acceptance report and either
returning it to us by post or by faxback within 10 days
of successful commissioning to the above address.
The discount as agreed in writing in the invoice will
only be granted if we receive the countersigned report
within the stated period of time. Furthermore, access
to a free of charge hotline which provides rapid help
should the equipment malfunction will be granted if the
report is returned on time.
Fax: +49 (0)7305/10 261
Dossier no.:
Dossier-Nr.:
Order confirmation no.:
AB-Nr.:
Symbole
Sehr geehrter Betreiber unseres Prfsystems,

momentan stellen wir die Warnzeichen an unseren Prfsystemen um.
In der bergangszeit kann es vorkommen, dass die im fortlaufenden Text der Betriebsanleitung abgebildeten Symbole nicht mit dem Aufkleber auf dem Prfsystem bereinstimmen.
Daher finden Sie hier eine bersicht mit den von der Umstellung betroffenen Zeichen, also
auch die Alternativen der Aufkleber im bergangszeitraum.
Zeichen Variante 1
Zeichen Variante 2 Bedeutung

Warnung vor Quetschgefahr!
Die Traverse fhrt eine Bewegung aus.
Vorsicht: Kein automatisches Abschalten bei
Berhrung der Traverse.
Warnung vor Handverletzung!

Probenhalter knnen mechanisch, manuell oder
automatisch geschlossen werden.
Vorsicht: Kein automatisches Abschalten bei
Berhrung der Probenhalter.
Warnung vor heier Oberflche!

Die Temperiereinrichtung (wenn vorhanden)
kann sehr hei sein/werden.
Warnung vor Klte!
Die Temperiereinrichtung (wenn vorhanden)
kann sehr kalt sein/werden.
11.08 / Symbole / V5.01
Zwick Technische Dokumentation

Betriebsanleitung
Symbols
Dear user of our testing system,

we are currently replacing the warning signs on our testing systems.
It may happen in the transitional period that the symbols depicted together with written
descriptions in the instruction manuals may not coincide with the stickers on the testing
systems.
Following is an overview of all stickers used by Zwick, including the alternative ones for the
transitional period.
Sticker 1
Sticker 2
Meaning
Risk of injury!
The crosshead is moving.
Caution: No automatic shutdown if the
crosshead is touched.
Risk of pinching parts of the body!

Specimen grips can be closed mechanically,
manually or automatically.
CAUTION: no automatic shutdown when
touching the specimen grips.
Risk of frostbite!
The temperature conditioning device
(if installed) can get extremely cold.

Instruction manual
11.08 / Symbole / V5.01
Risk of burning!
The temperature conditioning device
(if installed) can get extremely hot.
Zwi ck
Materials Tes
ting
Zwick
Materials testing
Copyright 2005, Zwick GmbH & Co. D-89079 Ulm
Instruction manual
for materials testing machines
BT1-FB005TN.D14
Serial number:
AB/Dossier number:
03.05 / Ident-MPM / V5.1

Instruction manual
179947
2142429
Zwi ck
Materials Tes
ting
Document
Materials testing machine
Materials testing machine:

Serial number:
Order confirmation/Dossier number:
Model:
Manufacturer:
Zwick GmbH & Co. KG
August-Nagel-Strae 11
D-89079 Ulm
Germany
Telephone: 07305 10-0
Hotline:
Supportline:
BT1-FB005TN.D14
179947
2142429
2009
Customer service:
ZwickService
D-89079 Ulm
07305 10225
0190 8 81988
Help for malfunctioning

Support for operation and
application
Fax:
eMail:
Internet:
07305 10200
info@zwick.de
http:\\www.zwick.de
http:\\www.zwick.com
Further addresses from service and sales companies are listed in the appendix.
Document:
Version:
Print date:
Instruction manual Materials testing machine

is split into:
- Safety manual
- Technical manual
- Installation manual
- User manual
- Service and maintenance manual
See the respective manual

February 2009
All rights reserved

We have done our best to make sure that this instruction manual is complete and free
of errors. Should you notice anything that is unclear in spite of this please inform us.
Our products are being continuously improved upon. Therefore it may happen that
some statements in this manual do not always correspond to the latest state. Exact
info can be obtained by calling Zwick in Ulm if you are not entirely sure.

Instruction manual
03.05 / Ident-MPM / V5.1
Copyright (c) 2009 by Zwick GmbH & Co.

August-Nagel-Str. 11
D-89079 Ulm-Einsingen
Zwi ck
Materials Tes
ting
Instruction manual
Testing system
Section contents
Contents
Tab
Safety manual................................................................................. 1
2
13
Technical manual .......................................................................... 2

Installation manual ........................................................................ 3
2 3
5 6
8 9
User manual ................................................................................... 4

Reserved for expanded, optional operation .............................. 5
Reserved for the instruction manual for retrofit parts ............. 6
Reserved for special user programs .......................................... 7
Free .................................................................................................. 8
Free .................................................................................................. 9
Service and maintenance manual ............................................. 10

Circuit diagrams .......................................................................... 11
Reserved for spare parts/consumables ................................... 12
Certificates/Calibration reports ................................................. 13
Free ................................................................................................14
Appendix ....................................................................................... 15
06.08 / Ident_PS / V5.2

Instruction manual
Zwi ck
Materials Tes
ting
Instruction manual
Testing system
Should you resell your test system, you must also provide your customer
with the complete instruction manual. The instruction manual is an integral
part of the test system.
Instruction manual layout

Read through this short introduction to enable you to find the topic that
interests you more quickly as this introduction provides information on
navigating through the manual.
The instruction manual is split into different categories:
Important for everybody
Section 1
Safety manual.
The contents must be known to everyone.
For technicians
Section 3
Installation manual.
Aimed at personnel responsible for transport,
installation, dismantling, packing and storage.
Section 4
User manual.
Aimed at operating personnel and describes the
operation/operating elements of purchased
components.
Register 10 Service and maintenance manual.

Aimed at maintenance personnel and contains
maintenance intervals as well as error rectification.
What everybody needs

Section 2
Technical manual.
Contains the technical data.
Register 15 Appendix.
Contains addresses and a maintenance order form.

Instruction manual
06.08 / Ident_PS / V5.2
Register 11 Circuit diagrams

Aimed at maintenance and service personnel.
Zwi ck
Materials Tes
ting
Instruction manual
Testing system
Reserved or free
These sections could contain the following documents, the contents
correspond to the optional components purchased by you.
Section 5
Expanded operation
is aimed at the operating personnel and describes the
possibility of operating the equipment without using a
PC.
Operating the automating software is described for
automated test systems.
Section 6
Retrofit parts
does not have any documention in the initial shipment.
File away the descriptions/instructions for
subsequently purchased components.
Register 7 Special user programs

Contains an introduction to the purchased PC
software.
Section 12 Spare parts/Wear and tear parts
are not contained in the instruction manual as
standard.
Section 13 Certifications/Calibration reports
Contains the declaration of conformity or the
manufacturers declaration, calibration reports, safety
data sheets and other certifications.
Directories
The instruction manual uses contents and hit word indexes.
List of contents:
Index:
06.08 / Ident_PS / V5.2
To be found on the third page of the

respective section.
To be found at the end of the respective
section.

Instruction manual
Zwi ck
Materials Tes
ting
Instruction manual
Testing system
The instruction manual layout is to the same repetitive pattern.

The single chapters are compiled in the sequence:
- Testing system
- Sensor
- Tools
- Test accessories
Exception is dismantling (see the example on this page).
Some parts of the manual may not be included in your manual as the
manuals are supplied for that equipment as per the configuration of your
test system. Some chapters do not require a detailed description for
certain parts.
Following is a setup of a section of the manual on the basis of the
installation manual
Installation manual
- Safety
- Transport
- Initial commissioning
- Dismantling
- Storage
Sequence of the chapter Dismantling

Test accessories
Tool
Sensor
Testing system

Instruction manual
06.08 / Ident_PS / V5.2
- Installation/Erection
Sequence of the chapter Installation/Erection

Testing system
Sensor
Tool
Test accessories
Zwi ck
Materials Tes
ting
Instruction manual
Testing system
Each page of the instruction manual contains the entire important

information on the
- Manual
- Chapter
- Device
as well as
- Date of compilation
- File name
- Version of the description.
The following example should make this clear.
Setup
Sensor
Device/Components
(Electronics or type of drive system could be contained here)
Chapter
(These can be found in the respective list of contents)
Pictogram of the manual
(Navigation help)
Date of compilation of the description file
File name
Version no. of the description file

Please provide us with this information
should you have any enquiries.
Versioning
The instruction manual consists of individual text modules. Versioning of
these files is made via the Zwick internal document management. The
latest version of the files of a respective section is indicated on the
second page of each section.
06.08 / Ident_PS / V5.2

Instruction manual
Zwi ck
Materials Tes
ting
Instruction manual
Testing system
Zwick Roell AG
August-Nagel-Strasse 11
Tel.:
+49 7305- 100
Fax:
+49 7305-10200
eMail: info@zwickroell.com
Internet: http://www.zwickroell.com
Zwick Roell AG
Zwick GmbH & Co. KG

Tel.:
+49 7305 100
Fax:
+49 7305-10200
eMail: info@zwick.de
Internet: http://www.zwick.de
Toni Technik
Baustoffprfsysteme GmbH
Gustav-Meyer-Allee 25
D-13355 Berlin
Tel.:
+49 30 64403921 / 23
Fax:
+49 30 64403922
eMail: info@tonitechnik.com
Internet: http://www.tonitechnik.com
Zwick Series
Zwick projects
ZwickService
Certified to ISO 9001 and EMAS
DKD accredited to ISO/IEC 17025
no. DKD-K-13201
Certified to ISO 9001

DKD accredited to ISO/IEC 17025
no. DKD-K-23301
Indentec
Hardness Testing Machines Ltd.
Lye Valley Industrial Estate, Bromley Street
Lye, Stourbridge
West Midlands DY9 8HX Great Britain
Tel.
+44 1384 896949
UKAS accredited to ISO/IEC 17025
eMail: mail@indentec.demon.co.uk no. 0232
Internet: http://www.indentec.demon.co.uk
Zwick Asia Pte Ltd.

Singapore 609916
Tel.:
+65 8995010
Fax:
+65 8995014
Zwick Testing Machines Ltd. (GB)

Leominster, Herefordshire HR6 OQH
Tel.:
+44 1568 613516
Fax:
+44 1568 612626
Certified to ISO 9001
UKAS accredited to ISO/IEC 17025
no. 0167
Zwick USA LP
Kennesaw, Atlanta, GA 30152
Tel.:
+1 770 4206555
Fax:
+1 770 4206333
A2LA accredited to ISO/IEC 17025
no. 1891.01

Instruction manual
Zwick France S.a.r.I.

F-95971 Roissy Airport
Tel.:
+33 1 48632140
Fax:
+33 1 48638431
COFRAC accredited to ISO/IEC 17025
No. 1-1213
06.08 / Ident_PS / V5.2
Acmel Labo
10/12 Rue de lOrme Saint Germain
F- 91160 Champlan
Tel.:
+33 1 69109595
Fax: +33 1 69100186
eMail: info@acmel.fr
Internet: http://www.acmel-labo.com
Zwi ck
Materials Tes
ting
Instruction manual
Testing system
Manufacturing companies
Zwick Roell AG
Zwick GmbH & Co KG

Zwick Series
Zwick projects
ZwickService
- Electro-mechanical
materials testing
machines and
accessories
- Test software
- Macro-hardness tester
- Plastics testers
- Melt index
measurement devices
- Pendulum impact testers
up to 750 J
- Automated
test systems
- Magnet testing devices
- Materials testing
machines for loads
greater than 250 kN
- Customised testing
systems
- High-velocity testing
machines
- Servo-hydraulic testing
machines
- Installation
- Maintenance
- Accredited calibration
service
- Spare parts supply
- Retrofits
- Refurbishment
- Used machines
- Tuition
- Tests as ordered by
customers.
Toni Technik
Baustoffprfsysteme GmbH
- Servo-hydraulic testing
machines
- Automated specimen
preparation devices
- Chronometers
- Devices for determining
hydration heat
- Complete laboratories
- Service and refurbishment
of test machines
06.08 / Ident_PS / V5.2
Indentec
Acmel Labo
Hardness Testing
Machines Ltd.
Building materials test

equipment
- Rockwell hardness
testers
- Vickers hardness testers
- Brinell hardness testers
- Devices for testing cement

and mortar

Instruction manual
Zwi ck
Materials Tes
ting
Instruction manual
Testing system
Product description
The Zwick test systems can be put to universal use. They are designed
for almost all test requirements to national and international standards, as
well as for a large part of the requirements as described by a wide range
of in-house standards.
Thesetest systems are not only for use in quality assurance for routine
research, but also for research whereby test programs must first be
defined.
Overview:
Sensor system 1
Sensor system 2
MCE
Unit
Testing system
(Measurement
Control
Electronics)
Sensor system n
Communication
interface
PC
Test tools
Safety device
The modular construction enables supplementary retrofits to be made

very easily.
10

Instruction manual
06.08 / Ident_PS / V5.2
Physical measurement
unit
Dossier
Section 1:
Instruction manual
Safety manual
BT1-FB005TN.D14
Serial number:
AB/Dossier number:
03.05 / SiInhalt / V5.1

Instruction manual
179947
2142429
Document
Instruction manual
Section 1
General
This section contains information that is important for maintenance and
service for your materials testing machine and its accessories.
The safety manual must be read and used by all persons authorised to
work at and with the machine.
Document:
Safety manual
Version:
Print date:
V 6.20
February 2009
Tips, notes and constructive criticism are always welcome. Please direct
these to:
Zwick GmbH & Co. KG
Technische Dokumentation
D-89079 Ulm
Fax: +49 - (0) 7305 - 200

Instruction manual
03.05 / SiInhalt / V5.1
All rights reserved
List of contents
Safety manual
List of contents
List of contents .................................................................................................................. 3
Introduction ....................................................................................................................... 5
Supplements ............................................................................................................... 5
Transport ..................................................................................................................... 6
Proper use ......................................................................................................................... 7
Improper use ............................................................................................................... 8
Remaining risks ........................................................................................................... 9
Checks and preventive measures .............................................................................. 10
Symbols and signal words ............................................................................................. 11
Symbols on materials testing machines ..................................................................... 11
Signal words in the instruction manual ........................................................................ 12
Persons involved ............................................................................................................ 13
Operator .................................................................................................................... 13
Workplace ................................................................................................................. 15
Safety measures and notes ............................................................................................ 17
Before switching on ................................................................................................... 17
At operation ............................................................................................................... 18
At maintenance and servicing .................................................................................... 25
When working with electrical equipment ..................................................................... 26
When working on hydraulic and pneumatic equipment ................................................ 27
Cleaning recommendations ........................................................................................... 29
Index ................................................................................................................................. 31
03.05 / SiInhalt / V5.1

Instruction manual

Instruction manual
03.05 / SiInhalt / V5.1
Safety
Introduction
Introduction
The test system is manufactured to the state of the art technology and to
recognised safety requirements. This, however, neither excludes any
danger to life and limb of the operator or third parties which could occur
when using the test system. Nor can interference nor impairment to the
impact tester be excluded.
The test system may only be used if it is in perfect technical order as long
as it is being used properly. At the same time safety and hazard risks as
well as observation of the contents of the instruction manual must be
taken into account. The test system must be shut down immediately
should any interference occur that impairs safety. The interference or its
cause must then be rectified.
Supplements
Supplement the user manual with instructions from national regulations
on accident prevention and environmental protection.
Please observe and adhere to:

- Valid, binding regulations on accident prevention
- Recognised technical rules for safety and correct working
- Regulations on safety and health protection when preparing and using
working means
- Instruction manuals
The entire instruction manual must always be available at the installation
site of the test system.
03.05 / Einleitung / V5.1

Instruction manual
Safety
Transport
Transport
Adhere to the regulations governing safety and health protection at work
(Liability of the system supervisor) when making work means available.
These are, amongst others:
Instructing the employees
Proper use of transport means and lifting tackle
Personal safety equipment
Transport of the test system and accessories is described in chapter
Transport in the installation manual. Zwick does not accept any liability
whatever for the use of any types of transport other than that described in
this chapter.

Instruction manual
03.05 / Einleitung / V5.1
Safety
Proper use
Proper use
Our materials testing machines (test system) can be used to determine
properties on test pieces such as bars, shaped elements, components
and component assemblies. The testing machines apply mechanical
loading to specimens in the form of continuous, increasing, pulsating or
cyclic tests through an electrical or hydraulic drive system.
The test pieces are loaded via the test quantities force, moment or
deformation with defined values, time sequence and frequency.
The materials are undergo destructive or non-destructive tests
depending upon the testing machine and test method used.
The classical types of test are tensile, compression, flexure and torsion
test on the basis of a variety of test standards.
Please make sure that the specimen and specimen mountings used can
neither be propelled away from the testing machine nor can drop to the
floor when under load, or in the case of failure. This could lead to damge
to test equipment and to injury to persons in the vicinity of the machine.
The instruction manual is constructed in modular form. Thus observe
section 2 Technical manual. This section describes the proper use of
each component.
Copyright 2008, Zwick GmbH & Co.KG D-89079 Ulm
Inspection and maintenance, transport, installation and operating

instructions belong to the proper use of the test system.
04.08 / Bestimmung / V5.3

Instruction manual
Safety
Proper use
Improper use
Any use other than those expressly stated is recognised as being
improper use. Zwick does not accept any liability whatever for damge
resulting from any application or use not included under proper use.
Liability is the sole responsibility of the user. The guarantee for the
testing system expires.
Examples of improper use:
Amendments to the testing system not agreed upon by Zwick
Use of the testing system in the sense of a production machine if
not agreed upon by Zwick
Overriding the safety devices
The safety devices are used to protect the operator and the
vicinity.
Never ever shut down or override the functions of safety devices!
Zwick does not accept any liability for tools, appliances or devices
integrated by the user. Any necessary safety measures are then the sole
responsibility of the operator/user.

Instruction manual
04.08 / Bestimmung / V5.3
Safety
Remaining risks
Remaining risks
Remaining risks may be present in, for example, the following cases (For
examples also see DIN 51233):
Using hardened or ceramic jaw inserts without protection against
shattered parts
Danger of trapping fingers, etc. when opening and closing
specimen grips which are electrically, hydraulically or pneumatically
operated.
Specimen or parts of specimen that are, or can be, propelled away
from the test system or fall to the ground with high energy
absorption and resilience owing to the type of loading and the
properties of the specimen, i.e.
- Springs
- Ropes
- Belting
Basically we stipulate that the user is well versed in the use of the testing
system.
Safety devices such as EMERGENCY STOP buttons and limit switches
are integrated in our materials testing machines to provide protection to
the user and the vicinity.
A speed limitation of 600 mm/min for opening and closing specimen

grips is a safety measure for automatically operated specimen grips
(Hydraulic, pneumatic, motorised).
The safety device is used to protect the operator and the vicinity.
The functions of the safety device must never, ever be overridden!
Never disassemble the actuator of the interlock switch for the
safety device.
Never use a replacement actuator. Always close and interlock
safety devices correctly.
Actuator
06.08 / RestR / V5.21

Instruction manual
Safety
Preventive measures
Checks and preventive measures

The following checks and preventive measures must be carried out independent of your running checks for any evident deficiencies.
-
Electrical equipment and systems should be checked regularly, at

least every 4 years, for proper functioning by qualified and
competent electricians (BGV A2).
Please make regular visual checks of all hydraulic hoses. They must
be replaced immediately if any damage is detected. According to
DIN 20066 fluid technology, hoses hydraulic hoses should be
replaced every six years at the latest as a precautionary measure.
Recommendation
Let the safety devices (for example EMERGENCY STOP, limit
switches, safety device, etc. if installed) be checked by a trained,
competent and authorised person:
- Immediately upon detection of damage
- Following maintenance work
- At least once monthly
10

Instruction manual
06.08 / RestR / V5.21
Safety
Symbols and hit words
Symbols and signal words

Symbols on materials testing machines
The following safety notes can be fixed to the test system and to the
accessories. Please pay attention to it.
Risk of injury!
The crosshead is moving.
Caution, no automatic shutdown if the crosshead is
touched.
Risk of pinching parts of the body!

Specimen grips can be closed mechanically, manually or
automatically.
Caution, there is no automatic shutdown when touching the
specimen grips.
(Automatically closing wedge grips are mounted in our
example.)
Dangerous electrical voltage!

