READ THIS MANUAL BEFORE USING THE INSTRUMENT
ANTES DE UTILIZAR EL INSTRUMENTO, LEA ATENTAMENTE ESTE MANUAL
LIRE CE MANUEL AVANT D'UTILISER L'INSTRUMENT
LEIA ATENTAMENTE ESTE MANUAL ANTES DE UTILIZAR O INSTRUMENTO
使用仪器前请阅读本操作手册
DIESES HANDBUCH VOR DER VERWENDUNG DES MESSGERÄTS LESEN
LEGGERE ATTENTAMENTE QUESTO MANUALE PRIMA DI UTILIZZARE QUESTO STRUMENTO
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FMM DIGITAL FORCE TESTER USER MANUAL
PKG08813-UMFMM 3
TABLE OF CONTENTS
PAGE
PAGE
General Safety Precautions
5 5 8 8 8 8 9
6.1.1 6.1.2
Manual Operation Automatic Operation
18 18 18 18 18 19 19 19 19 19 19 19 19 20 20 21 21 21 22 22 22 22 22 22 23 23 23 23 23 23 23 23 23 24 24 24 24 24 24 25
Warnings
1.0 1.1 1.2 1.3 2.0 2.1
Introduction
6.2
Force Controller Operation - DFC
System Description
6.2.1 6.2.2 6.2.3
Load Limit Testing
System Safety and Labeling Calibration and Verification
Distance Limit Testing Break Limit Testing L1 System Operation Load Limit Testing
Specifications
6.3
Common Specifications
10 10 10 10 10 10 10 10 10 11 11 11 11 11 11 12 12 13 13 14 14 15 15 16 16 16 16 17 17 17 17 17 18 18
6.3.1 6.3.2 6.3.3 6.3.4 6.3.5 6.3.6
2.1.1 2.1.2 2.1.3 2.1.4
Power Noise
Load Hold Testing
Distance Limit Testing Distance Hold Testing Cycle Count Testing Cycle Duration Testing
Environmental
Measurement Accuracies Lifting and Handling General Precautions Unpacking Your System
3.0 3.1 3.2 3.3 4.0 4.1 4.2 4.3 4.4 4.5
6.4 6.5 6.6 6.7 6.8
System Startup
Setting Crosshead Travel Limits
Positioning Your System for Use
Setting Grip Protection Load Cell Protection
Installation
Customer Responsibilities Starrett Responsibilities
Starting a Test
6.8.1 6.8.2 6.8.3
Starting Using FMM Test Frame Start Test Using DFC Force Controller
Site Considerations
Input Power
Start Test Using L1 Software
Connecting System Components
6.9
Stopping a Test
4.5.1 4.5.2 4.5.3
Using DFG Force Gage
6.9.1 6.9.2 6.9.3 6.10
Stopping Using FMM Test Frame Stopping Using DFC Force Controller
Using DFC Force Controller
Using L1 Software Installing L1 Tablet
Stopping Using L1 Tablet Emergency Stopping
4.5.3.1 4.5.3.2
Installing BLC Load Cell Sensor Installing Base Clevis Assembly
7.0 7.1
Maintenance
4.5.4 4.5.5
Preventive Maintenance Daily Maintenance Checks
Installing Test Fixtures
7.1.1 7.1.2 7.1.3 7.1.4
4.6 5.0 5.1 5.2 5.3 5.4 5.5
Using Anti-Skid Mounting Clips
Authorized Factory Maintenance
FMM Controls Power Switch
Cleaning
Lubrication
Emergency Stop Switch
7.2
Maintenance Procedures
Jog Keys
7.2.1 7.2.2 7.2.3
Travel Limits
Display
Emergency Stop Switch
Selection Knob
Fuse Replacement
5.5.1 5.5.2
Selecting Units of Measure Selecting Crosshead Velocity
8.0 8.1 8.2 9.0
Accessories
Standard Accessories Optional Accessories
5.6 6.0 6.1
Setting Travel Limits
Operation
Dimensions
Force Gage Operation - DFG
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GENERAL INFORMATION
PRODUCT WARRANTY Starrett force measurement products carry a 3-year (from date of purchase) warranty against defects in material and workmanship (parts and labor), subject to factory inspection. Starrett will repair or replace, at its option, any part or parts found to be defective in workmanship or material. Starrett warrants repaired or replaced parts for the balance of the original warranty period or 90 days, whichever is longer. Parts returned to the factory under warranty will be repaired at no charge. Freight charges to the factory will be paid by the customer. Return freight charges to the customer will be paid by Starrett. This warranty does not cover damages from such causes as abuse, accident, neglect, fire or freight damage. It does not apply to defects resulting from modifications made by the customer or improper use of the system or its components. DISCLAIMER OF LIABILITIES Starrett shall have no liability or responsibility to the customer or any other person or entity with respect to any liability, loss or damage caused or alleged to be caused directly or indirectly by this documentation, or the hardware described in it. This includes but is not limited to any interruption of service, loss of business or anticipatory profits, or consequential damages resulting from the use or operation of hardware or equipment. GENERAL SAFETY PRECAUTIONS Force measurement systems are potentially hazardous. Prior to operating your testing system, Starrett recommends that you read and understand the instruction manuals for your system and components and that you receive training on the proper use of this equipment from your authorized Starrett representative. Observe all warnings and cautions identified in this manual for your equipment. A warning identifies a function that may lead to injury or death. A caution identifies a hazard that may lead to damage to equipment or loss of data. Starrett products, to the best of our knowledge, comply with various national and international safety standards as they apply to material and force measurement testing. This Starrett product has been tested and found to comply with the following recognized standards: • EN61010-1 Safety Requirements for Electrical Equipment • EN61000-6-3 EMC Generic Emissions Standard • EN61000-6-1 EMC Generic Immunity Standard Starrett also certifies that this product complies with all relevant EU directives and carries the CE mark.
ELECTROMAGNETIC COMPATIBILITY Your FMM force measurement system is designed to comply with International Electromagnetic Compliance (IEC) standards. To ensure reproduction of this EMC performance, connect this equipment to a low impedance ground connection. Typical suitable connections are a ground spike or the steel frame of a building. WARNINGS EMERGENCY STOP Press the emergency stop button whenever you feel there is an unsafe condition during a test. The emergency stop button removes power to the motor drive system causing the crosshead to stop. FLYING DEBRIS Eye protection, protective clothing and splinter/safety shields should be used whenever any possibility exists of a hazard from the failure of a sample, assembly or structure under test. Due to the wide range of materials that may be tested and that may result in a failure which may cause bodily injury, the precautions and preventative methods taken prior to testing is entirely the responsibility of the owner and the user of the equipment. CRUSH HAZARD Always use caution when installing or removing apparatus and your sample material between the frame’s crosshead and the base. A potential pinch/crush hazard exists. Keep clear of the testing fixture, and particularly the jaw faces at all times. Keep clear of the crosshead during movement. If available, always make sure the Pinch Load feature is enabled. This will stop inadvertent crosshead operation if in manual mode. Always ensure that other personnel cannot operate the system while you are working within the test fixture area. ELECTRICAL HAZARD Disconnect equipment from the electrical power supply before removing any electrical safety covers. Disconnect power when replacing fuses. Never reconnect power while the covers are removed. Never operate the system with protective covers removed. ROTATING MACHINERY HAZARD Always disconnect power before removing covers that protect the user from the internal rotating mechanisms. If maintenance to the drive mechanism is required, and power is needed to perform maintenance to the drive system, maintenance should be performed by an authorized Starrett representative who has received factory training on performing such procedures.