Only qualified electricians are allowed to open the casing.
System display
12.08 / Signalworte / V5.4

Instruction manual
11
Safety
Symbols and hit words
Signal words in the instruction manual

The instruction manual marks functions which may contain risks of injury
for the operating personnel or danger for a testing system with the signal
words as indicated below. These functions may only be carried out by
trained operating personnel with due care and diligence.
WARNING
Indicates an imminently hazardous situation
which, if not avoided, could result in serious injury or fatality.
CAUTION
Indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate injury.
ATTENTION
Safety notes with the signal word WARNING or CAUTION may also
contain hazards for testing systems, accessories and the environment.
12

Instruction manual
12.08 / Signalworte / V5.4
Possible hazardous situations

at which the test system or an object in the vicinity could
become damaged.
Safety
Instructions for the operating personnel
Persons involved
A differentiation is made in this instruction manual between user and
operating personnel.
User:
Owner of the company or person in charge who

has authority to give instructions and orders.
Operating personnel: Persons who work at or with the testing system
Operator
The machine safety can only be implemented in every day use if all
necessary measures are taken.
Determine the operating personnels responsibilities for
Operating
Setup
Maintenance and repairs
Tuition on the above is offered by Zwick
The test systems user must make sure that the following is observed
(due diligence).
Tests which could cause injury to persons or damage to machinery

are not to be performed with the testing system.
The testing system may only be used if it is in perfect working order
04.08 / Personen / V5.61
The test system may only be used according to its proper use.
Anything that could impede safety has neither been added nor
converted

Instruction manual
13
Safety
Instructions for the operating personnel
The safety devices (safety devices, Limit switch, proximity switch

and EMERGENCY STOP) must be checked regularly for obvious
damage.
Should the testing system malfunction in any way, further operation

is permitted only following consultation with the responsible safety
officer (if necessary please ask Zwick)
All safety notes and warning signs attached to the testing system
must not be removed and must be legible.
The operating personnel must know the safety notes contained in

the instruction manual and adhere to them
The testing system must be operated by qualified and authorised

operating personnel only.
The operating personnel must have some knowledge of:
- Safe operation.
- Suitable safety clothing.
- Any potential risks emanating from the test system.
The operating personnel must be instructed with respect to work
safety and environmental protection as follows:
- Before the beginning of their work
- About any eventual alterations/amendments to the testing
system
However, at least
- Annually
14
Safety devices have not been manipulated
The operating personnel wears suitable protective clothing (safety

goggles/face shield, safety shoes, protectice gloves, tightly fitting
clothing, hairnets for long hair).

Instruction manual
04.08 / Personen / V5.61
Safety
Workplace
Workplace
The operators workplace is in front of the materials testing machine
during operation.
For safety reasons only one operator must operate the
materials testing machine at a time.
Materials testing machine installed near to a wall
> 0.5 m
PC/Monitor
2m
Table
2m
> 0.5 m
Stool
04.08 / Arbeitsplatz / V5.2
Workplace

Instruction manual
Workplace
15
Safety
Workplace
Materials testing machine with a safety device

The users workplace is always in front of the materials testing
machine.
When testing.
Verification/Equipping of the materials testing machine
16

Instruction manual
04.08 / Arbeitsplatz / V5.2
Working or bodily presence at the rear of the materials

testing machine is expressly forbidden!
Safety
Safety measures and notes

Before switching on
Please check the following before switching the test system on:
-
Only authorised persons may be allowed into the working range of

the test system.
Check all safety devices (safety devices, limit switches, proximity

switches and EMERGENCY STOP button) for evident malfunctions
Please check the test system for visible damage! Report any
determined damage immediately!
The test system must not be used at all if the following (examples)
defects are detected:
Defective or damaged separating safety devices.
Defects or damaged pneumatic leads.
Defects or damaged hydraulic leads.
Defects must be rectified before putting the test system into operation.
12.08 / Massnahmen / V5.5

Instruction manual
17
Safety
At operation
Please get acquainted with how to react in case of defects/
interference before switching the test system on.
Non-observance could lead to injury.
EMERGENCY STOP button

In case of danger any movement of the materials testing
machine must be stopped immediately by hitting or pressing
the EMERGENCY STOP button.
Set free buttons

The set free buttons can always be selected, the only
exception is when the <EMERGENCY STOP> button has
been pushed in. The set free buttons are active again after the
<EMERGENCY STOP> button has been released.
ON
Exemplary drawing
18

Instruction manual
Set free buttons
The set free buttons are also active even if the <ON> button
has not been pressed.
The set free buttons are used to release the limit switches.
Thus the crosshead motion can neither be monitored nor shut
down via the limit switches. You must, therefore, think carefully
about the direction in which you want to drive the crosshead.
There is a danger of irreparable damage occurring to the test
system and the installed components if the direction of drive is
incorrect.
Safety
Rotating lead screws

Be careful when lead screws, such as those for crossheads or
extensometers are rotating.
Long hair, jewelry or loose clothing (e.g. sleeves) could get
caught up in rotating lead screws.
Please take the following precautions
Wear closely fitting clothing
Do not wear jewelry
Use a hairnet if necessary
Notes:
This safety note is only relevant if a lead screw cover has
either not been installed or if it has been dismantled/removed.
Working area
Risk of pinching and/or potential danger through falling
objects.
Never place objects in the materials testing machines test
area nor on the test tools.
Exemplary drawing

Instruction manual
19
Safety
Working in the working area

Danger of pinching parts of the body.
Keep your hands away from the test area when the materials
testing machine is running.
Connecting parts
Zwick mounting studs and lock- pins may only be loaded up to
the maximum load as indicated in the list.
Prestress nut
Mounting stud
D g6
8 mm
20 mm
36 mm
60 mm
Lock-pin
d H7
3 mm
8 mm
18 mm
30 mm
Maximum
Load
1 kN
10 kN
50 kN
250 kN
Mounting stud
Lock-pin
Never ever overload mounting studs and/or lock-pins.

The maximum permissible loading is always determined by
the weakest link in the chain (Test arrangement)!
Please make sure that any pneumatic and/or hydraulic

equipment of, or for use with, the test system is at zero
pressure before you start doing any work on it.
Exemplary drawing
20

Instruction manual
Specimen grip hydraulic/pneumatic

Keep your fingers away from between the gripping jaws.
Always use specimen tongsfor inserting specimen!
Specimen tongs are available for use with hydraulic grips.
Safety
Tensile tests: Risk of pinching

There is a danger of trapping parts of the body after test
during return of the crosshead to its initial position. There is a
danger of pinching parts of the body especially between
specimen grips when they are being moved close to one
another, i.e. the free grip to grip separation is very small.
You must wait until the test is ended and the crosshead has
stopped moving before attempting to access the working
area.
Compression and flexure tests: Risk of pinching

There is a danger of pinching parts of the body during these
tests whilst the compression platens or flexure test elements
are in motion. Never ever attempt to access the space
between compression platens or flexure test elements with
parts of your body whilst a test is running.
Increased risk of pinching hands and fingers if, for example,

there is not much space between upper and lower
compression platens (also see safety standards concerning
safety room and minimum distances for avoiding pinching
parts of the body).
In such cases please take preventive measures by using
specimen tongs (not supplied by Zwick) which are especially
suitable for handling your specimen .
Exemplary drawing

Instruction manual
21
Safety
Spring tests
Danger of springs, or parts thereof, being propelled away
from the test equipment.
Springs or spring components must neither move crosswise
with respect to the test axis nor may they slip sideways.
Use an anti-buckle device and a form fitting specimen
mounting for tests on compression springs.
A safety device is necessary for the test area depending upon
the type of test(s)!.
Insert the specimen

Potential danger through incorrectly gripped or placed
specimen:
Parts of the specimen or jaw inserts could be propelled away
from the testing system.
Check only correctly gripped/inserted specimens. Off-centre
testing may only be carried out with special tools.
Tensile,
Compression
Compression test devices may have a centring groove or a

guide mandrel. The specimen must then either be seated in
the groove or secured against being propelled away from the
test device by the mandrel.
Flexure test
22

Instruction manual
Safety
Open specimen grip

Potential danger through incorrectly gripped or placed
specimen:
Parts of the specimen or jaw inserts could be propelled away
from the testing system.
Never ever open specimen grips which are under load.
Any load must be removed from the gripped specimen before
opening the specimen grips.
Safety goggles, safety gloves

Risk of injury!
Example:
Tests on specimen which shatter
Tests with jaw inserts which might shatter
Component testing
Everybody, even observers, must wear safety goggles and/or
protective gloves if potentially dangerous tests are being run
(EN 166).
Temperature
Parts of the machine such as the motor can become very hot.
+
0
-
Exemplary drawing

Instruction manual
23
Safety
Noise
Loud specimen break can lead to damage to your hearing.
Use ear-protectors in such cases.
The materials testing machine does not normally emit any
noise which could damage your hearing.
Continuous noise, which could damage your hearing, is
generated by hysteresis or vibration tests. Please wear ear
protectors in such cases.
The respective noise levels for the materials testing machines
and their components are to be found in section 2 Technical
manual
Exemplary drawing
24

Instruction manual
Safety
At maintenance and servicing

Please note the following points to help avoiding serious injuries or
machine damage when carrying out maintenance work on the test
system. These topics are listed for each component in section 10 Service and maintenance manual:
Adhere to prescribed Inspection and maintenance intervals
Please pay attention to the maintenance and service manuals.
Only use the indicated operating fuels and lubricants, etc.
Use original Zwick spare parts only
Before carrying out service and maintenance and service work:
Switch the power supply off via the main switch Secure the main
switch against inadvertant switching on with a padlock.
Unplug the mains plug or disconnect the mains supply.
Wait until all parts of the test system that may perhaps be touched
(e.g. motor, temperature chamber, etc.) have cooled down to
ambient temperature!
Check the following after maintenance or repair work:

Have all threaded connections been screwed tight again?
Have container lids/covers, sieves or filters that have been removed
been replaced again?
Have all materials, tools, equipment, etc. that are required for
maintenance and repair work been removed from the pendulum
impact testers working area
Have any liquids that may have leaked been removed?
Are all safety devices such as limit switches, proximity switches and
EMERGENCY STOP of the testing system in perfect working
order?
The test system can be operated by operating personnel only if all of the
above work has been done correctly and is free of error.
Only use lift bearing fixtures (such as a fork lift truck, crane, etc.) which is
suitable and in first class condition when replacing or exchanging heavy
machine parts!
12.08 / Instandhaltung / V5.31

Instruction manual
25
Safety
When working with electrical equipment

The leads from the mains cable(s) and mains input filters up to the input
of the main switch are under current even when the test system is
switched off.
Maintenance and repair work on electrical equipment must be carried out
by competent and qualified electricians only!
-
Electrical equipment and systems should be checked regularly, at

least every 4 years, for proper functioning (BGV A3)
by qualified and competent electricians.
Please keep the switch console closed at all times! Access is only
permitted for electricians with keys/tools!
Switch consoles/Housing for electrical equipment (such as

electronic housing, motors) should never come into contact with
water nor steam (i.e. steam jet cleaners)!
26

Instruction manual
12.08 / Instandhaltung / V5.31
Safety
Preventive maintenance and maintenance
When working on hydraulic and pneumatic equipment

Maintenance and repair work on hydraulic and pneumatic equipment
must only be performed by competent personnel trained and with
experience in hydraulics/pneumatics!
When working with hydraulic oil please observe the corresponding
remarks on the safety data sheet (section 13 Certificates/Calibration
reports).
Set the testing systems pneumatic and hydraulic equipment to zero
pressure before carrying out maintenance and repair work on them!
These topics are listed for each component in section 10 Service
and maintenance manual
Please check all leads, hoses and threaded connections for

leakage and for visible damage!
Replace any damaged hoses/pipes immediately!
Hydraulic hoses must neither be repaired nor may parts from old
hoses and fittings be used to make new ones.
12.08 / Instand_hyd / V5.61

Instruction manual
27
Safety
Preventive maintenance and maintenance
Spraying oil could lead to injuries and fires!

-
As a precautionary measure, please replace all hydraulic hoses

every 6 years (recommendations to DIN 20066 Fluidics - Hoses)
even if damage to them is not obvious!
Hydraulic oil may escape when cleaning the equipment.

Please make sure that emergency precautions (oil sump, oil
binders, etc.) have been taken to make sure that oil cannot intrude
into the ground and/or the sewer system.
Please adhere to the safety data sheets for the hydraulic oil used
and to the necessary rules and regulations.
Hydraulic oil and contaminated agents (Oil binders) must always be
disposed of in an environmentally safe way. The safety data sheets
are to be found in section 13 Certificates/Calibration reports
When replacing hydraulic and compressed air hoses, mount them

in the same manner/direction.
Risk of slipping
28

Instruction manual
12.08 / Instand_hyd / V5.61
Safety
Cleaning
Cleaning recommendations
When carrying out work on and with test systems, please observe any
legal requirements for avoiding waste, and for its correct disposal/
recycling.
Water contaminating substances must neither contaminate the ground
nor drainage systems especially at installation, repair and maintenance
work!
Examples of water contaminating substances
Lubricant grease and oil.
Hydraulic oil.
Coolants
Cleansing fluids containing solvents.

Used oil
These substances should be collected in suitable containers and then

stored, transported and disposed of in an environmentally safe manner.
Dispose of hydraulic oil according to safety data sheet (Section 13
Certificates/Calibration reports).
Dispose of all replacement parts safely and in an environmentally safe

manner.
12.06 / Reinigung / V5.2

Instruction manual
29
Safety
30

Instruction manual
12.06 / Reinigung / V5.2
Index
Instructing the transport personnel ........................... 6
Index
L
A
ATTENTION ............................................................ 12
Avoiding waste ....................................................... 29
B
Before switching on ................................................ 17
C
CAUTION ...............................................................
Checks and preventive measures ...........................
Cleaning recommendations ....................................
Compressed air hoses ...........................................
Compression tests .................................................
12
10
29
28
21
D
Dangerous electrical voltage .................................... 11
Definition
ATTENTION ....................................................... 12
CAUTION .......................................................... 12
WARNING ........................................................ 12
Disposal ................................................................. 29
Disposal in an environmentally safe manner ........... 29
Document ................................................................ 2
E
Ear protectors ........................................................ 24
Electrical voltage ..................................................... 11
EMERGENCY STOP ....................................... 14, 25
EMERGENCY STOP button .................................. 18
F
Flexure tests .......................................................... 21
H
Heat ....................................................................... 23
Hoses .................................................................... 28
Hydraulics .............................................................. 27
I
Insert the specimen ................................................ 22
Inspection intervals ................................................. 25
Instructing the operating personnel ......................... 13
11.04 / SiIndex / V5.0
Lift bearing fixtures ................................................. 25

Limit switch ............................................... 14, 17, 25
Lock-pins ............................................................... 20
Machine safety .......................................................

Mains plug .............................................................
Mains supply ..........................................................
Maintenance ..........................................................
Maintenance intervals .............................................
Maintenance work
Electrical equipment .........................................
Environmental protection ...................................
Hydraulic equipment .........................................
Pneumatic equipment .......................................
Switch off ..........................................................
Mounting stud ........................................................
13
25
25
25
25
26
29
27
27
25
20
N
National regulations .................................................. 5
Noise level .............................................................. 24
O
Operate ..................................................................
Operating personnel ...............................................
Operation ...............................................................
Operator .................................................................
18
13
13
15
P
Padlock .................................................................. 25
Perfect working order ............................................. 13
Personnels responsibilities ..................................... 13
Persons involved .................................................... 13
Pneumatics ............................................................ 27
Preventive measures .............................................. 10
Print date ................................................................. 2
Proper use ............................................................... 7
Protection
Clothing ............................................................ 14
Proximity switch ....................................... 14, 17, 25
R
Remaining risks ....................................................... 9

Instruction manual
31
Index
Risk of injury ........................................................... 11

Risk of pinching ..................................................... 21
Risk of pinching parts of the body ........................... 11
Risk of slipping ....................................................... 28
Working area .................................................... 19, 20

Workplace .............................................................. 15
S
Safety
Devices ....................................................... 14, 17
Gloves ............................................................... 23
Goggles ............................................................ 23
Safety devices ............................................. 8, 14, 17
Safety measures
At operation ...................................................... 18
Before switching on ........................................... 17
Ear protectors ................................................... 24
Safety notes ..................................................... 14, 17
Servicing ................................................................ 25
Set free buttons ..................................................... 18
Setup ..................................................................... 13
Signal words
In the instruction manual ................................... 12
Symbols on materials testing machines ............. 11
Specimen tongs ............................................... 20, 21
Spring tests ............................................................ 22
State of the art ......................................................... 5
Supplements ............................................................ 5
Symbols
Electrical voltage ................................................ 11
Risk of injury ...................................................... 11
Risk of pinching parts of the body ...................... 11
T
Tensile tests ........................................................... 21
Tongs ..................................................................... 20
Transport .................................................................. 6
U
Usage
Improper use ....................................................... 8
Proper use .......................................................... 7
User ....................................................................... 13
W
WARNING ..............................................................
Warning signs ........................................................
Working
On hydraulic equipment ....................................
On pneumatic equipment ..................................
With electrical equipment ..................................
32
12
14
27
27
26

Instruction manual
11.04 / SiIndex / V5.0
Dossier
Section 2:
Instruction manual
Technical manual
BT1-FB005TN.D14
Serial number:
AB/Dossier number:
03.05 / THInhalt / V5.11
2
13

Instruction manual
179947
2142429
2
13
Document
Instruction manual
Section 2
General
This section contains data that is important for the materials testing
machine (MTM).
The technical manual
- Makes learning about the machine easier and also provides
information on utilising its applicational possibilities.
- Contains important notes on using the materials testing machine
safely and economically. Please pay attention to these notes. They
make it possible to increase the reliability and life span of the
machine.
- Must be read and used by all persons authorised to work at and with
the machine.
Document:
Technical manual
Version:
Print date:
V 6.20
February 2009
these to:
Zwick GmbH & Co. KG
D-89079 Ulm
Fax: +49 - (0) 7305 - 200

Instruction manual
03.05 / THInhalt / V5.11
All rights reserved
List of contents
Technical manual
2
13
List of contents
List of contents .................................................................................................................. 3
Technical details................................................................................................................ 5
Materials ............................................................................................................................. 7
testing machine ................................................................................................................. 7
5 kN ..................................................................................................................................... 7
Technical data ............................................................................................................. 8
Measurement and control electronics ........................................................................... 9
Measurement module DCSC ..................................................................................... 15
Load cell, function description .................................................................................... 19
Load cell 5 kN ............................................................................................................ 23
Load cell 500 N ......................................................................................................... 25
Pneumatic control unit ................................................................................................ 27
Pneumatic specimen holders 5 kN ............................................................................. 29
Screw grips ............................................................................................................... 33
Environmental and operating conditions ...................................................................... 37
Index ................................................................................................................................. 41
03.05 / THInhalt / V5.11

Instruction manual
2
13
Safety
Applied standards
The test standards relevant for materials testing machines are listed in
the
Declaration of conformity or in the manufacturers declaration.
In addition we have provided information on the proper use of the
machine in section 1 of the safety manual.
National regulations
Supplement the technical manual with instructions from national
regulations on accident prevention and environmental protection.
working means
Notes on product and manufacturers liability
Notes:
We recommend annual calibration with respect to EN ISO 9001.