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FMM DIGITAL FORCE TESTER
THIS IS A STARRETT USER GUIDE FOR THE FMM DIGITAL FORCE TESTER. ALL SPECIFICATIONS IN THIS DOCUMENT ARE CORRECT AT TIME OF PRODUCTION AND ARE SUBJECT TO CHANGE. PLEASE CONTACT STARRETT FOR FURTHER INFORMATION.
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1.0 INTRODUCTION Thank you for selecting the FMM Digital Force Tester for your force measurement testing. Your FMM testing system may be used for tension and compression testing including specific test methods such as peak, break, constant hold, flexural, shear, peel, coefficient of friction and more. Your FMM testing system should be used with Starrett equipment and accessories only. And for optimum performance, your FMM testing system should be maintained and serviced annually by an authorized Starrett representative. 1.1 SYSTEM DESCRIPTION Your FMM system consists of the FMM testing frame, a DFG or DFC force gage, or the L1 tablet and software, load cell sensors and test fixtures. Together, these components provide you with a full-featured testing system for most force measurement testing applications.
1.2 SYSTEM SAFETY AND LABELING ISO and ANSI safety labels are affixed to Starrett equipment to alert users and operators of the equipment to warnings and cautions. System users should obey all warnings and cautions and should be trained on the safe operation of this equipment by an authorized Starrett representative. 1.3 CALIBRATION AND VERIFICATION Your FMM System is calibrated and tested at our factory prior to shipment to you. Our factory calibrations are traceable to national standards. If you require an ASTM E4 or ISO 7500-1 calibration, Starrett or a Starrett authorized representative can perform a calibration on-site in order to comply with these international calibration standards. Starrett recommends that you calibrate your system at least annually. More frequently calibrations may be required depending on the frequency of which the system is used. If your system is calibrated to ASTM E4 or ISO 7500-1, it must be calibrated whenever the system is relocated, e.g. moved from its location where the previous calibration occurred.
Shown: L1 System comprised of FMM-330 standard travel digital force tester with L1 Tablet and software, BLC Load Cell and test fixtures
Shown: FMM-550X extended travel digital force tester with DFC digital force gage
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2.0
SPECIFICATIONS
FMM - DIGITAL FORCE TESTERS
STANDARD TRAVEL
EXTENDED TRAVEL
MODELS
FMM-110
FMM-330
FMM-550
FMM-110X
FMM-330X
FMM-550X
Lbf
110 500
330
550
110 500
330
550
Load Capacity, Full Scale
N
1,500
2,500
1,500
2,500
Kgf
50
150
250
50
150
250
inch/min 0.002 mm/min 0.05 inch/min 40 mm/min 1000 inch/min 40 mm/min 1000
Crosshead Speed, Minimum
Crosshead Speed, Maximum
Maximum Speed, Full Load
Accuracy- Speed
Better than 0.1% of test speed
inch Better than 0.0008 mm Better than 0.02mm
Accuracy- Crosshead Position
inch 0.001 mm 0.025 lbf/in 13,750
Travel Resolution
17,368
17,742
12,222
13,750
14,865
Axial Frame Stiffness
kN/mm 2.5
3.1
3.1
2.2
2.5
2.5
Counts 99,999 Duration 27 hours Duration 27 hours
Cycling, Maximum
Constant Hold, Maximum
inch
22
32
Vertical Test Space 1
mm 559
813
inch
20
30
Crosshead Travel
mm 508
762
Communication
USB 2.0, RS-232
Input/Output Channels
0 - 24Vdc (independent, configurable)
Power
Single Phase Voltage (Vac) +10% 110, 120, 220, 230, 240 50/60 Hz
0.09A Holding
0.11A Holding
0.18A Holding
0.09A Holding
0.11A Holding
0.18A Holding
Using 117V Mains at Full Scale Load
10.5 Watts
12.9 Watts
21.1 Watts
10.5 Watts
12.9 Watts
21.1 Watts
°F °C
+40 to +110
Operating Temperature
+5 to +43
Humidity
10 to 90%, non-condensing
inch 3.9 mm 100
Throat
inch
37
47
Height
mm 940 11.5 mm 292 inch inch 16.5 mm 419
1,194
Width
Depth
inch
#10-32, 5/16-18, 1/4-28, 1/2-20 (optional)
Base Plate Threads
mm M4, M6, M10, M12 (standard)
lbs
80
95 43
Weight (approx.)
kgs
36.3
CE Compliance
Meets all relevant CE standards for safety, immunity, noise
NOTES Total vertical space is the distance from the top surface of the base plate to the bottom surface of the crosshead.
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2.1 COMMON SPECIFICATIONS The common specifications for all FMM frames are described in the following sections. 2.1.1 POWER FMM frames feature a self-regulating power input module. There is no need to adjust your system with jumpers or voltage regulators based on the source input power. FMM frames are single phase voltage instruments capable of support source power at 100, 120, 220 and 240Vac ±10%. Frequency is 47 to 63 Hz. 2.1.2 NOISE The FMM frames are designed to limit noise produced by the frame to less than 70dB(A). 2.1.3 ENVIRONMENTAL The following environmental specifications are common to all FMM frames.
3.0 LIFTING AND HANDLING Your FMM force measurement system is packed in a sturdy plywood crate. The protective crate is environmentally friendly and assembled with clamps that secure the walls together without screws. Clamps may be removed with the special clamping tool supplied or using a screw driver. Your FMM system is intended to be used on a table or work bench. Make sure the table or work bench has sufficient strength to support the weight of the testing frame. Before you locate your frame, please ensure the following: Read the section Site Considerations. Verify that all conditions are met prior to transporting and locating your frame. Your equipment operators are trained and appropriately licenses (if necessary) to your local safety standards. At the location where your frame is to be established, there is sufficient ceiling clearance from the top of the frame. You have adequate protective materials to protect your frame when moving to its intended site. 3.1 GENERAL PRECAUTIONS WARNING At least two adults to should used to move the FMM frame. CAUTION Be careful to not put any strain on the Emergency Stop or other controls located on the front panel of your system. Make sure the crosshead travel limits are clear and free from becoming entangled during lifting. 3.2 UNPACKING YOUR SYSTEM The FMM test frame is shipped in a heavy-duty corrugated carton. Foam inserts are used on the base, top and mid-section to help dampen vibration during shipment. WARNING Use caution if opening corrugated carton with a knife or utility blade. It is recommended you un-staple the top portion of the corrugated carton from the bottom base. • Remove the stapes that hold the top carton to the bottom base. • Remove the top cap. Leave the foam insert in place. • Remove the foam inserts. • Remove the Accessory boxes. NOTE Save the carton in case you need to store or ship your FMM frame at a later date. 3.3 POSITIONING YOUR SYSTEM FOR USE Using at least two (2) adults, firmly grasp the frame base. Lift the frame off of the foam base. Place the frame on to its operating position.
PARAMETER
SPECIFICATION +40° to +110°F +5° to +43°C -40° to +150°F -40° to +66°C
Operating Temperature
Storage Temperature
Humidity
+10% to +90%, non-condensing
Designed for use under normal laboratory conditions. Protective measures may be required if location is subject to excessive dust, corrosive fumes, electromagnetic fields or hazardous conditions.