Instruction manual
03.05 / THInhalt / V5.11
The accuracy limits stated in our specification(s) (Order confirmation) are

not infinitely valid. Regular checks must be made depending upon the
measurement accuracy.
You can do this yourself if you have suitable measurement means. If not,
it can be done by accredited centres such as German materials testing
authorities or by Zwick. The Zwick DKD calibration laboratory is
accredited under registration no. DKD-K-13201.
Test standards
2
13
Technical details
This section contains the description of the materials testing machine
(MTM) with all accessories.
All technical details are contained here.
Here we have defined the proper use of the accessories. Information on
improper use of the materials testing machine and the accessories is
also contained here.
The entire instruction manual must always be available at the

installation site of the materials testing machine.
Electronic rating plate
All of a materials testing machines important data, such as the nominal

force of the load application device, is saved to an electronic rating
plate. This materials testing machine is thus capable of determining its
own configuration.
03.05 / THInhalt / V5.11

Instruction manual
2
13
Identification
Identification
Each materials testing machine has two serial number plates as
standard. A large serial number plate is on the electronics console and a
small one is on the rear of the machine base. An exception to this is
single screw materials testing machines, each of these has only one
serial number plate.
Large serial number plate

Here is the CE sign for those materials testing
machines that have a declaration of conformity.
Manufacturer with address
Zwick/Roell
Order number = Machine type
August-Nagelstr. 11, D-89079 Ulm

type
serial no
order no
Power
BXX-XXXXXXX
000000 / 0000
000000
000/000V - 00/00Hz
00A
Fnom 000kN
Serial number/Year of construction

Order confirmation number/
Dossier number
Mains connection
Nominal value of the materials testing machine
Small serial number plate

Manufacturer with address
Zwick/Roell
type BXX-XXXXXXX
serial no 000000 / 0000
Order number = Machine type
Fnom 000kN

Nominal value of the materials testing machine

Instruction manual
03.05 / THInhalt / V5.11
Here is the CE sign for those materials testing

machines that have a declaration of conformity.
2
13
Technical details
Materials testing machine 5 kN
Materials
testing machine
5 kN
Overview
200
720
Head plate
110
Load frame
Upper limit
switch stop
Moving crosshead
Ruler
1331
Position pointer,
crosshead pointer
Operator panel
440
Set free button
EMERGENCY STOP
EMERGENCY STOP
Lower limit
switch stop
356
Fixed base crosshead
770
930
Main switch
141
200
Wall
436
Motor
> 200
Levelling element
Working area
Operators workplace
Illustration not to scale
04.08 / Tech / V5.01
Electronics
EMERGENCY STOP

Instruction manual
Technical details
Materials testing machine 5 kN
2
13
Technical data
Type ................................................................................... Materials testing machine
Load frame
Test load in tensile/compression ......................................................................... 5 kN
Height:
Load frame height ................................................................................. 1,303 mm
with levelling elements ........................................................................... 1,331 mm
Width:
Load frame width ...................................................................................... 770 mm
with electronics ........................................................................................ 930 mm
Depth:
Load frame depth ..................................................................................... 356 mm
with electronics ........................................................................................ 437 mm
Test area height w.o. accessories:
Lower test area ..................................................................................... 1,070 mm
Test area width .............................................................................................. 440 mm
Weight:
With electronics console ............................................................................ 110 kg
With typical accessories, approx. .............................................................. 125 kg
Space requirements:
Pure contact area .................................................................................... 154 cm
Load frame, base area ........................................................................... 2,741 cm
Specific floor loading:
Related to the typical accessories ..................................................... 0.81 kg/cm
With 50% safety ................................................................................ 1.22 kg/cm
Floor loading:
Related to the typical accessories ..................................................... 0.06 kg/cm
With 50% safety ................................................................................ 0.09 kg/cm
Drive system
Crosshead speed ...................................................................... 0.001 to 500 mm/min
Accuracy of the set
speed ........................................................................................... 0.011 % of Vnom
Drive systems travel resolution ................................................................... 0.039 m
Positioning, repetition accuracy ................................................................... < 2.0 m
(w.o. reverse of direction)
Maximum test frequency .................................................................................. 0.5 Hz

Instruction manual
04.08 / Tech / V5.01
Finish .................................................................................. RAL 7011 and RAL 3031

Ambient temperature ..................................................................... + 10 C to + 35 C
Humidity ............................................................................................... 20 % to 90 %
Noise level ................................................................................................... 58 dB(A)
Technical details
2
13
Measurement and control electronics

Test data recording rate in the system ............................................................ 500 Hz
Measurement data transmission rate to the PC ............. Adjustable from 10 to 100 Hz
Number of module slots ........................................................................................... 2
Zero-drift correction of the entire measurement chain
without sensor ................................................... Automatic at measurement begin
Measurement signal, runtime correction ............................................................... Yes
Output interface .............................................................................................. RS232
Required PC connection ................................................................ COM 1 or Ethernet
Type of protection, casing .................................................................................. IP 32
Notes on the electronics
- A measurement value recorder board is inbuilt in the electronics. A further,
optional measurement value p.c.b. can be purchased for the second module
slot.
-
The ventilation slits in the electronics unit must never be covered, not even those
on the units underside.
The electronics must have a constant temperature for exact measurements.

Thus switch the materials testing machine on an hour before the beginning of
testing, especially for long term tests.
Force measurement
The measurement electronics for the force measurement corresponds to ISO 7500/1.
Load cell, type I
Grade 1
in the range of 0.4 to 100 % of Fnom.
Grade 0.5
in the range of 2 to 100 % of Fnom.
Load cell, type II
Grade 1
At Fnom >= 500 N in the range of 0.2 to 100 %,
At Fnom <= 200 N in the range of 0.4 to 100 %,
Grade 0.5
in the range of 1 to 100 %
The percentage values refer to the nominal force (Fnom) of the connected load cell.
01.09 / TDat / V5.2

Instruction manual
Technical details
2
13
Operating data
Rated values
Voltage selection
switch
3
1 2
4 5
input voltage
selector
0: 240 ... 250 V~
1: 220 ... 239 V~
2: 200 ... 219 V~
3: 120 ... 129 V~
4: 110 ... 119 V~
5: 100 ... 109 V~
Electronics, rear side
Electrical connections ........................................................................... See the table

(Ph, N, PE)
Adjustable from: ............................................................................ 100 V to 109 V
110 V to 119 V
120 V to 129 V
200 V to 219 V
220 V to 239 V
240 V to 250 V
Permissible mains drift .................................................................... - 10 % to + 10 %
(with reference to the set range)
Full current consumption at the setting:
100 V to 109 V
110 V to 119 V
120 V to 129 V
200 V to 219 V
220 V to 239 V
240 V to 250 V
......................................................... 4.4 A
............................................................ 4 A
......................................................... 3.7 A
......................................................... 2.2 A
............................................................ 2 A
......................................................... 1.9 A
Power consumption (full load) ......................................................................... 440 VA

Mains frequency ......................................................................................... 50 / 60 Hz
Mains fusing for the power supply ................................................................. <= 16 A
Internal danger of explosion!
10

Instruction manual
01.09 / TDat / V5.2
There is an extremely high risk of an internal explosion if an

incorrect rated voltage is connected.
Always set the correct rated mains voltage correctly!
Technical details
2
13
Function description
Load frame
The load frame of the materials testing machine, and the electronic
measurement and control unit make up the basic unit for testing a range
of materials. The load frame consists as standard of two guide profiles
with integrated, play-free ball lead screws, a fixed lower and a moveable
central crosshead as well as a head plate.
The mechanical drive is to be found in the base of the load frame.
A bellows cover integrated in the guide profile protects lead screws and
guide even if there is an extremely large amount of fibrous remains,
fragments and dust.
The central mounting on the crossheads serves to mount test tools or
load cells.
Proper use
Details about the proper use of the materials testing machine are to be
found in section 1 Safety manual.
Limitation
The materials testing machine is unsuitable for tests on elastic
specimen such as elastomers, springs or similar materials where the
actual test load is greater than 50 % of the machines nominal force.
03.06 / Verwend / V5.0

Instruction manual
11
Technical details
2
13
Improper use
Materials testing machines must not be put to use for any kind of
applications whatsoever that constitute potential sources of danger for
persons and for the environment.
Emissions
Heating up
The motor temperature can reach 80 C when performing cyclic tests
(Continuous operation).
Free from vibrations
Vibrations and jolts at specimen break are dependent upon the material
tested, and on the test arrangement.
Noise level
The materials testing machines noise level is listed in the technical data.
A loud noise can be generated at specimen failure (Specimen break).
We recommend the use of ear-protectors for such tests.
12

Instruction manual
03.06 / Verwend / V5.0
Technical details
2
13
Fire fighting equipment

Fire extinguishers to DIN EN 2 combustion classes A and B may be
used for combatting fire and/or smouldering.
Combustion class A Burning of solid materials
A
B
Combustion class B, Burning of liquid or liquifying materials
Tools
A set of Allen keys and a hook spanner belong to the standard
accessories of our materials testing machines. The delivery note will list
any further accessories which are also supplied. These tools are then
needed for running operation.
Tools which are needed seldomly or just once off (E.g. scissors, openended spanners), e.g. for assembling/disassembling the machine/
equipment, are not supplied by us.
03.06 / Verwend / V5.0

Instruction manual
13
Technical details
2
13
Accessories
The materials testing machine can be used with a wide range of
accessories. The system elements and accessories listed here are only
a part of the Zwick spectrum of products. You can direct any enquiries
you may have on the Zwick range of products to your local representative
or directly to Zwick in Ulm, Germany.
Accessories, connection to
materials testing machines
Physical measurement
units, connection via PC
Load cell
Electronics
Vernier gauge
Micrometer
Extensometer
Thickness
gauge
or
Crosssectional area
monitor
Test tool
Optional base
Scales
Safety pane
Printer
Network (LAN), Laboratory file server
14

Instruction manual
03.06 / Verwend / V5.0
PC
2
13
Technical details
Measurement module DCSC
Measurement
module DCSC
Overview
135
Screw fixing
108
Sensor or test data recorder

25-pin, sub-D pin-plug
Screw fixing
96-Pin module bus plug
The TC-MODCSCC module is the link between a test data recorder with
a strain gauge measurement bridge, e.g. a strain gauge load cell, and
the electronics.
11.04 / Tech / V5.0

Instruction manual
15
Technical details
2
13
Technical data
Type ............................................................................... Measurement module DCSC
Measurement range .................................. 0.2 to 165 %** of nominal measured value
Test data recording rate ............................ switchable via software, maximum 500 Hz
Resolution at 100% nominal measurement value:
at 500 Hz test data recording rate ................................................... 162000 points
at 50 Hz test data recording rate ..................................................... 297000 points
Type of measurement input ................................................................ Difference input
Zero-point, temperature dependent .............. < 5* 10-4 %/K of nominal measured value
Maximum linearity error .......................... +/- 0.01 % of measurement range end value
Temperature range ............................................................................... +10 to +45 C
Dimensions:
Height ........................................................................................................ 30 mm
Width ....................................................................................................... 108 mm
Depth ....................................................................................................... 135 mm
Connectable sensors
Strain gauge measurement bridges ............................................................ Full bridge
Type of connection ................................................................ 4 and 6 lead technology
Nominal characteristic value, sensitivity ......................................................... 2 mV/V
Maximum characteristic value tolerence ......................................................... +/- 2 %
Permissible strain gauge bridge resistance ......................................... 100 to 1200
Sensor supply voltage ................................................................................... 10 V DC
Proper use
16

Instruction manual
11.04 / Tech / V5.0
The DCSC module is foreseen for connecting strain gauge full-bridge

sensors. This module enables you to operate strain gauge load cells and
also other strain gauge measurement bridge sensors in 4 and 6 lead
technology.
Technical details
2
13
Inappropriate use
Inductive systems cannot be operated with this measurement module.
Block diagram
Socket for the load cells

or strain gauge
measurement bridges
plug.
To the module
bus output plug
0 % Ref.
100 % Ref.
Meas. signal
Analog
multiplexer
Differential
amplifier
Low pass
filter
AnalogDigital
converter
Module and data control
Power supply and

monitoring
Block diagram with plug.
11.04 / Tech / V5.0

Instruction manual
17
Technical details
2
13
18

Instruction manual
11.04 / Tech / V5.0
Load cell
2
13
Screen
Supply voltage (-)
Measuring voltage (+)
Supply voltage (+)
Measuring voltage (-)
Load cell, function description
Connection cable
Load cells convert the physical quantity force into an electrical,

measurable voltage. They consist of a mechanical deformation body with
bonded strain gages.
The strain Gages are strain-dependent, electrical resistances which are
interconnected to a measuring bridge.
The value of the measurement voltage at the measuring bridge output is
analog to the force (F) to be measured; this force acts on the
deformation body and on the entire sensor system.
The leading sign (Polarity) for the measuring voltage changes depending
upon the tensile or compression loading of the load cell.
A high quality, screened data cable with a 25-pin sensor plug connects
the measurement amplifier to the measurement electronics.
The sensor plugs p.c.b. has a small data storage IC to which the load
cells characteristic and calibration data (Important for the system setting)
is saved.
Rating plate
Plug casing
Identification
There is a serial number plate on the sensor plug of the load cell. The
serial number plate contains the type of sensor, the serial number with
date of manufacture and the nominal value.
Here is the CE mark for the load cell for those materials testing machines that
have been purchased with a declaration of conformity.
Zwick/Roell
type BXX-XXXXXXX
serial no 000000 / 0000
Fnom 000kN
Order number = Type of load cell

Nominal value of the load cell
04.08 / Ffunk / V5.01

Instruction manual
19
2
13
Load cell
Load cell cable guide

As the respective test requirements are so different, the
followingrequested recommendations are to be observed and the
corresponding measures are to be taken:
1. The data cable of the load cell must not be subjected to any
mechanical stressing or stretching at all over the entire crosshead
travel.
=>Feed the load cell cable so that there is always sufficient available
to avoid the above happening.
2. The load cell data cable must not be fed together with the connection
leads of the motor nor direct on the motor.
=> Feed the load cell data cable out of the cable duct above the
motor.
3. Specimen remains must not damage any part of the load cell
measurement cable at specimen break.
=>Place the cable so that it is correspondingly protected.
Cable clip
Cable conduit
Moving crosshead
Load cell
Cable loop => Reserve for the crossheads entire

travel
Feed the cable from the side
testControl electronics
Motor
System overview, rear view
20

Instruction manual
04.08 / Ffunk / V5.01
2
13
Load cell
Definition of the characteristics

The VDI/VDE guidelines 2638 (April 89) define the following
characteristics for load cells:
Nominal force
Measurement range
The accuracy limits as stated in the
technical data can be complied with.
Operational force
Operational range
The accuracy limits as stated in the technical data
can be exceeded.
Limit force
Maximum load range

The accuracy limits contained in the technical data are not
complied with, no measurement capability over and above
the operational force, no damage to the load cell.
Force at break
Destruction range
Permanent changes to
the load cell.
Nominal force
F nom
The nominal force for which the load cell has been
designed.
Maximumoperational force
FG in N
Greatest force in the direction of the load cells

measurement axis up to which a defined and repeatable
relationship between the force and the output signal exists.
However an eventually existing protection against overloading wont be tripped at this point.
Force at break
FB in N
Force in the direction of the load cells measurement axis

above which mechanical destruction must be reckoned
with.
04.08 / Ffunk / V5.01

Instruction manual
21
Load cell
2
13
Greatest force that may be applied at the load cells force

introduction point vertical to the measurement axis without
any significant changes to the load cells measurement
properties being detectable when using the load cell again
up to its nominal force.
This is also valid at simultaneous loading of the load cell to
nominal force.
Permissible torque
MG in Nm
Permissible torque about the load cells measurement axis

without any significant changes to the load cells
measurement properties being detectable when using the
load cell again up to its nominal force.
This is also valid at simultaneous loading of the load cell to
nominal force.
Characteristic value
C in mV/V
The output signal at nominal force is diminished by the preload signal.
Temperature influence on the

characteristic value per 10 K
TKC
Relative change to the characteristic value of the load cell

owing to a change in the ambient temperature by 10 k
within a defined temperature range after setting the
stationary states.
Temperature influence on the

zero signal per 10 K
TK0
Changes to the load cells zero-signal related to the

characteristic value due to a temperature drift of 10 K within
a defined temperature range after setting the stationary
states.
22

Instruction manual
04.08 / Ffunk / V5.01
Static limit lateral force

FQ in N
2
13
Technical details
Load cell 5 kN
Load cell 5 kN
Overview
Mounting stud
Slotted nut
Load cell
Prestress nut
Hole for a lock-pin
Mounting stud

measurable voltage.
10.04 / Tech / V5.0

Instruction manual
23
Technical details
Load cell 5 kN
2
13
Technical data
Type ..................................................................................................... Load cell 5 kN
Nominal force Fnom ....................................................................................................................................... 5 kN
Maximum force to be used FG ......................................................................................... 120 % of Fnom
Limit force FL .............................................................................................................................. 150 % of Fnom
Force at break FB ..................................................................................................................... 300 % of Fnom
Static permissible limit and transverse force FQ ..................................................... 10 % of Fnom
Fixing screw torque MA ........................................................................................................................... 5 Nm
Nominal measurement travel ....................................................................... 0.10 mm
Maximum temperature influence on the zero-signal TK0 ........................... 0.05 % FN/10K
Maximum temperature influence on the characteristic value TK0 ......... 0.05 % FN/10K
Measurement range, initial value:
Grade 1
0.2 % (FN 500 N), 0.4 % (FN<200 N) ................................... 20 N
Grade 0.5
2.0 % of nominal value ........................................................ 100 N
Temperature range in use ................................................................. -20 C to +60 C
Type of protection ................................................................................................ IP42
Model ...............................................................................................................KAP-Z
Dimensions:
Height ...................................................................................................... 100 mm
Width ......................................................................................................... 60 mm
Depth ......................................................................................................... 26 mm
Mounting stud ........................................................................................ 20 mm
Weight ............................................................................................................. 1.0 kg
Proper use
Inappropriate use
Load cells are precision measurement devices and, as such, should be
treated with the utmost care during transport and at assembly. They could
become irreparably damaged if subjected to shocks and/or knocks.
24

Instruction manual
10.04 / Tech / V5.0
This load cell is designed for measuring static and dynamic tensile and
compression forces. It must be operated in the direction of the test axis
and only up to its nominal force whilst adhering to the conditions as
contained under the technical data.
2
13
Technical details
Load cell 500 N
Load cell 500 N
Overview
Mounting stud
Slotted nut
Load cell
Prestress nut
Hole for a lock-pin
Mounting stud

measurable voltage.
10.04 / Tech / V5.0

Instruction manual
25
Technical details
Load cell 500 N
2
13
Technical data
Type ................................................................................................... Load cell 500 N
Nominal force Fnom .................................................................................................................................... 500 N
Maximum force to be used FG ......................................................................................... 120 % of Fnom
Limit force FL .............................................................................................................................. 150 % of Fnom
Force at break FB ..................................................................................................................... 300 % of Fnom
Static permissible limit and transverse force FQ ..................................................... 10 % of Fnom
Fixing screw torque MA ........................................................................................................................... 5 Nm
Nominal measurement travel ......................................................................... 0.1 mm
Maximum temperature influence on the zero-signal TK0 ........................... 0.05 % FN/10K
Maximum temperature influence on the characteristic value TK0 ......... 0.05 % FN/10K
Measurement range, initial value:
Grade 1
0.2 % (FN 500 N), 0.4% (FN<200 N) .................................... 2 N
Grade 0.5
2.0 % of nominal value .......................................................... 10 N
Temperature range in use ................................................................. -20 C to +60 C
Type of protection ................................................................................................ IP42
Model ...............................................................................................................KAP-Z
Dimensions:
Height ........................................................................................................ 86 mm
Width ......................................................................................................... 42 mm
Depth ......................................................................................................... 14 mm
Mounting stud .......................................................................................... 8 mm
Weight ............................................................................................................. 0.4 kg
Proper use
Inappropriate use
Load cells are precision measurement devices and, as such, should be
treated with the utmost care during transport and at assembly. They could
become irreparably damaged if subjected to shocks and/or knocks.
26

Instruction manual
10.04 / Tech / V5.0
This load cell is designed for measuring static and dynamic tensile and
compression forces. It must be operated in the direction of the test axis
and only up to its nominal force whilst adhering to the conditions as
contained under the technical data.
2
13
Technical details
Pneumatic control unit
Pneumatic
control unit
Overview
Foot switch for the lower specimen holder
Position: Specimen holder is open
Pressure gauge
Foot switch for the upper
specimen holder
Compressed air
connections for the
lower specimen
holder
Open hose (Black)

Close hose (Red)
Position:
Specimen holder is
closed
Compressed air supply from the

mains, NW7 nipple
(Suitable for automatic
NW7 shut-off hose coupling)
Pressure limiting valve
Close hose (Red)

Open hose (Black)
Compressed air connections for the upper
specimen holder
Always plug the colored pneumatic hoses into the correspondingly

marked compressed air connector.
Close hoses are red,
open hoses are black.
11.04 / Tech / V5.0

Instruction manual
27
2
13
Technical details
The pneumatic control unit controls opening and closing of Zwick
pneumatic specimen holders.
Technical data
Type ........................................................................................ Pneumatic control unit
Inlet pressure .............................................................................................. 2 to 8 bar
Adjustable operating pressure ................................................................ 2 to 8 bar
Connector, supply ................................................................................... NW7 Nipple
Connector, specimen holder .................................................................NW5 Coupling
Temperature range .......................................................................... +10 C to +35 C
Weight ............................................................................................................. 4.8 kg
Proper use
The pneumatic control unit is designed to operate Zwick pneumatic
specimen holders. It may only be used if it is/has:
- Placed safely and level on the floor
- A maximum closing pleasure of up to 8.5 bar
- Operated with filtered and oiled compresssed air.
If the last two conditions are not fulfilled, a maintenance unit must be
connected in series with the pneumatic control unit.
Inappropriate use
Operating data
Compressed air connection ......................................................................... 2 to 8 bar
With recommended oil to ....................................................................... ISO 3448
Viscosity ............................................................................................... 32 mm/s
Filtered, dehumidified and oiled
28

Instruction manual
11.04 / Tech / V5.0
The pneumatic control unit must not be operated with un-oiled, un-filtered
or humid compressed air.
The operating pressure of the compressed air must not exceed 10 bar.
Technical details
Pneumatic specimen holders 5 kN
2
13
Pneumatic specimen
holders 5 kN
84
Overview
Depth stops scale

266
164
162
Mounting hole
Pneumatic connections:
Open (Black plug-coupling)
Pneumatically
operated jaw side
Depth stop
Handwheel
for setting
the
specimen
thickness
Interchangeable jaw inserts
Close (Red plug connection)
The pneumatic specimen holders may be used up to a nominal load of