Environmental Conditions
2.1.4 MEASUREMENT ACCURACIES The measurement accuracies for all FMM systems are shown below.
PARAMETER
ACCURACY
DFC Force Gage Accuracy DFG Force Gage Accuracy
±0.1% Full Scale ±0.2% Full Scale ±0.1% Full Scale ±0.2% of set speed
BLC Sensor Accuracy
FMM Frame Speed Accuracy FMM Frame Distance Accuracy
Better than 0.02% Full Scale (No Load)
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4.0 INSTALLATION This section will provide you with installation guidelines for your FMM force measurement system. Starrett recommends that your authorized Starrett Representative be responsible for installing and commissioning your system at your location. NOTE Starrett recommends that your authorized Starrett Representative installs and commissions your FMM force measurement system. CUSTOMER RESPONSIBILITIES As the customer for this product, you are responsible for: • Insurance and safety responsibilities during installation and operation of this precision instrument. • Arrange to off-load and unpack the equipment using qualified personnel or an authorized Starrett Representative. 4.1 • Transportation of the equipment to its intended test location. This includes responsibility for any special handling or rigging considerations. • Preparation of the test site including the physical, electrical and environmental considerations. • Proper disposal of any waste materials generated from the installation. 4.2 STARRETT RESPONSIBILITIES Starrett recommends that an authorized Starrett Representative be responsible for the unpacking, siting, installation and commissioning of your FMM force measurement system. Starrett or an authorized Starrett Representative will: • Install the machine, its components and any additional accessories that were purchased from Starrett or your Starrett Dealer. • Perform an initial operation of the system and a verification check to ensure that the system is working properly and measuring accurately. • Perform a customer demonstration that describes how to operate the system. • Supply documentation on the operation of the system including manuals and user guides. NOTE Starrett recommends that customers purchase a one-day hands-on training session for all customer personnel who will operate the equipment.
4.3 SITE CONSIDERATIONS Proper site preparation is important to ensure that your FMM force measurement systemoperates in accordance to its published specifications. Customer should consider the following prior to installation and siting of your equipment: • Ensure that the work table or bench where the system is to be placed onto has sufficient strength to carry the weight of the testing frame and all of its connected components. A table with leveling feet is preferred. • Ensure that the table top can make use of optional anti-skid clips if required. Skid clips are bolted to the table therefore the table material should allow for drilling holes and attaching screws or bolts. Anti-skid clips are not required, but may be recommended for certain types of tests. • The frame is not located against a wall or other object that may interfere with air ventilation around the frame base and column. Proper air ventilation is required to dissipate the heat generated from the internal components and motor. • The site is free of vibrations and away from other equipment that can cause vibration, e.g. compressors. • There is adequate clearance between the frame’s top cap and ceiling. Starrett recommends at least 24 inches of clearance. • The system is accessible for routine service. Much of the service is performed at the back of the machine. Allow at least three (3) feet of space on all sides of the frame. • The electrical power source rating is within the voltage rating specified for the machines. • The electrical power source is within 8 ft. (2.4m) from the system. WARNING • Never use extension cords with your FMM system. • The test site meets the system’s environmental specifications. INPUT POWER Your FMM system has a self regulating power input module. There are no jumpers to set. Simply plug the power cord into a clear source of power. CAUTION 4.4 • Make sure the power source voltage is within the published frame specifications. • Use a 3-wire, grounded main power cable for the FMM frame and L1 tablet. CONNECTING SYSTEM COMPONENTS This section will describe how to connect components to your FMM frame. WARNING Electrical Hazard. Do not connect power cables when the power switch is in the ON position. 4.5
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4.5.1 USING DFG FORCE GAGE The DFG can be used with the FMM test frame. The FMM test frame must be used in manual mode where you control the crosshead movement using the jog keys. The DFG serves as a digital indicator for the applied forces during the testing. The DFG can be connected to the FMM for automatic charging of the force gage battery, however, there is no communication or controls through the force gage. The DFG mounts to the FMM testers crosshead using the Force Gage Mounting Block (p/n SPK-FG-BLOCK). The block has an alignment pin that fits into the back of the force gage’s back housing. This ensures correct axial alignment for testing. Four M4 mounting screws are used to attach the force gage to the mounting block. The mounting block is then attached to the crosshead using six flat head screws on the crosshead.