5 kN.
01.05 / Tech / V5.0

Instruction manual
29
Technical details
Pneumatic specimen holders 5 kN
2
13
These pneumatic grips are one-sided closing grips. The fixed jaw side
can be adjusted steplessly. The interchangeable jaw inserts enable the
specimen holders to be adapted for gripping a variety of materials. The
opening width can be adjusted from 0 to 24 mm.
The jaw inserts for the jaw mountings are permanently guided play free
via spring elements in the tensile direction. Each jaw insert is secured
via a locating spring. You can replace these without using tools.
Technical data
Type .............................................................................. Pneumatic specimen holders
Maximum test load ............................................................................................. 5 kN
Maximum gripping force at operating pressure
6 bar ................................................................................................. approx. 9 kN
10 bar ............................................................................................. approx. 16 kN
Piston area ....................................................................................... approx. 167 cm
Operating pressure .................................................................................... 1 to 10 bar
Clamping range:
Maximum opening width ............................................................................. 24 mm
Clamping travel........................................................................................ 12.5 mm
Temperature range .......................................................................... +10 C to +35 C
Connection diameter ....................................................................................... 20 mm
Weight per grip (w.o. jaws) ............................................................................... 8.2 kg
30

Instruction manual
01.05 / Tech / V5.0
Dimensions:
Width ....................................................................................................... 271 mm
Height ...................................................................................................... 162 mm
Depth (With connecting parts) ........................................................... 84 (164) mm
Technical details
Pneumatic specimen holders
2
13
Proper use
These pneumatic specimen holders are constructed for central gripping
of tensile specimen.
They are suitable for:
- Metals
- Plastics
- Paper
- Textiles
- Elastomers
Similar materials
The following specimen shapes can be used:
- Round specimen
- Flat specimen
- Films
- Yarns
- Adhesive specimen
The specimen holders can be adapted for different applications via
interchangeable jaw inserts.
Compression and flexure tests are also possible owing to the optional
connection system.
Plug the color marked pneumatic hoses into the correspondingly
marked compressed air connectors.
Plug the red close hose into the red marked compressed air
connection.
Plug the black open hose into the black marked compressed air
connection.
01.05 / Tech_A / V5.0

Instruction manual
31
2
13
Technical details
Inappropriate use
These pneumatic specimen holders must not be used for tests in
temperature chambers.
Operating data
Compressed air connection ....................................................................... 6 to 10 bar
With recommended oil to ....................................................................... ISO 3448
Viscosity ................................................................................................ 32 mm/s
Filtered, dehumidified and oiled
32

Instruction manual
01.05 / Tech_A / V5.0
2
13
Technical details
Screw grips
Screw grips
Overview
Setting screw for the optional specimen stop

Mounting hole
Optional specimen stop
Basic body
32
Setting marking
85
Adjustment wheel
Movable jaw
mounting
Fixed jaw
mounting
10
162,5
Interchangeable jaw inserts

Drawings not to scale All dimensions are in mm.
The screw grips may be used up to a nominal load of 1 kN.
10.08 / Tech_S / V5.1

Instruction manual
50
2
13
Technical details
Screw grips
These screw grips are one-sided closing grips for tensile tests (static,
continuous, pulsating). Both the fixed and movable jaw mountings can be
offset (the specimen axis lies in the test axis) for symmetrical gripping.
The interchangeable jaw inserts enable these specimen grips to be
adapted to suit a range of different materials which are to be tested.
The jaws for the jaw mountings are permanently guided play-free in the
tensile direction by spring elements. Each jaw insert is secured via a
locating spring. You can replace these without using tools.
The screw grips are factory set to a specimen thickness of 0 mm.
Technical data
Type .........................................................................................................Screw grips
Maximum test load .............................................................................................1 kN
Maximum permissible torque ............................................................................ 2 Nm
Gripping range
Flat/Round specimens ........................................................................ 0 to 18 mm
Maximum gripping length ................................................................................ 30 mm
Maximum gripping width .................................................................................. 60 mm
Temperature range ....................................................................... - 70 C to + 250 C
Dimensions
Minimum width ...................................................................................... 162.5 mm
Maximum width ..................................................................................... 182.5 mm
Height (+ overhang) ............................................................................. 85 (10) mm
Depth (with handwheel) ....................................................................... 32 (50) mm
Minimum initial gage length L0 ........................................................................ 10 mm
Weight per specimen grip ................................................................................ 550 g

Instruction manual
10.08 / Tech_S / V5.1
Connection diameter ......................................................................................... 8 mm
Technical details
Screw grips
2
13
Proper use
These screw grips are constructed for gripping tensile specimens.
They are suitable for:
- Ferrous and non-ferrous metals
- Foam materials
- Paper
- Tile
- Insulating material
- Artificial leather
- Similar materials
Round and flat specimen can be gripped.
Inappropriate use
Neither compression nor flexure tests may be carried out using the screw
grips.
03.08 / Tech_A / V5.01

Instruction manual
35
Technical details
Screw grips
2
13
36

Instruction manual
03.08 / Tech_A / V5.01
Environmental and operating conditions
2
13

Our materials testing machines and testers are designed for use in
atmospheres that are not an explosion risk. Please note that the user
accepts liability to choose a safe installation site. Explosion protection
guidelines also require that the explosion hazard and thus the resulting
zoning must be taken into consideration.
The following conditions must exist at the site of installation to enable
reproducible and exact results to be obtained. Otherwise the
measurement results could be negatively influenced.
Mains
Voltage fluctuations ...................................................................... < 10 % related to
the set range
Short term interference .................................................................................. < 20 ms
Frequency ...................................................... 1 % related to the nominal frequency
Protective earthing ................................................................. Earth resistance < 5
Suitable voltage stabilisators are required if strongly fluctuating mains

voltages are to be reckoned with.
Temperature
+
0
Permissible range for ambient temperature .................................... + 10 C to + 35 C

Permissible ambient temperature drift
during a test ................................................................................................. 1 K
Humidity, non-dewing ............................................................................ 20 % to 90 %
Transport and storage temperature ................................................. - 25 C to + 55 C
Please make sure of sufficient ventilation. You must place a de-humidifying agent
to the materials testing machine if its to be stored for a lengthy period of time.
System operation emits heat depending upon the performance. Please

take measures to ensure sufficient heat dissipation.
Type of protection
Corresponds to IP 32 (To EN 60529).
The electronics is protected against:
- Solid foreign bodies with a diameter greater than 2.5 mm
- Dripping water if the casing is inclined up to 15.
06.06 / Umgeb_D30 / V5.0

Instruction manual
37
2
13
External influences
Materials testing machines and testers are highly sensitive measurement
systems. Thus the following must be avoided at the installation site:
- Jolts and vibrations
- Oscillations
- Vibrations
- Schock
- Conducting air
- Corrosive contamination
Recommendation
Installing shock absorbers, air filters or signal filters.
We would be only too pleased to be of assistance to you should you be
confronted with these problems.
Electrical, magnetic and electromagnetic fields

Our materials testing machines and testers are laid out to the now valid
EMC guidelines.
The following measures have already been taken against the named
interferences in the construction of materials testing machines with
electronics consoles:
- Enclosed metallic casing.
- Screened leads.
- Connection of all devices and screens to the protective earthing.
- Star shaped reference conductor system.
38

Instruction manual
06.06 / TUmgeb_D30 / V5.0
You must take the following measures if the above ones are insufficient:
- Place power cables spacially separate to measurement leads.
- Use twisted wire pairs for self-made measurement leads, each wire
pair should be separately screened (Screen mesh).
- Screen the materials testing machine from any nearby
- Substations
- Busbars
- HF generators (Such as induction oven, welding gear, etc.)
2
13
Connection of computer systems/Periphery devices

Devices connected to the materials testing machine must be within the
radio interference limits.
Interference free operation is only possible if these devices are plugged
into the materials testing machines mains output sockets, or connected
to the same phase plug as that for the materials testing machine.
Whereby all cables should be as short as possible.
Compressed air
The materials testing machine does not require any compressed air.
However, some of the optional test tools used in conjunction with the
machines require compressed air.
Operating pressure .................................................................................... 6 to 10 bar
With recommend oil to ........................................................................... ISO 3448
Viscosity ................................................................................................ 32 mm/s
Filtered, dehumidified and, depending upon the application,
oiled/de-oiled
Water, Gases
The materials testing machine requires neither water nor gas
connections. Exceptions to this are hydraulically operated materials
testing machines and auxiliary devices that need these connections for
cooling purposes.
Please make sure of sufficient ventilation if emission of gases can be
expected.
06.06 / Umgeb_D30 / V5.0

Instruction manual
39
2
13
Installation plan
The space requirements are listed in the Technical manual in
paragraph Technical data.
Storing accessories
Depending upon the accessories to be stored, you should have a
lockable storage place (Cabinet or similar). This furniture hasnt been
taken into consideration for the installation plan.
Why a cabinet that can be locked-up? Extensometers, load cells and
physical measurement units such as Vernier gauges, micrometers,
scales are measuring devices and must be well protected against
damage.
Structural requirements
The specific loading of the floor for the materials testing machine is listed
in the technical data. Please note that the height of the room must be
approx. 20 cm higher than the testing machines maximum height (See
the respective technical data).
The materials testing machine is normally free standing, however, some

hydraulic testing machines are fixed to the floor.
Align the machine and pay attention that it stands safely on its own on a
level floor.
40

Instruction manual
06.06 / TUmgeb_D30 / V5.0
Requirements for fixing
Index
Index
2
13
G
Gases .................................................................... 39
Accessories
Materials testing machine ................................. 14
Ambient temperature .............................................. 37
Heating up .............................................................. 12
Humidity ................................................................ 37
Calibration ................................................................ 4
Characteristic value ................................................ 22
Compressed air ...................................................... 39
Computer systems ................................................. 39
Connection of computer systems ........................... 39
Identification ............................................................. 6
Improper use
Inappropriate use
Load cell ..................................................... 24, 26
Measurement module ........................................ 17
Pneumatic control unit ...................................... 28
Pneumatic specimen holders ............................ 32
Screw grips ....................................................... 35
Installation plan ...................................................... 40
Internal danger of explosion .................................... 10
Block diagram
Danger of explosion ................................................

Definition
Characteristic value ...........................................
Force at break ...................................................
Maximum operational force ...............................
Nominal force ....................................................
Operational force ...............................................
Permissible torque ............................................
Static limit lateral force ......................................
Temperature influence .......................................
Torque ...............................................................
10
22
21
21
21
21
22
22
22
22
E
Electromagnetic fields ............................................ 38
Electronic rating plate .............................................. 5
Environmental conditions ........................................ 37
F
Fire fighting equipment ........................................... 13
Force at break ........................................................ 21
Force measurement ................................................. 9
Free from vibrations ................................................ 12
Materials testing machine .................................. 11
Screw grips ....................................................... 34
11.04 / THIndex / V5.0
Limitation ................................................................ 11
Load cell ................................................................ 19
Characteristic value ........................................... 22
Data cable ........................................................ 19
Data storage ..................................................... 19
Definition of the characteristics ......................... 21
Force at break ................................................... 21
Function description .......................................... 19
Load cell ........................................................... 20
Maximum load range ......................................... 21
Maximum operational force ............................... 21
Measurement range .......................................... 21
Nominal force .................................................... 21
Operational range .............................................. 21
Permissible torque ............................................ 22
Plug casing ....................................................... 19
Static limit lateral force ...................................... 22
Temperature influence ....................................... 22
Load cell 5 kN
Inappropriate use ............................................... 24
Overview ............................................................ 23
Proper use ........................................................ 24
Technical data ................................................... 24
Load cell 500 N
Overview ............................................................ 25
Proper use ........................................................ 26
Technical data ................................................... 26
Load cell cable guide ............................................. 20

Instruction manual
41
Index
2
13
Magnetic fields ....................................................... 38

Mains requirements ................................................ 37
Accessories ...................................................... 14
Drive system ....................................................... 8
Electronic rating plate ......................................... 5
Emissions ......................................................... 12
Force measurement ............................................ 9
Function description ........................................... 11
Improper use ..................................................... 12
Limitation ........................................................... 11
Load frame .......................................................... 8
Measurement and control electronics .................. 9
Operating data .................................................. 10
Operators workplace ........................................... 7
Overview .............................................................. 7
Proper use ......................................................... 11
Technical data ..................................................... 8
Technical details ................................................. 5
Tools ................................................................. 13
Voltage selection switch .................................... 10
Maximum operational force .................................... 21
Measurement amplifier ........................................... 19
Block diagram ................................................... 17
Connectable sensors ........................................ 16
Overview ............................................................ 15
Proper use ........................................................ 16
Technical data ................................................... 16
Measuring bridge .................................................... 19
Permissible torque ................................................. 22

Operating data .................................................. 28
Overview ............................................................ 27
Proper use ........................................................ 28
Technical data ................................................... 28
Pneumatic hoses ................................................... 31
Operating data .................................................. 32
Overview ............................................................ 29
Proper use ........................................................ 31
Technical data ................................................... 30
Power consumption ................................................ 10
Proper use
Load cell ..................................................... 24, 26
Materials testing machine .................................. 11
Screw grips ....................................................... 35
Screw grips
Overview ............................................................ 33
Proper use ........................................................ 35
Technical data ................................................... 34
Serial number plate .................................................. 6
Static limit lateral force ........................................... 22
Storage temperature ............................................... 37
Strain gage ............................................................. 19
Structural requirements .......................................... 40
Noise level .............................................................. 12

Nominal force ......................................................... 21
Notes on the electronics .......................................... 9
Operating conditions .............................................. 37

Operating data
Overview
Load cell ..................................................... 23, 25
Materials testing machine ................................... 7
Screw grips ....................................................... 33
42
Rated values .......................................................... 10

Requirements for fixing ........................................... 40
T
Technical data
Load cell ..................................................... 24, 26
Materials testing machine ................................... 8
Screw grips ....................................................... 34

Instruction manual
11.04 / THIndex / V5.0
Index
2
13
Technical details ...................................................... 5

Temperature influence ............................................ 22
Temperature requirements ...................................... 37
Tools ...................................................................... 13
Type of protection ................................................... 37
V
Voltage selection switch ......................................... 10
Water ..................................................................... 39
Workplace ................................................................ 7
11.04 / THIndex / V5.0

Instruction manual
43
2
13
44

Instruction manual
11.04 / THIndex / V5.0
Dossier
Section 3:
Instruction manual
Installation manual
BT1-FB005TN.D14
Serial number:
AB/Dossier number:
03.05 / AHInhalt / V5.1

Instruction manual
179947
2142429
Document
Instruction manual
Section 3
General
This section contains information on transport, erection, installation,
dismantling and storage of your materials testing machine and its
accessories.
Document:
Installation manual
Version:
Print date:
V 6.20
February 2009
these to:
Zwick GmbH & Co. KG
D-89079 Ulm
Fax: +49 - (0) 7305 - 200

Instruction manual
03.05 / AHInhalt / V5.1
All rights reserved
List of contents
Installation manual
List of contents
Transport ........................................................................................................................... 5
Materials testing machine ............................................................................................ 7
Installation/Mounting ....................................................................................................... 11
Materials testing machine .......................................................................................... 11
Electrical connections ................................................................................................ 19
Initial operation with the Ethernet interface ................................................................. 23
Load cell .................................................................................................................... 31
Initial commissioning ...................................................................................................... 37
Dismantle ......................................................................................................................... 43
Load cell .................................................................................................................... 47
Deinstallation of the materials testing machine ........................................................... 49
Materials testing machine .......................................................................................... 51
Storage ............................................................................................................................. 55
Index ................................................................................................................................. 57
03.05 / AHInhalt / V5.1

Instruction manual
Safety
Your safety
This instruction manual contains important notes on transporting the
materials testing machine correctly, safely and economically and on
installing, dismantling and storing it. Paying attention to the manual is the
best way of avoiding danger and of increasing the reliability and the life
span of the test machine.
The instruction manual must be read and used by all persons authorised
to work at and with the machine, e.g.
- Transport
- Setup
- Installation
- Dismantling
- Storage
Supplement the installation manual with instructions from national
regulations on accident prevention and environmental protection.
working means

Instruction manual
03.05 / AHInhalt / V5.1

site of the testing machine.
General
Transport
Transport
This chapter contains the transport for the materials testing machine and
its accessories. All requirements for the installation site are described
here.
Safety measures materials testing machine

The following must be observed to ensure safe transport for both
personnel and the machine:
- The valid, binding regulations on accident prevention
- The acknowledged technical rules for safety and correct working
- The regulations on safety and health protection when preparing and
using working means
- The instruction manuals
Single parts and large assembly groups must be carefully fixed and
secured to any lifting tackle when mounting or removing them. Make sure
that the lifting tackle doesnt present any sort of danger.
Only suitable and technically first class lifting tackle and lifting
accessories of sufficient lifting capacity must be used.
Neither stand around nor work beneath any sorts of suspended

loads/weights!
Dimensions, weight
Outer dimensions and weight of the packaging units can be obtained
from the dispatch papers which are attached to the packaging.
12.08 / TranspA / V5.21

Instruction manual
General
Transport
Packaging and transport variants

The materials testing machine and its accessories should, if possible, be
transported in their original packing right up to the installation site. The
following types of transport are available:
Standing transport on palettes, reinforced cartons or crates
Lying transport on palettes or on transport frames, reinforced
cartons or crates
Flat
On edge
Palettes or transport frames have guide grooves for transport, e.g. with a
forked lift truck.
Point of lifting and transport lugs are described in the product specific
transport instructions of paragraph Transport means. Use them.
Centre of gravity
The centre of gravity is indicated on the packaging unit if it happens not
to be in the middle.
The materials testing machines centre of gravity is between the lower
and centre crossheads. See paragraph Transport means.
The centre of gravity may change corresponding to any mounted test
tools.
Centre of gravity
Please see the indications on the packing for the valid location of
the centre of gravity.
Check all packaging units for completeness and for Transport damage.
Please contact the transport agents or Zwick immediately in case of
transport damage.

Instruction manual
12.08 / TranspA / V5.21
Check for completeness
Transport

Transport means
The materials testing machine and the accessories are usually shipped
on a transport pallet, or in a pallet box. If a high amount of accessories
are being transported with the test machine, they and the electronics
console can be shipped on a separate transport pallet, or in a pallet box.
Otherwise you can move the parts using the usual means of transport for
palettes.
WARNING
Risk of injury!
The materials testing machines centre
of gravity is between the lower and
centre crossheads.
Centre of gravity
The centre of gravity may change corresponding to any mounted test

tools. The indications on the packing are valid for the location of the
centre of gravity.
11.05 / Transp / V5.1

Instruction manual
Transport
You can also transport the materials testing machine suspended from a
crane. The materials testing machine must be removed from the pallet in
this case.
Lift bearing fixtures/

Lifting tackle
Use lifting tackle of sufficient capacity for suspended transport. Lift

bearing fixtures/Lifting tackle of sufficient capacity can be screwed into
the free threaded holes in the ends of the lead screws in the head plate.
Please always pay attention that all elements used in conjunction with
lifting are safe and secure, and have sufficient capacity.
Lift bearing fixtures/Lifting tackle do not belong to the scope of supply
and are not contained in the accessories.
Head plate
CAUTION
Danger of irreparable damage!
The head plate will be irreparably
damaged.
The displayed type of transport
damages the materials testing
machine.

Instruction manual
11.05 / Transp / V5.1
No force must be applied to the head

plate!
Transport
Relocate
All activities described under Dismantling must be done before
relocating the materials testing machine.
You can transport the materials testing machine with lifting tackle such as
a fork lift truck, or suspended on a crane.
Underlay
Fork lift truck:

Place a suitable underlay on the lifting forks. Carefully lift the materials
testing machine at the moving, centre crosshead.
Crane
Lift bearing fixtures/Lifting tackle of sufficient capacity can be screwed
into the free threaded holes in the ends of the lead screws in the head
plate.

Example of lift bearing
fixtures/Lifting tackle
11.05 / Transp / V5.1

Instruction manual
Transport
After transport/Relocate
Please remove any objects such as separate lifting accessories,
accessories, etc. from the materials testing machine Lifting accessories/
commissioning it, and before putting it into operation.
10

Instruction manual
11.05 / Transp / V5.1
Setup
Installation/Mounting
As already described in chapter Transport, the materials testing
machine and the accessories should be transported to the installation
site in their original packing.
You have already removed the packaging from the materials testing
machine according to the transport and unpacking instructions attached
to the packaging.

Safety measures to be observed
Please observe all valid and binding national laws on accident
prevention when installing and assembling the materials testing machine.
Required tools
For unpacking, installing and assembly you (May) require:
- One each SW8 and SW17 open ended spanner
- One each angled screwdriver, Allen key, SW2.5 and SW5
- Scissors
The materials testing machine can be removed from the palette with
lifting tackle such as:
- Crane
- Fork lift truck:
- Other suitable lifting tackle
10.05 / Aufb / V5.1

Instruction manual
11
Setup
Unpack
The Transport and unpacking instructions were/are attached to the
acking of the materials testing machine. The polyester tapes have been
cut through, the PE foil has been removed and the crate with the
accessories has been opened in accordance with the above mentioned
instructions.
Please remove the crate from the palette if you have not already done so.
Remove the accessories. Each part is contained in its own separate
packing. Remove the packaging from the individual parts and place the
parts in safe keeping.
The delivery note lists all parts supplied, please check the list.
Lifting locations
Underlay
Different lifting tackles can be used for lifting or aligning the materials
testing machine. The procedure depends upon the lifting tackle.
Fork lift truck:
Place a suitable underlay on the lifting forks. Lift the materials testing
machine from underneath the moving crosshead.

Head plate
12

Instruction manual
10.05 / Aufb / V5.1
M12 or M16
for lift bearing fixtures/
lifting tackle
Crane:
Lift bearing fixtures/Lifting tackle of sufficient capacity can be screwed
into the free threaded holes in the ends of the lead screws in the head
plate.
Setup
CAUTION
The head plate will be irreparably damaged.
The displayed type of transport damages the materials testing
machine.
No force must be applied to the head plate!
Force must never be applied to the materials testing machines head

plate.
Please remove the materials testing machine from the

palette
View from below
You must secure the palette after lifting it so that it does not fall once the
fixing screws have been undone. Only then may you:
- Remove the 4 fixing screws with the size 17 open-ended spanner

- Carefully remove the palette from below the materials testing machine
Fixing screws
10.05 / Aufb / V5.1

Instruction manual
13
Setup
Location of installation
Are you satisfied with the required location site?
Please adhere to the required free spaces.
These are indicated in the Technical manual under paragraph
Technical data.
Should this not be the case, please use the lifting tackle to move the
materials testing machine so that these distances are o.k. Pay attention
to the necessary distances.
14

Instruction manual
10.05 / Aufb / V5.1
Setup
Materials testing machine without the optional base

The levelling elements must be mounted in the free standing materials
testing machine.
This page can be skipped if a machine with the optional base has been
purchased.
Underlays
Materials testing machine without the optional base:

Lift the materials testing machine as already described under paragraph
Lifting locations.
Lifting tackle,
example, fork lift truck
Mount levelling elements

Hexagonal nut
Washer
SW8
Levelling element
10.05 / Aufb / V5.1
Please remove the levelling elements from the accessories.

Mount the levelling elements in the feet of the machine base if an optional base has not been ordered and supplied.
- Screw the hexagonal nut with washer onto the adjustment screw of
each levelling element.
- Screw the levelling elements into the front and rear threaded holes in
the machine base from below
- Set the height adjustment screw to the required height with the size 8
open ended spanner

Instruction manual
15
Setup
16

Instruction manual
10.05 / Aufb / V5.1
Setup
Following transport and installation

Please remove any objects such as separate lift bearing fixtures,
accessories, etc. from the materials testing machine before
commissioning it, and before putting it into operation.
Disposal of packaging material

The packing for the materials testing machine and the accessories
consists of the following materials:
-
Wood (transport palettes/support slats)

PE foil and PE shaped parts
Palette box (Cartons)
Polyester cord tapes
Packing paper
All of the above parts can be reintroduced to the cycle of materials by

recycling them.
12.05 / Aufb / V5.1

Instruction manual
17
Setup
Cleaning
You must free the materials testing machine of all packing materials.
Visible soiling is to be removed carefully with a soft rag. Otherwise there
isnt any other special cleaning work to be done following installation.
18

Instruction manual
12.05 / Aufb / V5.1
Setup
Drive
Electrical connections
The materials testing machine must be switched off when wiring it.
Connector plug
All devices connected to the test system are equipped with uniform
connector plugs. The connector plugs lock screws can be screwed in/
unscrewed by hand.
Tools are not generally needed.
Use a size PH0 or PZ0 screwdriver to unscrew the lock screws if it is not
possible to unscrew them by hand.
Only tighten the lock

screws by hand
PC connection via a serial interface

The PC can be operated via the serial COM1 interface, or via the optional Ethernet interface with the materials testing machine.
Below is the schematic connections of the PC via the COM1 port with
possible electronics connections.
Optional extensometer
Attention!
IV
X15
module slots
III
safety device
electrostatic
sensitive
devices
Load cell
COM2
debug
COM1
PC
X9
X9
remote
control
X16
X17
system diagnosis
II
LPT1
printer
PC
Rear view of the
electronics
Illustration of a PC connection via COM1 in principle

01.09 / Aufb / V5.2

Instruction manual
19
Setup
Drive
Ethernet link
The following depiction shows the schematic connections of the PC via
the optional Ethernet port with possible electronics connections.
Attention!
control
X15
module slots
II
I
Load cell
X9 COM1
PC
safety device
electrostatic
sensitive
devices
Rear view of the

electronics
COM2 /
Ethernet
X16
PC
X16
Illustration of a PC connection using Ethernet
20

Instruction manual
01.09 / Aufb / V5.2
The Ethernet port is activated at the Zwick factory if a test system with a
PC has been purchased. The description Initial operation using the
Ethernet interface can be skipped over in such a case.
Setup
Drive
Check the set voltage

Check the mains voltage set with the voltage selector switch. The voltage
selection switch is to be found at the rear of the electronics. Set the
voltage selection switch to the value of the mains voltage if necessary.
Rear side of
the
electronics
3
0
ATTENTION
3
input voltage
selector
0: 240 ... 250 V~
1: 220 ... 239 V~
2: 200 ... 219 V~
3: 120 ... 129 V~
4: 110 ... 119 V~
5: 100 ... 109 V~
Danger of irreparable damage

The electronics!
The voltage selected with the voltage selection switch must
coincide with the mains voltage.
Please select the

mains voltage via the
voltage selection
switch!
01.09 / Aufb / V5.2

Instruction manual
21
Setup
Drive
Mains plug
The materials testing machine is supplied with a power supply cable and
a three-fold socket strip. In some cases this power supply cable of the
socket outlet must be replaced by a cable which is specific to your
country.
Country specific
mains connection
22

Instruction manual
01.09 / Aufb / V5.2
Setup
Ethernet connection
Initial operation with the Ethernet interface

These instructions must only be followed if you
- have purchased the materials testing machine without a PC
- want to connect a new PC to the materials testing machines
electronics
- want to subsequently swap from serial operation to Ethernet operation
In such cases the Ethernet addresses are known neither in the PC nor in
the materials testing machines electronics. The Ethernet ports must now
be set via the serial interfaces on the PC and via the materials testing
machines electronics. This Ethernet connection is described in this
paragraph.
Rear side of the

electronics
Attention!
X15
IV
II I
sa fe ty d evi c
e lec tr osta ti c
se nsi tive
d evi ces
mo du le slo ts
a ti on an d
II
Procedure
Connect the PC to the materials testing machine via the COM1 port.
Should another serial port have to be used you will then have to inform
the following program of that port in the form of a start parameter.
I
C OM1 PC
COM2/
Eth ern et
X9
X16
X17
L PT1 pr in te r
X10
COM1
Switch on both the materials testing machine and the PC.

Insert the testXpert installation CD in the CD ROM drive.
Go to the directory Tools in Windows Explorer.
PC
01.09 / Ether-inst / V5.1
Call the program IpSetup.exe.

If you have used another serial port, e.g. COM5, please start the
program with the start parameter -CONNECT=serial port.
Example for COM5:
IpSetup.exe -CONNECT=COM5

Instruction manual
23
Setup
Ethernet connection
The menu for configuring the electronics appears on the screen.
testControl Connection Configuration

Initialize testControl...
serial connection
OK
TCP/IP connection
Cancel
testControl IP address:
Help
allowed PC adapter:
<everyone>
Intel(R) PRO/1000 GT Desktop Adapter - Gigabit Ethernt uEye
Intel (R) 82566DM Gigabit Network Connection - Gigabit Ethernet
MAC address:
Menu: Initialising the materials testing machines electronics - testControl
Wait until the the request to enter the testControl address appears on the
statusbar. This can also be recognised when the grey text changes
colour to black.
testControl Connection Configuration

Select the connection type to testControl.
serial connection
OK
TCP/IP connection
testControl IP address:
172
16
Cancel
86
Help
allowed PC adapter:
<everyone>
Intel(R) PRO/1000 GT Desktop Adapter - Gigabit Ethernt uEye
Intel (R) 82566DM Gigabit Network Connection - Gigabit Ethernet
MAC address:
Select the option field TCP/IP connection here.

Enter the IP address for the materials testing machines electronics testControl.
For example 172.16.6.86. The IP address must be confirmed by your
network administrator so as to avoid network conflicts due to double
assignments
Select the PCs network card.
24

Instruction manual
Menu: Enter the Ethernet address for the materials testing machines electronics and
the PC.
Setup
Ethernet connection
Acknowledge the inputs by activating the button <OK>.

The configuration is now adjusted in the materials testing machines
electronics - testControl and then the electronics is started anew.
X16
Ethernet port
Plug the serial connection cable into the COM ports of the materials
testing machines electronics and the PC.
Attention!
X15
IV
II I
a ti on an d
II
sa fe ty d evi c
e lec tr osta ti c
se nsi tive
d evi ces
mo du le slo ts
I
C OM1 PC
COM2/
Eth ern et
X9
X16
X17
Plug the Ethernet cable into the PC and into the materials testing
machines electronics Ethernet port X16.
L PT1 pr in te r
X10
PC
Settings for testXpert

testXpert must know testControls Ethernet address so that it can
communicate with the materials testing machine. This setting is
described below:
The new machine connection is established via the program periphery
settings.
Procedure
Select Start menu - Programs in Windows
Select Zwick applications here.

Call the command Testing machine electronics.
Select the <Add-on> button.
Select the testControl electronics from the list Testing machine
electronics.

Instruction manual
25
Setup
Ethernet connection
The menu for configuring the testing machine electronics appears on the
screen.
Configuration Testing machine electronics

Device:
OK
DUPS
testControl
Cancel
Help
IP address:
Port:
COM3
COM4
COM5
COM6
Ethernet
Name:
172
16
86
testControl
Menu: Configuration of the materials testing machine electronics - testControl in the

testXpert periphery setup
Select the testControl electronics as the device.

Select Ethernet as the port.
The Ethernet connection is not licensed if the item Ethernet does not
appear in this list.
Enter the same address as entered described above in the previous
menu for configuring the electronics.
Close the Periphery setup program.

You can now operate the materials testing machine via testXpert.
26

Instruction manual
Close the dialog with the button <OK>.
Setup
Load cell
Load cell
Load cells must be handled carefully when installing them. Avoid jolts,
and never, ever drop a load cell. Otherwise it could become irreparably
damaged.
Do not drop it!
CAUTION
The load cell will be irreparably damaged.
Never ever drop it.
Exemplary drawing
Example:
Front view
Flange
Mounting
Crosshead with a throughgoing hole
Prerequisite: The load cell must be mounted on a flange.
- Place the load cell with the flange on the crosshead, which has a
throughgoing hole, from the test area side.
- Align the load cell so that the hole in the mounting stud appears at the
front.
- Tighten the screws.
Screws
10.04 / Aufb / V5.0

Instruction manual
27
Setup
Load cell
Examples:
Front view
Crosshead with a
threaded connection
hole
Crosshead with a threaded connection hole

- Place the load cell on that side of the crosshead, which has a
threaded connection hole, that is in the the test area.
- Screw the load cell into the threaded connection hole.
- Align the load cell so that the hole in the mounting stud appears at the
front.
- Carefully tighten the load cell nut with a hook spanner. Please make
sure that the hole through the mounting stud always shows to the front.
Slotted nut
Mounting stud
Mounting the adapter

Mounting stud
Prestress nut
The adapter is mounted on the lower, fixed crosshead as standard.
Slotted nut
Fixed crosshead
28

Instruction manual
10.04 / Aufb / V5.0
Setup
Load cell
Mounting as a second load cell

Example:
Front view
Mounted load cell
1) The load cell can be slipped onto a load cell which is already mounted
on the crosshead via the optional adapter. The mounted load cell must
have a greater capacity than the second load cell. It must also have a
mechanically larger adapter.
2) Please secure the adapter with a lock-pin.
Prestress nut
3) After mounting, please tighten the prestress nut of the 1st load cell by
hand.
2.
1.
Lock-pin
Second load cell
Align and prestress
The test arrangement must be aligned and prestressed. This is done

after the test tools have been mounted. This procedure is described in
the User manual under chapter Conversion, paragraph Test tools.
10.04 / Aufb / V5.0

Instruction manual
29
Setup
Load cell
Cable guide
Side panel of the
load frame
Moving crosshead
Cable clamp
Please pay attention that the load cell data cable does not get
stretched anywhere in the entire range of travel of the crosshead.
Care must also be taken that specimen remains do not damage
the load cells data cable at specimen failure.
Relocate the load cell data cable
- With sufficient reserves
- Correspondingly protected
Cable loop =>

Reserve for the
crossheads entire travel
30

Instruction manual
10.04 / Aufb / V5.0
Setup
Load cell
Load cell
The load cell is mounted on the moving crosshead of the materials
testing machine as standard.
The load cell must be installed centrally with respect to the test
axis.
Moving crosshead
Working area
Load cell
Test axis
Crosshead
Example of mounting a load cell on a materials testing machine
10.04 / Aufb / V5.0

Instruction manual
31
Setup
Load cell
The load cells connection cable must now be connected to the
electronics.
The sensor plug is plugged into one of the testControl electronics TCMODCSCC modules as standard. The TC-MODCSCC module is
slotted into one of the module slots. You can recognise it by the 25-pin
plug.
Attention!
X15
module slots
IV
III
safety device
electrostatic
sensitive
devices
Section of the rear view of the

testControl electronics,
Showing a mounted
TC-MODCSCC module in
module slot I.
II
25-Pin plug
I
COM1 PC
COM2 debug
X16
TC MODCSCC Module
32

Instruction manual
10.04 / Aufb / V5.0
Setup
Pneumatic hoses
Pneumatic hoses
Mounting and play free prestressing of specimen holders has already
been treated in the user manual Specimen holders in chapter Retrofit.
However the pneumatic hoses must be correctly connected as non-fixed
pneumatic hoses falsify measurements.
Fixing the pneumatic hoses

Hose clamps have been attached to the materials testing machine for
the pneumatic hoses. These are to be found on the moving crosshead
and on the load frame.
Hose clamps
Retrofit
You must fix the supplied hose clamps to the crosshead and to the
materials testing machine when subsequently using the pneumatic
specimen holders.
Please select the fixings of the pneumatic hoses so that, during the test,
they will not
- Get pulled
- Rub against the load cell
- Rub on the specimen holders
Leave sufficient movable pneumatic hose free for the moving crosshead.
The drawings show an exemplary fixing of the pneumatic hoses.
07.06 / Aufb / V5.1

Instruction manual
33
Setup
Pneumatic hoses
Fixing to the electronics

console
Fixing to an angled (Moving) crosshead
Fixing to the moving crosshead
Fixing to the base of a table-top

machine
Placing the pneumatic hoses

Fix the pneumatic hoses.
Press them into the hose clamps.
34

Instruction manual
07.06 / Aufb / V5.1
Setup
Pneumatic hoses
Plug in pneumatic hoses

The compressed air connection must be disconnected at the mains
supply before plugging in any pneumatic hoses. The entire pneumatic
equipment of the materials testing machine must be at zero pressure.
WARNING
Danger of squashing parts of the body
Potential risk of injury to your hands.
Please keep away from the area of movement of the
specimen holders when plugging in the pneumatic
hoses.
Please make sure that the control unit is at the position Opened
specimen holder.
Please plug the colored pneumatic hoses into the correspondingly

colored compressed air connectors for specimen holders and control
units.
Close hoses are marked red.
Open hoses are marked black.
The compressed air connection can be plugged into the mains supply if
the specimen holders are correctly connected.
07.06 / Aufb / V5.1

Instruction manual
35
Setup
Pneumatic hoses
36

Instruction manual
07.06 / Aufb / V5.1
Initial commissioning
Drive
Different safety measures must be checked before the materials testing
machine is switched on for the very first time.
Function check of safety devices

Preparations before the materials testing machine is switched on for the
very first time.
- Please check the <EMERGENCY STOP>
It must be unlocked.
Release the
<EMERGENCY
STOP>
Please set the limit switch stops
5 mm
Set the limit switch stops approx. 5 mm above and below the moving
crosshead. Make sure that there is at least 10 cm added space above
and below the moving crosshead, with all fixtures, than you have just set.
5 mm
Limit switch stops
04.08 / Ersti / V5.21

Instruction manual
37
Drive
Set free buttons

The two set free buttons are to be found on the operating panel.
ON
The set free buttons can always be selected, except when the
<EMERGENCY STOP> button has been pushed in. The set free buttons
are active again after the <EMERGENCY STOP> button has been
released.
The program cannot influence the set free buttons. Thus they remain
functionable even if the electronics is partially defect.
The set free buttons are also active even if the <ON> button has not been
pressed.
Set free buttons
The set free buttons are used to release the limit switches. Thus the
crosshead motion can neither be monitored nor shut down via the limit
switches. You must, therefore, think carefully about the direction in which
you want to drive the crosshead. There is a danger of irreparable
damage occurring to the materials testing machine and any installed
components if the moving crosshead is driven in the wrong direction.
ATTENTION
The set free buttons are active as long as you keep them
depressed.
38

Instruction manual
04.08 / Ersti / V5.21
The limit switches are always without function at set free!
Drive
Switch the materials testing machine on.

A system check is run automatically.
Main switch
Rear side of the

electronics
testXpert
testXpert must be started (if using a test system equipped with a PC)
and a test program must be loaded.
The system check can be made as soon as testXpert is ready for
testing.
The following is valid for both variants, PC controlled and

materials testing machines with display panels:
PC
EN TER
Display panel
- Press the <ON> button.

The lamp in the <ON> button illuminates.
04.08 / Ersti_R / V5.21

Instruction manual
39
Drive
- Check the red <EMERGENCY STOP> buttons function by pressing it.

The lamp in the <ON> button must extinguish.
An error message with reference to the pressed EMERGENCY STOP
button must appear on screen.
<EMERGENCY STOP>
Have both of the above occurred?

If no,
please contact ZwickService. The telephone no. and address are to
be found in the appendix.
If yes,
please release the red <EMERGENCY OFF> button. Turn it
clockwise until it is unlocked.
Release the
<EMERGENCY STOP>
- Press the <ON> button again.

The <ON> buttons lamp illuminates.
- Delete the error message mask on screen.
TEST
- Press the <POS> button again.

The <POS> button illuminates.
POS
POS button
40

Instruction manual
04.08 / Ersti_R / V5.21
Drive
TEST
POS
- Press and hold the <UP> drive button. The crosshead must move
upwards at an ever increasing speed. The position pointer moves the
upper stop of the limit switch upwards. The materials testing machine
stops after a path of approx. 6 mm.
<UP> drive button

Upper stop
The error message mask appears on the monitor with a warning that
a limit switch has been tripped.
- Now press the set free button <DOWN>.

Release the buttons as soon as the upper stop is free.
Press the set free

button <DOWN>.
- Press the <ON> button again.

The <ON> buttons lamp illuminates.
TEST
POS
- Press and hold the <DOWN> drive button. The crosshead must move
downwards at an ever increasing speed. The position pointer moves
the lower stop of the limit switch downpwards. The materials testing
machine stops after a path of approx. 6 mm.
<DOWN> drive button
04.08 / Ersti_R / V5.21

Instruction manual
41
Drive
The error message mask appears on the monitor with a warning that a
limit switch has been tripped.
Lower stop
- Now press the set free button <UP>.

Release the button as soon as the lower stop is free.
Press the <UP>
set free button
Switch the materials testing machine off again.
The safety monitoring is now finalised. If no errors have appeared then

you can work with the materials testing machine.
42

Instruction manual
04.08 / Ersti_R / V5.21
Please contact ZwickService in errors occur. The address and telephone

number are to be found in the appendix.
General
Dismantling
Safety measures to be observed

Please observe the valid, binding laws and regulations on accident
prevention at deinstallation of the wiring and at disassembly of the
materials testing machine.
Dismantle
You can dismantle the materials testing machine simply and without the
need for special tools.
You must remove/dismantle all test tools and any other accessories
before deinstallation of the materials testing machine. Dismantling of test
tools and accessories is described in the instruction manual, under
chapter Retrofit.
Before beginning de-installation of the materials testing machine, the
moving crosshead must be positioned in the position at which it is to be
stored.
Switch the materials testing machine off.
The materials testing machine must be switched off before the

wiring is removed.
Please make sure that the materials testing machine is switched on. The
materials testing machine must be switched off before its disconnected
from the power supply.
11.04 / Abbau / V5.0

Instruction manual
43
General
Dismantling
44

Instruction manual
11.04 / Abbau / V5.0
Dismantling
Load cell
Disconnecting a load cell electrically.

Unplug the load cell at the electronics console.
Attention!
X15
module slots
IV
III
safety device
electrostatic
sensitive
devices
DCSC Module
II
I
25-Pin plug
COM1 PC
COM2 debug
X16
Section of the rear view of the

electronics,
showing a mounted DCSC Module
module in module slot I as an
example .
Roll-up the cable and bind it. Use a cable binder or similar for this
purpose.
06.07 / Abb / V5.02

Instruction manual
45
Dismantling
Load cell
46

Instruction manual
06.07 / Abb / V5.02
Dismantling
Load cell
Load cell
Load cells must be handled carefully when installing them. Avoid jolts,
and never, ever drop a load cell. Otherwise it could become irreparably
damaged.
CAUTION
Do not drop it!

The load cell will be irreparably damaged.
Never ever drop it.
Exemplary drawing
All test tools and adapters/connectors must be removed before a load

cell can be dismantled.
Dismantling mechanically
Crosshead with a
throughgoing hole
Crosshead with a throughgoing hole:
- Unscrew the bolts from the load cell flange.

- At the same time the load cell must be securely held, and care should
be taken not to drop it.
Screws
10.04 / Abb / V5.0

Instruction manual
47
Dismantling
Load cell
Crosshead with a
threaded connection
hole
Crosshead with a threaded connection hole:

- Unscrew the load cells slotted nut with a hook spanner.
- At the same time the load cell must be securely held, and care should
be taken not to drop it.
Slotted nut
Mounting stud
Mounted load cell

Prestress nut
Dismantle the second load cell

This load cell can be slipped onto an installed load cell.
Unplug the load cell at the electronics console
Dismantle:
- Slacken off the pre-stress nut of the load cell that is mounted on the
crosshead by hand.
- Hold the second load cell tight with one hand.
- Pull the lock-pin out. Do not drop the load cell.
- Now pull the second load cell off.
Lock-pin
Second load cell
Load cell storage

Store the load cell in a safe and clean place. Best of all in a cabinet that
can be locked up.
48

Instruction manual
10.04 / Abb / V5.0
Symbolic view from

the front
Dismantling
Drive, electronics and PC
Deinstallation of the materials testing machine

The materials testing machine must be switched off before any cables
are disconnected.
Please check that the materials testing machine is switched off.
Unplug or disconnect the materials testing machine from the mains
supply.
The materials testing machine can be connected to a PC either via the
serial COM1 port or the optional Ethernet port.
Following is an illustration for connecting a PC via the COM1 port.
Attention!
IV
X15
module slots
III
safety device
electrostatic
sensitive
devices
Load cell
COM2
debug
COM1
PC
X9
remote
control
X16
X17
system diagnosis
II
LPT1
printer
Attention!
X15
safety device
electro static
sensitive
device s
module slots
IV
III
X9
system diagnosis
II
I
COM1
PC
COM2
debug
remote
control
X9
X16
X17
Rear view of the

electronics
X14
X (NA-OUT)
X (NA-IN)
drive system
diagno sis
extern al emergency off
X10
safety
limit switch
LPT1
printer
PC
230 V ~ / N / PE
max. 1 000 W
for external d evices
resolver
motor
Caution!
Disconnect power supply before
carryin g out any repair work.
High voltage of 900 V can prevail
up to 5 minu tes after power off.
MA18.1-3/27
power suppl y
230 V ~ / N / PE
50 - 60 Hz
Do not disconnect the cabling
Illustration
01.09 / Abb / V5.1

Instruction manual
49
Dismantling
Drive, electronics and PC
The materials testing machine can also be operated via an optional

Ethernet port.
Following is an illustration for connecting a PC via the Ethernet port.
Attention!
control
X15
module slots
II
I
Load cell
X9 COM1
PC
safety device
electrostatic
sensitive
devices
Rear view of the

electronics
COM2 /
Ethernet
X16
X16
PC
Illustration of a PC connection using Ethernet
Prepare cables for storage
Store the sensorm in a safe, clean place; at the best in a cabinet that can
be locked up.
50

Instruction manual
01.09 / Abb / V5.1
Roll-up the cable and bind it to the sensor. Use a cable binder or similar
for this purpose.
Dismantling

No dismantling must be made with the materials testing machine.
Generally valid is: The materials testing machine can be transported or
stored in this state.
Please read section Transport means in this manual if you want to

transport the materials testing machine.
10.04 / Abb / V5.0

Instruction manual
51
Dismantling
52

Instruction manual
10.04 / Abb / V5.0
Re-pack
Re-pack
Materials testing machines must be conserved if they are to be put in
storage for a lengthy period of time. This means that grease must be
applied to all bright metal parts. The same applies to any corresponding
accessories. We recommend high pressure resistant low viscosity
grease for lubricating.
This materials testing machine can be packed standing upright or lying
down. The materials testing machine must be lifted before packing it.
Please see section Transport means for information on lifting the
machine. You can store or pack the materials testing machine standing
up on a normal floor or lying on a palette.
Exemplary drawing
The materials testing machine can be placed on a palette, and can be

secured with transport belts.
Please pay attention that the materials testing machine does not
get damaged.
Generally valid is:

The materials testing machine can be secured with retaining belts. Cover
the materials testing machine with a dust cover, e.g. plastic foil. Make
sure there is sufficient ventilation and place a dehumidifying agent to the
equipment.
The accessories must be protected against mechanical jolts and

vibrations and they must also be dust protected. Please make sure that
no loads are applied in any way to the machine. Store the accessories
near to the testing machine together with the instruction manual.
Recommendation:
Create a packing list. Keep a copy yourself and place one to the test
machine.
10.04 / WPack / V5.0

Instruction manual
53
Re-pack
54

Instruction manual
10.04 / WPack / V5.0
General
Storage
Storage
The materials testing machine can be stored either standing or lying
down.
It must be sufficiently protected against damage and/or soiling.
Please make sure that the materials testing machine is stable at its
location of storing.
Storage conditions
Temperature conditions:
Humidity, non-dewing ................................................................................ 20 to 90 %
Storage temperature ............................................................................ - 25 to + 55 C
Please make sure of sufficient ventilation. You must place a dehumidifying agent to the materials testing machine if its to be stored for
a lengthy period of time.
11.04 / Lager / V5.0

Instruction manual
55
General
Storage
56

Instruction manual
11.04 / Lager / V5.0
Index
Index
H
Hose clamps .......................................................... 33
Humidity ................................................................ 55
A
After transport/Relocate ......................................... 10
Attention .......................................................... 21, 38
B
Base
Mount levelling elements ................................... 15
C
CAUTION ............................................. 8, 13, 27,
Check the voltage selection switch .........................
Cleaning .................................................................
Configuration of the electronics ..............................
Connector plug .......................................................
Country specific power supply ................................
Create a packing list ..............................................
47
21
18
26
19
22
53
D
Danger of irreparable damage .. 8, 13, 21, 27, 38, 47
Danger of squashing parts of the body ................... 35
Disconnect cabling ................................................. 49
Dismantling
Disposing of packaging material ............................. 17
E
Ethernet link ......................................................
Load cell ...........................................................
Materials testing machine .................................
Serial interface ..................................................
EMERGENCY STOP ....................................... 37,
Ethernet address input ...........................................
Ethernet link ...........................................................
Ethernet port ..........................................................
20
32
19
19
40
24
20
23
F
Function check
Limit switch .......................................................
Of safety devices ...............................................
Set free button ..................................................
Function control
EMERGENCY STOP ........................................
11.04 / AHIndex / V5.0
41
37
41
37
I
Initial operation with the Ethernet interface ............. 23
Initialising the electronics ....................................... 24
L
Lift bearing fixtures ............................................. 8, 17
Lifting accessories ................................................. 10
Lifting locations
Lifting tackle ............................................................. 8
Load bearing attachments ...................................... 10
Load cell
Dismantle the second load cell ......................... 48
Electrical connections ....................................... 32
Mechanical mounting ........................................ 27
Mounting ........................................................... 27
Unplug .............................................................. 45
M
After transport/Relocate .................................... 10
Centre of gravity ............................................. 6, 7
Cleaning ............................................................ 18
Disconnect the COM1 link ................................ 49
Disconnect the Ethernet link ............................. 50
Dismantling ....................................................... 51
Electrical connections ....................................... 19
EMERGENCY STOP ........................................ 40
Ethernet link ...................................................... 20
General on dismantling ..................................... 43
Initial commissioning ......................................... 37
Lifting locations ................................................. 12
Mains plug ........................................................ 22
Re-pack ............................................................ 53
Relocate ............................................................. 9
Remove any lift bearing fixtures/lifting tackle ..... 17
Required tools .................................................... 11
Serial interface .................................................. 19
Storage conditions ............................................ 55
Switch on .......................................................... 39
Tools ................................................................. 43
Transport means ................................................. 7
Voltage selection switch .................................... 21
Wiring ............................................................... 19
With display panel ............................................ 39

Instruction manual
57
Index
Mount levelling elements ........................................ 15

Mounting ................................................................. 11
Mounting as a second load cell .............................. 29
Mounting the adapter ............................................. 28
W
WARNING .......................................................... 7, 35
Wiring .................................................................... 19
O
ON button .............................................................. 39
P
Packaging material ................................................
PC connection via a serial interface ........................
PC variant ..............................................................
Placing the pneumatic hoses .................................
Pneumatic hoses
Fixing ................................................................
Picture of the fixing ...........................................
Plug in ..............................................................
Retrofit ..............................................................
Power supply cable ................................................
17
19
39
34
33
34
35
33
22
R
Re-pack ................................................................. 53
Recycling ............................................................... 17
Remove lift bearing fixtures ..................................... 17
Required tools ......................................................... 11
Risk of injury ............................................................ 7
Safety measures ......................................... 5, 11, 43

Serial interface COM1 ............................................ 19
Set free button ....................................................... 41
Set free buttons ..................................................... 38
Settings for testXpert .............................................. 25
Socket strip ........................................................... 22
Start parameter ...................................................... 23
Storage conditions ................................................. 55
Storing cables ........................................................ 50
T
Tools ................................................................ 11, 43
Transport
Safety measures ................................................. 5
Transport damage .................................................... 6
Transport fixings ....................................................... 6
Transport means ...................................................... 7
58

Instruction manual
11.04 / AHIndex / V5.0
Dossier
Section 4:
2 3
5 6
8 9
Instruction manual
User manual
BT1-FB005TN.D14
Serial number:
AB/Dossier number:
11.06/ BHInhalt / V5.2

Instruction manual
179947
2142429
Document
2 3
5 6
8 9
Instruction manual
Section 4
General
This section contains information that is important on operating your
materials testing machine and the accessories.
There are short instructions on carrying out tests at the end of the
section. You could copy it and afix it to the materials testing machine.
Document:
User manual
Version:
Print date:
V 6.20
February 2009
these to:
Zwick GmbH & Co. KG
D-89079 Ulm
Fax: +49 - (0) 7305 - 200

Instruction manual
All rights reserved
List of contents
User manual
2 3
5 6
8 9
List of contents
List of contents .................................................................................................................. 3
Safety remarks ................................................................................................................... 7
System diagrams of the safety functions ...................................................................... 8
Materials testing machine ............................................................................................ 9
EMERGENCY STOP linking ...................................................................................... 13
Switch the testControl electronics off .......................................................................... 15
Operational controls ....................................................................................................... 17
Main switch unit ......................................................................................................... 17
Switch devices .......................................................................................................... 18
Operational controls at the electronics ........................................................................ 21
Pneumatic specimen holders ..................................................................................... 23
Screw grips ............................................................................................................... 27
Commissioning of the materials testing machine ........................................................ 33
Shutdown the materials testing machine ...................................................................... 35
Recommissioning materials testing machines ............................................................. 37
Types of operation .......................................................................................................... 39
Tensile test ................................................................................................................ 41
Compression test ...................................................................................................... 43
Flexure test ................................................................................................................ 44
Retrofit .............................................................................................................................. 45
Error messages ............................................................................................................... 59
Set free ..................................................................................................................... 59
Electronics error messages ....................................................................................... 61
Temperature monitoring ............................................................................................. 63
External devices ........................................................................................................ 64
Drive system .............................................................................................................. 65
Short instructions............................................................................................................ 73
Index ................................................................................................................................. 79

Instruction manual
User manual
2 3
5 6
8 9

Instruction manual
Safety
Testing system
2 3
5 6
8 9
Your safety
This user manual should make it easier for you to get acquainted with the
test system and to use its range of applications.
This user manual contains important notes on using the test system
safely, properly and economically. Paying attention to these notes helps
to avoid danger, to reduce repair costs and down times as well as to
increase reliability and the lifespan of the test system.
The user manual must be read and used by all persons authorised to
work at and with the test system, e.g.
- Operating, repair work

- Disposing of production waste, as well as operating means
02.07 / Vorsch / V5.1

Instruction manual
Safety
Regulations
2 3
5 6
8 9
Supplement the user manual with instructions from national regulations
on accident prevention and environmental protection.
working means
site of the test system.

Instruction manual
02.07 / Vorsch / V5.1
Safety notes
2 3
5 6
8 9
Safety remarks
-
Safety devices are there to protect you and others in the

vicinity.
Never ever manipulate safety devices Never carry out tests with
safety devices that have been made passive.
Always adhere to the safety remarks as per section 1.
The following stickers with pictograms are attached to the Zwick testing
system and the respective accessories. Please pay attention to the
pictogram and the related safety remarks.
Risk of injury!
This part moves.
Caution: No automatic shut down when touched!
Danger of pinching parts of the body
This part is closed manually or automatically.
Caution: No automatic shut down when touched!
Risk of frostbite/burning!
These parts may be extremely hot/cold.
Dangerous electrical voltage!

Only qualified electricians are allowed to open the casing.
WARNING
Danger to life and limb!
Non-compliance to the above safety remarks
could lead to injury or danger to life for yourself or
others.
11.08 / Sicherh / V5.2

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

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

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

Instruction manual
11.08 / Sicherh / V5.2
The testing system is stopped immediately if an event from the

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

To enable you to use your materials testing machine safely and
effectively you must be able to handle a few important safety devices.
This paragraph introduces you to these important safety devices, and
informs you how to operate them safely.
EMERGENCY OFF button

In case of danger the moving crossheads movement can be stopped by
pressing or hitting the red <EMERGENCY OFF> button. The drive motor
is thus disconnected from its power supply and is braked.
TEST
<EMERGENCY
OFF> button
POS
ON
Limit switch
Principle:
Limit switch
Upper stop
Our materials testing machines are equipped with mandatory opening

safety limit switches.
These limit switches are tripped via a switch rod. There are two stops on
this switch rod. These stops are used to limit the amount of movement of
the moving crosshead.
Always set these stops so that mechanical destruction of test equipment
is prevented.
These stops must be adjusted anew for each new test

configuration.
An error state prevails if the crosshead movement is closed via a limit
switch. Quitting this error state is described overleaf.
3 8
0
3 7
0
3 4
0
Lower stop
03.06 / Sicherh / V5.0

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

The materials testing machine is in an error state if it has been switched
off via a limit switch. You can quit this state by
TEST
POS
ON
- Resetting the corresponding stop, or

- By pressing the correct set free button
Whereby you must pay attention to the correct set free direction.
The set free buttons can always be selected, except when the
<EMERGENCY OFF> button has been pushed in. The set free buttons
are again active after the <EMERGENCY OFF> button has been
released.
The program cant influence the set free buttons. Thus they remain
functionable even if the electronics is partially defect.
The set free buttons are also active even if the <ON> button has not been
pressed.
As these <Set free> buttons serve to release the limit switches, the drive
can neither be monitored nor shut down via the limit switches. You must,
therefore, think carefully about the direction in which you want to drive the
crosshead. Theres a danger of irreparable damage occurring to the
materials testing machine and the installed components if you drive the
moving crosshead in the wrong direction.
CAUTION
pressed.
10

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

Please use a safety pane for any potentially dangerous test
requirements. This is especially true for:
- Specimen with high potential energy and resilience properties, such
as springs, ropes, belts
- Specimen that splinter at break
- Positioning at high crosshead speeds

- Using hardened or ceramic jaw inserts
All materials testing machines can be equipped (retrofitted) with a .
03.06 / Sicherh / V5.0

Instruction manual
11
Safety remarks
Electronics
2 3
5 6
8 9
Disconnect non-required peripheral devices

You must unplug non-required peripherals directly from the electronics.
Never, ever disconnect peripheral devices at couplings or at other plugs.
Why?
The electronics does not receive any data from the open measurement
leads. The electronics then outputs an error message about the
corresponding peripheral and does not permit further testing.
Never here
Attention!
X15
module slots
IV
III
safety device
electrostatic
sensitive
devices
II
I
COM1 PC
COM2 debug
X16
Peripheral
Always here
Symbolic display
12

Instruction manual
03.06 / Sicherh / V5.0
Safety notes
Electronics
2 3
5 6
8 9
EMERGENCY STOP linking
X(NA-OUT)
external
emergency off
Rear side of the

electronics
Controllable Zwick components are linked to the materials testing

machine via the EMERGENCY STOP linking Only Zwick components
may be connected to the EMERGENCY STOP chain. These
components must be connected in series.
The EMERGENCY STOP linking belongs to the materials testing
machines safety system.
All components connected via the EMERGENCY STOP linking are shut
down should an event which is contained in the EMERGENCY STOP
monitoring occur.
Plug-in the terminator

here
Connection of
several Zwick
components
Operation with a
materials testing
machine only
X(NA-IN)
X(NA-OUT)
These components
must be connected in
series. The last
components of the
EMERGENCY STOP
linking must be closed
with a termination plug.
Please pay attention to
the following example.
X(NA-OUT)
X(NA-OUT)
X(NA-OUT)
Electronics
X(NA-IN)
Connection plug
plugged into the
materials testing
machines electronics
The terminator must be

plugged into the
electronics plug X(NAOUT) if no controllable
components are
connected to the
materials testing
machine.
X(NA-IN)
X(NA-OUT)
Electronics
Connection plug on
the last component
04.08 / Sicherh / V5.1

Instruction manual
13
Safety notes
Electronics
2 3
5 6
8 9
Check the EMERGENCY STOP linking

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

STOP linking
Check that the terminator is plugged into the last component in
the chain
14

Instruction manual
04.08 / Sicherh / V5.1
Please contact ZwickService if you cannot establish the correct

EMERGENCY STOP function in this manner. The address is to be found
in the appendix.
Safety notes
Electronics
2 3
5 6
8 9
Switch the testControl electronics off
ATTENTION
Risk of damage!
Before switching the measurement and control electronics
testControl off, close the testXpert test software.
07.07 / Sicherh / V5.0

Instruction manual
15
Safety notes
Electronics
2 3
5 6
8 9
16

Instruction manual
07.07 / Sicherh / V5.0
Operational controls
Drive/Electronics
2 3
5 6
8 9
The materials testing machine is controlled and monitored via a PC and
a modern program system.
Thus reducing the operational controls at the actual machine to a
minimum.
Main switch unit
Main switch
The main switch is to be found at the side of or behind the materials

testing machines measurement and control electronics console.
Switch the materials testing machine on. A 1 can be seen in the
switchs view window when the machine is switched on.
EMERGENCY STOP
The machine movement can be stopped immediately by hitting or

pressing the <EMERGENCY STOP> button. The drive motor is thus
disconnected from the power supply, and is eventually stopped via a
brake resistor.
Released
<EMERGENCY
STOP>
<EMERGENCY
STOP> at the Off
position
04.08 / Schalt / V5.2
The <EMERGENCY STOP> button remains at the Off position once it

has been activated. The <EMERGENCY STOP> button must be turned
to release it. The <EMERGENCY STOP> button then goes into the
unlocked position.
The drive remains at zero potential even after you have reactivated the
<EMERGENCY STOP> button. The <ON> button must be pressed.
STOP
Instruction manual
Turn until it is unlocked
17
Drive/Electronics
2 3
5 6
8 9
Switch devices
The machine control and the user program offer maximum safety. Additional mechanical-electrical safety limit switches are available for
protecting the test accessories.
Limit switch
9 70
9 60
Upper stop
9 50
9 40
9 30
9 20
5 60
5 50
Crosshead position indicator
8
3 0
7
3 0
4
3 0
5 30
5 20
5 10
3 80
3 70
3 60
3 50
Lower stop
3 40
3 30
System example
ATTENTION
Always consider an overshoot path of approximately 6 mm.

The position of the limit switches must be checked each time
any changes are made to equipment within the test area, and
must, if necessary, be corrected.
18

Instruction manual
04.08 / Schalt / V5.2
Select the limit switchs position corresponding to your test

arrangement.
Drive/Electronics
2 3
5 6
8 9
Function of the limit switch

The limit switch is controlled via a switch rod. Two adjustable stops
are fixed to the switch rod. These can be used to limit the moving
crossheads upper and lower end positions.
Should the crosshead position indicator hit the stops the switch rod
triggers the limit switch. This switches switches the drive off. The
materials testing machine goes into the set free state. Please pay
attention to the notes in paragraph Set free.
The correct direction of travel must be determined before carrying out
set free.
The upper limit switch has been hit==>
Set free downwards
The lower limit switch has been hit ==>
Set free upwards
Limit switch
670
Switch rod
660
Stop => Limit switch
3 8
0
3 7
0
3 4
0
640
Crosshead position indicator
630
620
Scale
System example
Sensibly set limit switches provide protection against damage

being caused.
04.08 / Schalt / V5.2

Instruction manual
19
Drive/Electronics
2 3
5 6
8 9
Temperature
The electronics is a high quality measurement electronics. To enable the
electronics to work to its utmost capabilities, you must
+
0
-
- Keep to the warm-up time of approx. one hour for the electronics
- Be able to maintain constant ambient and test temperatures
Why?
Tests to standards require constant temperatures for both the electronics
and for the vicinity. Relevant statements on your specimen can only be
made in this manner.
Heating up time
The internal temperature of the electronics stabilises after approx. one
hour.
Stable Ambient and test temperatures

The electronics will inform you if it has detected ambient temperature
deviations that happen to be too high. No test will be cancelled.
20

Instruction manual
04.08 / Schalt / V5.2
Electronics
2 3
5 6
8 9
Operational controls at the electronics

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

<TEST> button
POS
TEST
<POS> button
<Drive> buttons
ON
<ON> button
<EMERGENCY STOP>
button
<Set free> buttons
The power indicator lamp illuminates when the electronics is switched

on. It indicates that the electronics is switched on.
ON button
ON
TEST
POS
Press the <ON> button to switch the drive on. The button must be
activated if:
- You have switched the materials testing machine on via the main
switch, or
- A fatal error has occurred in the control electronics
ON
The <ON> button is illuminated when it is switched on. The lamp in the
<ON> button is off if the drive system is switched off.
04.08 / Bedien / V5.1

Instruction manual
21
Electronics
2 3
5 6
8 9
Control buttons
POS
TEST
The materials testing machine can be driven with the control buttons.
Selected and active buttons indicate this state with illuminated or blinking
button lamps.
TEST
POS
ON
The following control buttons are available:

STOP
POS
TEST
<Up>
<Down>
- The <STOP> button. This closes all of the materials testing machines
drive functions.
- The <POS> button. Press this button to drive the materials testing
machines crosshead using the drive buttons. Whereby no results will
be recorded.
Press the button <POS> again to quit this state.
- The <TEST> button. Press this button to switch the electronics to the
test state.
The <EMERGENCY STOP> button and the <SET FREE> button have
already been described in this manual under Safety notes.
22

Instruction manual
04.08 / Bedien / V5.1
- The drive buttons These drive buttons have functions that differ
depending upon whether the <POS> or <TEST> button has been
activated:
<POS>
You can move the moving crosshead if the <POS> button
illuminates. The speed is increased the longer the button is held
depressed.
<TEST>
You can start the test if the <TEST> button illuminates.
Operation
2 3
5 6
8 9

The pneumatic specimen holders are mounted so that both handwheels
are on one side.
The jaw inserts being used must be in a first class condition.

Please check the condition of the jaw inserts before each test.
The jaw inserts must be replaced by ones in perfect working
order should wear or damage to those in use be apparent.
Principle
The jaw inserts are held in place via a locating spring. You can replace
these without using tools.
Replacing jaw inserts

Flat jaw inserts:
The jaw inserts are removed by pushing them over the locating spring
and out of their guides. You can then pull them out.
Extract the jaw insert
1. Unscrew the grub

screw with the balltipped screwdriver
03.06 / Bedien / V5.1
Flat jaw inserts to round jaw inserts:

Unscrew the grub screw with an SW 2.5 ball-tipped screwdriver. Pull the
jaw holders from the stud.
2. Pull off the jaw

mounting
Instruction manual
23
Operation
2 3
5 6
8 9
Inserting new jaw inserts

Flat jaw inserts:
Place the jaw inserts at the guide and push them in, exerting only a little
pressure on them.
Round jaw inserts:
Now slip the new jaw holders onto the stud. Screw the grub screw tight
with an SW 2.5 ball-tipped screwdriver.
90
Slip-on the jaw mounting anew and tighten the
grub screw
Plug-in the pneumatic hoses

The pneumatic hoses are marked in color.
Close hoses are marked red.
Open hoses are marked black.
Always plug the color marked pneumatic hoses into the correspondingly
marked compressed air connector for specimen holders and control unit,
24

Instruction manual
03.06 / Bedien / V5.1
The pneumatic hoses must be held via the hose clamps. Non-fixed
pneumatic hoses falsify measurements.
Operation
2 3
5 6
8 9
Correct clamping of specimen

Front view
Side view
Select the correct jaws for the shape of specimen to be tested (Round or
flat). Please note the specimen material to be tested when doing this.
- As previously stated, the jaw must be in perfect working order when
put to use.
Test axis centre,

gripping length > 2/3
of the length of the
inserts
- Specimen must be gripped centrally.

Eccentric gripping loads the load cell in a non-permissible manner
and thus provides a possible source of irreparable damage to the
load cell.
A specimen stop is available to make central gripping easier.
- The gripping length must be at least 2/3 of the jaw length. Avoid
pointed loading of jaws and specimen holders.
It could lead to jaws shattering, or to non-permissible loading for the
jaw mountings.
Protective cover
The protective cover must be mounted over the pneumatically operated
jaw side when using the standard jaw mountings.
Safety cover
Standard jaw mountings
Jaw inserts
Pneumatically operated jaw side

03.06 / Bedien / V5.1

Instruction manual
Jaw side adjustable by hand
25
Operation
2 3
5 6
8 9
Setting the depth stop

The specimen stop eases central insertion of the specimen.
Its fixed with a screw. Undo this screw and set the required specimen
width with the help of the yardsticks scale. Finally tighten the screw
again.
Screw
Yardstick
Depth stop
The specimen holders are shown without jaw holders.
Use the depth stop even when using prismatic jaws.
26

Instruction manual
03.06 / Bedien / V5.1
Operation
Screw grips
2 3
5 6
8 9
Screw grips
Please check the condition of the jaw inserts before each test. The
jaw inserts must be replaced by ones in perfect working order
should wear or damage to those in use be apparent.
The jaw inserts are held in place via a locating spring. You can replace
these without using tools.
Replacing jaw inserts

The jaw inserts are removed by pushing them over the locating spring
and out of their guides. You can then pull them out.
Extract the jaw insert
Inserting new jaw inserts

Place the jaw inserts at the guide and push them in, exerting only a little
pressure on them.
03.08 / Bedien / V5.03

Instruction manual
27
Operation
Screw grips
2 3
5 6
8 9
Correct gripping of the specimen

Select the correct jaws for the shape of specimens to be tested (round or
flat). Please note the specimen material to be tested when doing this.
- As stated previously, the jaw inserts must be in working order when
put to use.
Front view Side view
- Please grip the specimen centrally.

Eccentric gripping loads the load cell in an impermissible manner,
thus presenting a potential source of irreparable damage to it.
An optional specimen stop serves to make central gripping easier.
- The gripping length must be at least 2/3 of the jaw length. Avoid
pointed loading of jaws and specimen grips.
It could lead to jaws shattering, or to non-permissible loading for the
jaw mountings.
Test axis centre,

gripping length > 2/3 of
the length of the
inserts
28

Instruction manual
03.08 / Bedien / V5.03
Operation
Screw grips
2 3
5 6
8 9
Opening width
One turn of the adjustment wheel corresponds to a distance of 1 mm.
Adjustment wheel
9 mm
Basic setting
The presets for the specimen width can be fixed via the
adjustment markings.
The basic setting is for a specimen thickness of 0 mm. The left
and right adjustment marks then coincide. The distance
between the jaw mounting and guide is 9 mm.
Adjustment markings
Changing the basic setting

- Unscrew the SW6 Allen screws of the fixed jaw side and, if required,
those for the movable jaw side.
Plan view:
SW 6 Allen screw
- Set the required position of the corresponding

jaw side via the notches.
One notch corresponds to a travel of 1 mm.
The fixed jaw mounting is to be offset by half
the specimen thickness. I.e. the offset is 2 mm
for specimens which are 4 mm thick.
- Now re-tighten the Allen screws.

Specimen thickness = 0 mm
Adjustment markings
Specimen thickness = 4 mm
2 mm
03.08 / Bedien / V5.04

Instruction manual
29
Operation
Screw grips
2 3
5 6
8 9
Adjust the specimen stop

The specimen stop eases central insertion of the specimen. The stop
can be moved once the adjustment screws have been unscrewed. Adjust
the specimen width according to the scale.
The height of the stop can be set via the 2 fixing screws at the stop plate
depending upon the specimen shape.
Specimen grips
Specimen stop (optional)
Adjustment screw
Guide slot
Dumbbell specimen
Screws for height adjustment
Test axis
30

Instruction manual
03.08 / Bedien / V5.04
Operation
Screw grips
2 3
5 6
8 9
Mounting the specimen grips

The specimen grips should be mounted as depicted on this page. This
will enable you to grip very short specimen.
Test axis
Specimen grip, upper
Specimen grip, lower
03.08 / Bedien_B / V5.01

Instruction manual
31
Operation
Screw grips
2 3
5 6
8 9
32

Instruction manual
03.08 / Bedien_B / V5.01
Commissioning
Drive
2 3
5 6
8 9
Commissioning of the materials testing machine

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

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

Instruction manual
33
Commissioning
Drive system
2 3
5 6
8 9
Switch the materials testing machine on

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

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

control of the materials testing machine.
34

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

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

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

Instruction manual
35
Shutdown
Drive system
2 3
5 6
8 9
36

Instruction manual
11.04 / Ausser / V5.0
Recommissioning
2 3
5 6
8 9
Recommissioning materials testing machines

If the materials testing machine has been idle for a lengthy period of time,
you must take the following measures.
- Please check the cabling of the materials testing machine.
The schematic display of the materials testing machine below also
depicts the cable connections. The machine must be switched off or
disconnected before any electrical alterations are made.
Rear view of the electronics

Attention!
Safety device
(Limit switch)
X15
II
I
Load cell
X9 COM1
PC
control
module slots
safety device
electrostatic
sensitive
devices
option
COM2
debug
X16
X9
Attention!
electrostatic
sensitive
devices
module slots
X15
III
safety
device
IV
I
option
COM2
debug
remote
control
X9
X16
X17
system diagnosis
II
COM1
PC
X18
X(N A-OU T)
X14
X19
X14
X19
X18
3
input voltage
selector
0: 240 ... 250 V~
1: 220 ... 239 V~
2: 200 ... 219 V~
3: 120 ... 129 V~
4: 110 ... 119 V~
5: 100 ... 109 V~
fuse motor
X10
safety
external
rotary drive system
limit switch emergency off encoder diagnosis
option LPT1
printer
input voltage
selector
0: 240 ... 250 V~
1: 220 ... 239 V~
2: 200 ... 219 V~
3: 120 ... 129 V~
4: 110 ... 119 V~
5: 100 ... 109 V~
power ON/OFF
fuse 4 AT
power supply
~/N/PE
50 - 60 Hz
MA18.1 -3/44
The voltage selected

with the voltage
selection switch must
coincide with the
mains voltage.
Motor
PC
Schematic display of the materials testing machine with cable connections

11.08 / Wieder / V5.2

Instruction manual
37
Recommissioning
2 3
5 6
8 9
Cleanse the materials testing machine of any visible

dirt.
WARNING
Risk of injury
When lead screws are rotating
and
When tampering in the test area whilst the machine is
running!
Long hair, jewelry or loose clothing (e.g. sleeves) could
get caught up in rotating lead screws.
Please take the following precautions
Wear closely fitting clothing
Do not wear jewelry
Use a hairnet if necessary
Please make sure that there is enough room for the
required travel.
Velcro fastener
38
Description and recommended low viscosity grease are to be found

under paragraph Service and maintenance in section Service and
maintenance manual.

Instruction manual
11.08 / Wieder / V5.2
- Check the state of the Please check the lubrication of the lead screws.
Apply grease if necessary.
How?
- Undo the lead screw cover. This is fastened to the crosshead with a
Velcro fastener.
- Start the machine so that the lead screws rotate at a low speed and
then carefully apply low viscosity grease to them with a brush.
Types of operation
Controller
2 3
5 6
8 9
Types of operation
The materials testing machine has the two types of operation Test and
Verification.
Test
Tests are run in type of operation Test.
Verification
Type of operation Verification is used to do preparatory tasks such
as component adjustment up to pre-load or mounting/removing test
tools.
A teype of test must be selected and the materials testing machine must
be adapted to it to enable type of operation Test to be run. Below is a
description of the settings to the materials testing machine due to the
type of test.
The materials testing machine can be controlled via a PC with the

corresponding test program. The online help for the respective test
program provides information as to which inputs and settings are to be
made.
11.05 / Betrieba / V5.1

Instruction manual
39
Types of operation
Controller
2 3
5 6
8 9
The correct test tools must be selected before the materials testing
machine is setup for a test.
Please make sure you select the
- Shape of the specimen to be tested
- The material to be tested
A safety device may also be necessary. This chapter describes
operation without such a safety device in this chapter.
The description of an optional, electrically interlockable safety device can
be found following the description of the electronics.
Information on preparation of test tools can be obtained from chapter

Retrofit, paragraph Specimen holders.
User manual
40

Instruction manual
11.05 / Betrieba / V5.1
Types of operation
Electronics
2 3
5 6
8 9
Tensile test
When using a PC, the stops for the limit switches must be set following
selection of the specimen grips.
Principle:
Our example describes the settings for a test in the lower test area.
3 8
0
3 7
0
3 4
0
Stop for the lower

limit switch
Set the limit switch so that

- The lower stop touches the crosshead indicator
- The upper stop permits the maximum travel, but eventually still
protects parts mounted in the upper test area from being destroyed.
You can grip the specimen when all test parameters have been correctly
entered in the PC test program.
Crosshead pointer
Lower stop
Please note the following when gripping the specimen:

- Always grip the specimen centrally.
Eccentric gripping loads the load cell in such a manner that there is a
potential risk of irreparable damage.
- Use at least 3/4 of the jaw length as the clamping length.
Thus avoiding pointed loading of grips and jaw inserts. Pointed
loading of jaws and grips could lead to jaws shattering, or to nonpermissible loading of the jaw mountings.
View from the side
You must pay attention

that the specimen is gripped centrally with respect to the test axis.
04.08 / Betrieba_PC / V5.2

Instruction manual
41
Types of operation
Electronics
2 3
5 6
8 9
- First grip the specimen at the upper grip.

- Now check the force display. The display should be round about the
zero-point. If not, you must zero the force.
- Finally you can close the second grip. The displayed force must not be
zeroed again.
- Any manual sensors must now be clamped. Then you can start your
test.
Inspection after each test

Please check the condition of the jaw inserts before each test. The jaw
inserts must be replaced by ones in perfect working order should wear or
damage to those in use be apparent.
42

Instruction manual
Types of operation
Electronics
2 3
5 6
8 9
Compression test
Mounting and alignment of compression test equipment is described in
chapter Retrofit, paragraph Compression test tools.
User manual
You must also adjust the limit switch stops here.

Principle:
3 8
0
3 7
0
3 4
0
50 mm
410

- The upper stop touches the crosshead indicator
- The lower stops permit the maximum travel, but prevents the test tools
from crashing
The lower stop is 50 mm below the crosshead indicator in this
example.
380
370
360
350
340
Lower stop
Plan views
You can insert the specimen when all of the test parameters have been
correctly entered in the PC test program.
The specimen must be in the middle of the grips.
Check the force display. The display should be round about the zeropoint. If not, you must zero the force.
You can start the test if you have finalised all other work for the test.
Side views

Instruction manual
43
Types of operation
Electronics
2 3
5 6
8 9
Flexure test
Mounting and alignment of flexure test equipment is described in chapter
Retrofit, paragraph Flexure test tools.
User manual
Check that the settings for the limit switche stops are correct.
- The upper stop touches the crosshead indicator
- The lower stops permit the maximum travel, but the materials testing
machine shuts down before the flexure tup touches the flexure table.
The work travel is
shown in the diagram.
You can insert the specimen if you have entered all relevant data into the
PC test program. The specimen must lie correctly on the respective
supports.
You can start the test if you have finalised all other work for the test.
44

Instruction manual
Check the displayed force. The display should be round about the zeropoint. If not, you must zero the force.
Test tools
Retrofit
2 3
5 6
8 9
Retrofit
Materials testing machines can only be put to use universally if the test
tools can be interchanged. The Zwick test tool system enables easy and
rapid interchanging of various test tools.
WARNING
Risk of injury!
Retrofitting represents an increased injury hazard. Please
pay attention to the safety notes in section 1 as well as to
the following notes.
Always take utmost care and pay attention.
Please make sure that any pneumatic and/or hydraulic equipment of, or
for use with, the materials testing machine is at zero pressure before you
start to work with it.
Connecting parts
The maximum permissible loading is always determined by the weakest
link in the chain (test arrangement)! Usually this is either the test tool(s) or
the load cell. The materials testing machine itself can nearly always
generate a greater force.
Prestress nut
D
Mounting stud
Some test tools allow other test tools and additional load cells (of lower
nominal forces) to be connected to them via connectors (mounting studs,
lock-pins, etc.).
The following maximum permissible forces are valid for the mounting
studs and lock-pins supplied by Zwick:
Lock-pin
Mounting stud
D g6
8 mm
20 mm
36 mm
60 mm
04.08 / Umrue / V5.31
Lock-pin
d H7
3 mm
8 mm
18 mm
30 mm

Instruction manual
Maximum
Load
1 kN
10 kN
50 kN
250 kN
45
Test tools
Retrofit
2 3
5 6
8 9
Specimen grips
Specimen grips are generally used to stretch specimen, usually up to
break, by applying a tensile load. Whereby different mechanical
characteristics are determined.
Two specimen grips are usually required. These hold the specimen
during the test. Specimen grips can be closed manually or automatically.
Pneumatic grips
The pneumatic grips can be operated in different ways:
- direct on the specimen grip itself via a rocker switch
- by a pneumatic control unit
Control direct on the specimen grip itself, or via a rocker switch

Pneumatic grips which can be controlled via a rocker switch are plugged
directly into the compressed air supply as standard.
WARNING
Risk of injury!
The rocker switch must be in position Open!
Please make sure that the rocker switch is switched to Open.

It would immediately close the specimen grip when the pneumatic hose
is connected if it were set at position Close.
46

Instruction manual
04.08 / Umrue / V5.31
If the rocker switch is in the position Close, the specimen

grip will close immediately when the pneumatic lead is
connected.
Test tools
Retrofit
2 3
5 6
8 9
Control via a pneumatic control unit

Please make sure that the pneumatic control unit is at zero-pressure
before the pneumatic grips are connected.
WARNING
Risk of injury!
Pneumatic hoses which are under pressure immediately
close the specimen grips when they are plugged in.
Only pneumatic hoses at zero-pressure must be inserted in
the specimen grips.
The pneumatic hoses differ in their color coding:

Close hoses are red,
open hoses are black.
The respective pneumatic hoses must be connected to both of the
specimen grips and to the pneumatic control unit before you connect the
pneumatic control unit to the compressed air supply.
Hydraulic grips
The hydraulic power pack must be switched off before and during
connection of the hydraulic hoses.
Please make sure that there is no leakage of hydraulic oil from neither
the hydraulic hoses nor the hydraulic grips.
Spraying oil could lead to injuries and fires!
Risk of slipping
04.08 / Umrue / V5.31

Instruction manual
47
Test tools
Retrofit
2 3
5 6
8 9
Mounting the specimen grips

Please mount specimen grips so that they are central with respect
to the test axis.
- Drive the moving crosshead so far that
specimen grips can be mounted without any
problems
Principle
Load cell
Lock-pin
Prestress nut
Upper specimen
grip
Test axis
Lock-pin
Lower specimen
grip
Flange
Prestress nut
Lower crosshead
- For light specimen grips, the upper

specimen grip can be placed on the load
cells mounting stud by hand.
Insert the lock-pin all the way with your free
hand.
- For heavy specimen grips, place a parallel
block of wood on the lower grip. Lift the
upper specimen grip onto this wooden
beam.
Please pay attention to the force display
during the next action. Switch any testing
machine movement off immediately should a
rapid force increase occur.
Now drive the mounting stud until it slips
easily into the corresponding hole in the
specimen grip at a very low speed, making
sure you do not cant it. Stop the movement
as soon as the lock-pin can be slipped
entirely into the mounting hole.
Insert the lock-pin all the way.

Instruction manual
04.08 / Umrue / V5.31
48
- Place the lower specimen grip on the

mounting stud. Push the mounting stud into
the connecting hole of the specimen grip
until the lock-pin can be easily slipped
through the connecting hole.
Test tools
Retrofit
2 3
5 6
8 9
Prestress the specimen grips

Specimen grips must be prestressed so that there is no play.
Requirements for mounting and dismantling:
Mounted are:
- Load cell
- Mounting stud
- Specimen grips
- Tensile specimen.
You require a tensile specimen that does not leave the elastic range
at maximum force.
- Permitted force
is the lowest nominal force of the mounted components (load cell,
eventually adapters and specimen grips).
Principle
Procedure for pre-stressing

Moving
crosshead
Load cell
- Grip the tensile specimen. The specimen

must not leave the yield range at
maximum force.
- Slowly apply load again up to approx.
100 % of the permitted force.
Test axis
- Manually screw on the prestress nuts at

the load cell and the specimen grips.
- Remove the load carefully and slowly.

Pre-stress nuts
- Ungrip the tensile specimen
Lower
crosshead
04.08 / Umrue / V5.31

Instruction manual
49
Test tools
Retrofit
2 3
5 6
8 9
Dismantle the specimen grips

Pneumatic or hydraulic grips
Make pneumatic or hydraulic hoses to zero-pressure.
Unplug the pneumatic or hydraulic hoses.
Cancel prestressing of the test arrangement.
Procedure:
Please observe the requirements for mounting and dismantling on the
previous page.
- Grip a tensile specimen. The specimen must not leave the yield
range at maximum force.
- Slowly and carefully apply load again up to approx. 100 % of the
permitted force.
- Manually slacken off the prestress nuts at the load cell and the
specimen grips.
- Remove the load carefully and slowly.
- Ungrip the tensile specimen
- Now drive the machine until the specimen grips are far enough away
from one another.
For light specimen grips:
- Hold the upper specimen grip tightly with one hand.
- Pull the lock-pin out of the upper specimen grip with your free hand.
Store the specimen grips in a safe, clean, dust free place, e.g. in a tool
cabinet.
50

Instruction manual
04.08 / Umrue / V5.31
For heavy specimen grips

- Place a block of wood on the lower specimen grip. Now drive the
specimen grips until contact is made with the wood.
- Pull the lock-pin out of the upper specimen grip.
- Drive very carefully and very slowly until the specimen grip is free.
Remove the upper specimen grip.
Test tools
Retrofit
2 3
5 6
8 9
Compression tools
Compression test kits serve to determine the behaviour of materials or
components that are subjected to single-axis compression loading
uniformly distributed over the cross-section.
Principle
Compression plate
Compression tools generally consist of a

compression table and a compression plate.
Compression platen
Please note:
Always mount all test tools centrally with
respect to the test axis.
Principle
Load cell
Mounting compression tools:

Lock-pin
Prestress nut
Lock screw
Adapter
Compression
plate
Test axis
Compression
platen
- Guide the upper compression platen into the

upper adapter and lightly tighten the
securing screw.
- Slip the upper adapter onto the mounting
flange of the load cell and insert the lock-pin
as far as it will go.
- Tighten all pre-stress nuts by hand.
Adapter
Lock-pin
- The lower mounting piece is to be slipped

onto the mounting flange on the lower
crosshead.
- Please secure the adapter with a lock-pin.
- Place the compression table on its adapter.
Flange
Prestress nut
Lower crosshead
04.08 / Umrue / V5.31

Instruction manual
51
Test tools
Retrofit
2 3
5 6
8 9
Align the compression tools:

Principle drawings:
Adjust the stops of

the limit switches
Drive slowly up to
contact
The two compression platens are

driven very slowly and carefully up
to contact (at a very low force).
The compression platens align
themselves in this manner. They
are now parallel to one another.
Check that the securing screw is
firmly seated.
Now drive the compression
platens approximately 7 mmapart
and set the lower safety limit stop
correctly.
(The 7 mm results from the
overshoot path of the limit
switches. More about this is to be
found in section Switch devices)
STOP at
traction
Dismantling compression tools:

- Loosen the pre-stress nuts by hand
- Hold the upper compression platen tight with one hand.
Carefully pull the lock-pin at the load cell.
Remove the compression platen complete with its connecting part.
Store the compression test kit in a safe, clean, dust free place, e.g. in a
tool cabinet.
52

Instruction manual
04.08 / Umrue / V5.31
- Lift the lower compression table from its adapter.

Extract the lock-pin from the lower mounting flange.
Remove the lower adapter.
Test tools
Retrofit
2 3
5 6
8 9
Flexure tools
Flexure test kits are used for investigating the
flexural behaviour of a specimen with
determination of the flexural properties.
Principle
Adapter
Flexure die
Flexure table
Lock screw
Flexure supports
The flexure tools consist of a flexure tup with

adapter, and a
flexure table with two flexure supports and a
mounting flange.
A 3-point flexure test kit is shown at the left.
Flange
Install the test tools.

Principle
Load cell
Mounting the flexure tools:

Prestress nut
Lock-pin
Adapter
Test axis
Lock screw
Flexure die
Flexure table
Screws
Lock-pin
- Screw the flexure table onto the mounting

flange with the two screws as supplied. This
has a 16 mm dia. connection hole.
- Slip the mounting flange of the 3-point flexure
table onto the 16 mm dia. mounting flange
(adapter) on the lower crosshead.
- Guide the flexure tup into the upper adapter
and lightly tighten the securing screw. This
adapter has a 16 mm dia. mounting hole.
- Slip the adapter of the flexure tup onto the 16
mm mounting flange of the load cell (adapter)
and insert the lock-pin as far as it will go.
- Tighten all pre-stress nuts by hand.
Flange
Flange
Prestress nut
Lower crosshead
04.08 / Umrue / V5.31

Instruction manual
53
Test tools
Retrofit
2 3
5 6
8 9
Align the flexure tools

You must align the flexure test tools once theyve been mounted.
Proceed as follows depending upon the flexure test kit:
- Undo the support bases.
Principle drawings
or
or
Remove the support (1).

Now you can loosen the screw (2).
Loosen the fixing screw or the retaining lever.
Principle
Approximately 10 to 15 mm
Stop
- Now drive the flexure tools at a low speed

until they are approx. 10 to 15 mm apart
from one another.
- Stop the motion
- Shift both supports right up to the flexure tup
by hand.
Thus the flexure tup is aligned in parallel.
- Now carefully tighten the lock screw by hand
Lock screw
- Now bring the corresponding safety limit

stop all the way to the crosshead pointer.
- Tighten it.
This is the lower stop in our example.
54

Instruction manual
04.08 / Umrue / V5.31
- Now drive the moving crosshead far enough

away so that you can easily insert (replace)
the specimen.
Test tools
Retrofit
2 3
5 6
8 9
Principle
Maximum travel
- Now set the required support separation.

- Tighten the support base screws.
- Replace the supports in their guides,
Maximum travel
Support separation
Dismantling the flexure tools

-
Drive the flexure tools apart.

Loosen the pre-stress nuts by hand.
Hold the flexure die tight with your hand.
Extract the lock-pin at the load cell with the other hand.
Remove the flexure die with the upper adapter.
- Tighten the lateral splash plates fixing screws.

- Now you can remove the lock-pin at the mounting flange of the lower
crosshead.
- Lift the flexure table from the mounting flange.
Store the flexure tools in a safe, clean, dust free place, e.g. in a tool
cabinet.
04.08 / Umrue / V5.31

Instruction manual
55
Test tools
Retrofit
2 3
5 6
8 9
56

Instruction manual
04.08 / Umrue / V5.31
Retrofit
Electronics console
2 3
5 6
8 9
Retrofit the electronics console

The electronics console is mounted on the side of the load frame of the
materials testing machine.
The electronics console can be height adjusted.
Please pay attention to the weight of the electronics console.
Procedure:
- Switch the materials testing machine off
- Undo the slotted nuts at the load frame.
- Please remove the electronics console carefully from the holder at the
load frame.
- Place the mounting bolt at the new position on the load frame.
- Tighten the slotted nuts.
Load frame
Mounting studs
Electronics console
Slotted nut
12.05 / Umr / V5.0

Instruction manual
57
Retrofit
Electronics console
2 3
5 6
8 9
58

Instruction manual
12.05 / Umr / V5.0
Error messages
Electronics
2 3
5 6
8 9
Error messages
The test system (materials testing machine) consists of two components.
The load frame and the measurement and control electronics.
Errors are shown on the PC monitor. Error messages and rectification
help and instructions are always displayed on the screen via the PC user
program. Please pay attention to these instructions.
Make sure that there has not been an operating error before you
start fault finding!
Only trained and competent personnel may work on the opened

electronics.
Attention
Observe handling regulations
Electrostatic sensitive components
Set free
Most interferences are caused by force or travel violations. These errors

can be rectified via Set free
ATTENTION
pressed.
04.08 / Fehler / V5.2

Instruction manual
59
Error messages
Electronics
2 3
5 6
8 9
Set free sequence:

Test system is switched off.
The cause is displayed.
Determine the exact cause!

Determine a remedy.
Force overload
FNom
or
Limit switch has
been hit
or
<EMERGENCY
STOP> actuated
60

Instruction manual
Switch the drive system on
04.08 / Fehler / V5.2
ON
Error messages
Electronics
2 3
5 6
8 9
Electronics error messages

LED display
You can read off the error message numbers and operating states from
the LED display at the rear of the electronics.
The following list contains the errors of the electronics that can be
displayed. Switch the test system off and then on again each time for all
of these errors. Please contact ZwickService if the above does not lead
to any success. The address is contained in the appendix. Please do not
forget to provide the corresponding error number.
Rear side of the

electronics
LED display
Error
The message buffer for the driver or the test task is full.
Monitoring has been triggerred.
The system capacity is utilised to 100%. Monitoring has

been triggerred.
An acute memory deficiency has been detected. The

system has triggerred a reset.
A reset has been triggered via the debug interface.
Could not be initialised.
01.07 / Fehler_nr / V5.2
The electronics has detected differences between new

sensors and the current program. A new software
version is required.
The electronics has detected an error.

Instruction manual
61
Error messages
Electronics
2 3
5 6
8 9
Electronics operating states

The following displays help to indicate the current states of the
electronics. Always indicate the current state if you have problems with
the electronics.
LED display
Current state
The module drivers are created.
The machine elements are created.
Devices and channels are created.
The device is finalised and the controller manager is

created.
Initialisation has been successfully completed.
The configuration has changed. A switch to the state

machine elements Create will take place.
62
Motherboard components are created.
The software is actualised via the PC.

Instruction manual
01.07 / Fehler_nr / V5.2
Error messages
Electronics
2 3
5 6
8 9
Temperature monitoring
The electronics must have a constant temperature. Thus switch the test
sytem on an hour before beginning any long-term tests.
Warning notes about excessive temperature
0
-
As test standards require constant temperatures, the electronics

monitors the ambient temperature. The electronics will keep you
informed if the ambient temperature fluctuates too strongly, or if it is too
high. A running test is not canceled.
The warning message can be acknowledged by pressing the RETURN
key on the PC keyboard.
Make sure that temperature conditions are as required by the
standards used for your testing.
=>
01.07 / Fehler_al / V5.2

Instruction manual
63
Error messages
Electronics
2 3
5 6
8 9
External devices
Disconnecting non-required periphery devices
Never here
You must unplug non-required peripherals directly from the electronics.

Peripheral
Never, ever disconnect peripherals at couplings or at other plugs.
Attention!
X15
module slots
IV
III
II
I
COM1 PC
COM2 debug
safety device
electrostatic
sensitive
devices
Why?
The electronics does not receive any data from the open
measurement leads. The electronics then outputs an error message
about the corresponding peripheral and does not permit further
testing.
X16
Always here
Symbolic display
Input of external voltages

An external voltage at the input channel of the electronics could trigger an
error message when switching the test system on. This error can only be
eliminated by switching the test system and all external devices off.
Thereafter switch the test system on first of all and then the external
devices.
64

Instruction manual
01.07 / Fehler_al / V5.2
Error messages
Drive system
2 3
5 6
8 9
Drive system
Error messages are shown on the screen.
You can read off the error message numbers, warning messages and
operating states from the LED digital display at the rear of the
electronics.
Display of the operating states, warning

messages and error message numbers of the
electronics
LED display
Display of the operating states, warning

messages and error message numbers of the
drive
11.06 / Fehler_L / V5.1

Instruction manual
65
Error messages
Drive system
2 3
5 6
8 9
Drive system error messages

Drive failure errors are first reset by switching the test system off
and then on again.
The error number is displayed alternately with E and the error number.
3
Please contact ZwickService should the following not bring any success.
The address is contained in the appendix.
Error:
Possible help:
The LED display shows E and 0'

alternately.
Voltage accuracy An internally needed voltage has failed.
=>
Switch the test system off and then on again.

66

Instruction manual
11.06 / Fehler_L / V5.1
Error messages
Drive system
Error:
2 3
5 6
8 9
Possible help:

alternately.
The motor current measurement is erroneous.
=>
11.06 / Fehler_14 / V5.1

Instruction manual
67
Error messages
Drive system
Error:
2 3
5 6
8 9
Possible help:

alternately.
The voltage for the power section has failed.
=>
Check:
The voltage selection switch fuse
Replace it if necessary
-
The voltage selection switch setting

Set the voltage selection switch to
the voltage of your mains supply
=>
That the mains tolerances have not been

exceeded
=>
Fuse 4 AT
3
Switch the test system off and then on

again.
Voltage selector
68

Instruction manual
11.06 / Fehler_14 / V5.1
Error messages
Drive system
Error:
2 3
5 6
8 9
Possible help:

alternately.
Erroneous current switch-on limit of the drive is erroneous.
=>

alternately.
An error has occurred when reading the EEPROM.
=>
11.06 / Fehler_a6 / V5.1

Instruction manual
69
Error messages
Drive system
Error:
2 3
5 6
8 9
Possible help:

alternately.
The plug of the motor or of the rotary encoder is either not plugged in or
incorrectly plugged in.
=>
Switch the materials testing machine off
X18 Rotary
encoder plug
Check that the support profiles fixing is

correct:
X18 Rotary encoder
X19 Motor
Plug-in the test system again.
3
X19 Motor plug

Rear side of the
electronics
70

Instruction manual
11.06 / Fehler_a6 / V5.1
Operating states
Drive system
Operating state
display of the
electronics
2 3
5 6
8 9
The following displays help to indentify the drive systems current states.
Always indicate the current state if you have problems with the drive
system.
Drive system operating

system display
LED display
Current state
The drive is initialised.
The data from the EEPROMs is read
The drive controller is initialised.
03.06 / Fehler / V5.0
The operating software is not available.
The drive is ready, however the ON button has not been

pressed.

Instruction manual
71
Operating states
Drive system
LED display
2 3
5 6
8 9
Current state
The lamp in the ON button illuminates but the drive is

locked.
The operating software is loaded.
The internal test program is called.

=> An operating program is not available.
Set free is run.
Internal configuration for service technicians.
The drive has detected an error. The error number is

displayed alternately with E.
72
The drive is ready and the ON button has been pressed.

The drive is released.
The drive has detected a fatal error.

Instruction manual
03.06 / Fehler / V5.0
Short instructions
2 3
5 6
8 9
Short instructions
Run a tensile test
Safety
A safety device is required for specimen that tend to burst or
shatter at specimen break, or for those that may possibly be
propelled away from the specimen grips.
Prepare the materials testing machine.
Set L0
Measure the specimen

(enter the test data)
12.34
Grip the specimen with the first specimen grip

(at the load cell)
Adjust the force zero-point
Grip the specimen with the second specimen grip
Start the test

100
80
[kN]
Close the safety door (if installed)
60
Test
40
20
0
0
[%]
10
After the test, if the crosshead or actuator is idle:

Open the safety door (if installed)
Remove the specimen
12.08 / Kurzanl / V5.11

Instruction manual
73
5 6
Short instructions
2 3
8 9
How to grip tensile specimen correctly

Which jaws?
Dependent upon the grips to be tested:
Only use suitable grips and jaws/jaw inserts.
- Flat specimen:
Use level jaw inserts
- Round specimen: Use jaw inserts with v-slots

- Jaw inserts must be in a good condition.
Do not use damaged or worn inserts.
Correct gripping
3/3
2/3
- The gripping length must be at least 2/3 of the jaw length.

If the gripping length is too short the specimen will most
probably slip in the grips.
- Please observe the specimen grip manual!
74

Instruction manual
12.08 / Kurzanl / V5.11
- Insert the specimen in line with the test axis.

Gripping specimen at an angle will falsify characteristics and
thus the results as well.
Short instructions
2 3
5 6
8 9
Run a compression test
Safety
Keep your hands away from between the compression platens
so long as the crosshead is in motion.
Set LE
12.34

Place the specimen on the lower compression platen
Start the test

100
80
[kN]
Test
60
40
20
0
0
[%]
10

Remove the specimen
12.08 / Kurzanl / V5.11

Instruction manual
75
5 6
Short instructions
2 3
8 9
Correctly inserting compression specimen

Place specimen in the middle of the compression platens.
Do not insert specimen off centre as this would lead to falsified
results, and to damage to the compression platens.
Compression tests with one-point contact damage the
compression platens.
76

Instruction manual
12.08 / Kurzanl / V5.11
Short instructions
2 3
5 6
8 9
Run a flexure test
Safety
Keep hands away from the flexure test kit as long as the moving
crosshead is in motion.
Set LE

10.23
Place the specimen on the supports
Start the test

100
80
[kN]
60
Test
40
20
0
0
[%]
10

Remove the specimen
12.08 / Kurzanl / V5.11

Instruction manual
77
Short instructions
2 3
5 6
8 9
Correct insertion of flexure specimen

Place the specimen centrally with respect to the flexure supports.
Do not insert specimen off centre as this would lead to falsified

results.
Do not insert specimen as depicted to the left as this could lead
to damaging the flexure test kit and/or load cell.
78

Instruction manual
12.08 / Kurzanl / V5.11
Index
5 6
8 9
A
Ambient and test temperatures .............................. 20
Attention .......................................................... 18, 59
Autorised persons .................................................... 5
C
Cabling ...................................................................
CAUTION ...............................................................
Check the EMERGENCY STOP linking .................
Check the lubrication .............................................
Clamp the specimen ..............................................
Clean the materials testing machine ......................
Commissioning ......................................................
Compression specimen
Insert .................................................................
Compression test ...................................................
Compression tools
Align .................................................................
Dismantling .......................................................
Mounting ...........................................................
Retrofit ..............................................................
Control buttons .......................................................
Correct clamping of specimen ................................
Correct gripping
Of tensile specimen ..........................................
Correct gripping of the specimen ............................
37
10
14
38
25
38
33
76
43
52
52
51
51
22
25
74
28
2 3
4
7
Index
Danger of irreparable damage .................... 10, 18, 59

Danger of pinching parts of the body ........................ 7
Danger to life and limb .............................................. 7
Dangerous electrical voltage ..................................... 7
Dismantle
Specimen grips ................................................. 50
Dismantling
Compression tools ............................................ 52
Flexure tools ..................................................... 55
Drive system
Error messages ................................................ 66
LED display ...................................................... 65
Operating states ............................................... 71
Drive systems operating states .............................. 71
Ear protectors ......................................................... 11

Electronics
Operating states ............................................... 34
Electronics console retrofit ..................................... 57
EMERGENCY OFF button ....................................... 9
EMERGENCY STOP ............................................. 17
EMERGENCY STOP linking
Cabling .............................................................. 13
Check ............................................................... 14
Terminator ......................................................... 13
EMERGENCY STOP monitoring .............................. 8
Error messages ..................................................... 59
Drive system .....................................

Sprache

Tensile Tester

Hochgeladen von

Dokumentinformationen

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Tensile Tester

Hochgeladen von

Copyright:

Verfügbare Formate

Acceptance report

Dossier no.: 702161

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

Order confirmation no.: 2142429

Doc.-No. F12-002 Ref. V12-006

Zwick technical documentation

07.08 / Abn / V5.2

for machines and instruments

Zwick GmbH & Co. KG

BSW Bag Solutions Worldwide s.r.o.

The above machine / system has been

Die oben genannte Maschine / Anlage wurde

Die Lieferung und/oder die Leistung wurde gem den

Please note that a missing confirmation on the part of

Doc.-No. F12-002 Ref. V12-006

Zwick department and signature

Name and address of the customer

Zwick technical documentation

07.08 / Abn / V5.2

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

The consignment and/or performance has been fulfilled

Fax: +49 (0)7305/10 261

Sehr geehrter Betreiber unseres Prfsystems,

Zeichen Variante 2 Bedeutung

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

Warnung vor Handverletzung!

Warnung vor heier Oberflche!

11.08 / Symbole / V5.01

Zwick Technische Dokumentation

Dear user of our testing system,

Risk of pinching parts of the body!

Zwick technical documentation

11.08 / Symbole / V5.01

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

Copyright 2005, Zwick GmbH & Co. D-89079 Ulm

Zwick technical documentation

Materials testing machine:

Help for malfunctioning

Instruction manual Materials testing machine

See the respective manual

All rights reserved

Zwick technical documentation

03.05 / Ident-MPM / V5.1

Copyright 2005, Zwick GmbH & Co. D-89079 Ulm

Copyright (c) 2009 by Zwick GmbH & Co.

Technical manual .......................................................................... 2

User manual ................................................................................... 4

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

Service and maintenance manual ............................................. 10

Zwick technical documentation

Instruction manual layout

Register 10 Service and maintenance manual.

What everybody needs

Zwick technical documentation

06.08 / Ident_PS / V5.2

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

Register 11 Circuit diagrams

Register 7 Special user programs

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

06.08 / Ident_PS / V5.2

To be found on the third page of the

Zwick technical documentation

The instruction manual layout is to the same repetitive pattern.