4.5.2 USING DFC FORCE CONTROLLER The DFC can be used as a controller where the gage serves as the universal interface to the FMM tester. The DFC has a TESTS feature where you can setup automatic testing methods. The DFC lets you setup test limits for measuring the loads plus it can be used to specify the FMM tester speed and distance limits. The DFC mounts to the FMM testers crosshead using the Force Gage Mounting Block (p/n SPK-FG-BLOCK). The block has an alignment pin that fits into the back of the force gage’s back housing. This ensures correct axial alignment for testing. Four M4 mounting screws are used to attach the force gage to the mounting block. The mounting block is then attached to the crosshead using six flat head screws on the crosshead. NOTE It may be easier to remove the mounting block from the crosshead and then attaching the block to the force gage. Once this is done, attach the mounting block on the gage to the crosshead. The DFC communicates with the FMM tester using the optional L1- CONTROL cable.
Fasten SPK-FG-BLOCK on to the FMM Crosshead using six (6) Flat Head M6 x 1 x 12mm screws
DFG mounted to Crosshead using SPK-FG-BLOCK
Shown: SPK-FG-BLOCK threaded on to the back housing of the DFC or DFG force gage.
NOTE It may be easier to remove the mounting block from the crosshead and then attaching the block to the force gage. Once this is done, attach the mounting block on the gage to the crosshead. If you require load limit control, where the FMM will stop when a load setpoint is achieved, you should use either the DFC force controller or the L1 software.
Shown: DFG force gage mounted to force gage block on crosshead.
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4.5.3 USING L1 SOFTWARE For more advanced and automated testing, Starrett recommends using our L1 software. L1 software operates on our L1 Tablet. The tablet is a 2-in-1 computer with touchscreen and removable QWERTY keyboard. The L1 tablet communicates with the FMM tester using USB 2.0 communications and the cable supplied with your FMM tester. Using the L1 software, you have total control for setting up a variety of common test methods. You have the ability to setup targets for load, distance and cycling limits. You control the FMM tester’s direction, speed and exceptions where you can have the crosshead stop if an event occurs, i.e., the sample became loose within the test fixture.
4.5.3.1 INSTALLING THE L1 TABLET The L1 tablet attaches to the FMM column. The column is fitted with a ball joint. The L1 tablet attaches to a plate with a ball joint. An adjustable RAM arm attaches to both ball joints. The RAM arm lets you position the L1 tablet for maximum comfort and easy operation. The tablet’s keyboard can be removed so that all operations, including text and numerical entries are performed using the touchscreen and a virtual keypad. The L1 tablet can also be used on the workbench. It does not have to be affixed to the FMM column. NOTE The L1 tablet is connected to the FMM test frame using the USB cable that is supplied with the test frame.
REF.
DESCRIPTION 1 Plate, Mounting for Lenovo MIIX 300 2 Nut, Hex, M5 x .8 3 Screw, Button Head, M5 x .8 x 16mm 4 Screw, Flat Head, M5 x .8 x 14mm 5 Washer, Locking, M5 6 Mounting Base, Diamond with 1-inch Ball 7 Mounting Arm, Double Socket for 1-inch Ball
Secure #6 Mounting Base to the pre-drilled holes on the FMM column (right-side).
6
7
Shown: L1 Tablet Mounted to FMM Column
5
3
1
2
5
6
4
After inserting #4 screws, secure the #1 Plate to the display module on the L1 tablet using double-back tape or hook and loop tape.
Shown: L1 Tablet Ram Mount Assembly Components
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4.5.3.2 INSTALLING BLC LOAD CELL SENSOR The BLC load cell sensors are used when the FMM tester is being controlled using the L1 software and tablet computer. The BLC mounts to the FMM testers crosshead using the Load Cell Mounting Block (p/n SPK-BLC-BLOCK). The BLC load cells mount to the FMM crosshead using either an M6 socket head screw or an M10 socket head screw (BLC-550 only). The BLC load cell sensor’s cable connects to the FMM frame’s back panel. Cable clips are supplied with your FMM tester so that you can manage the cable and keep the cable clear of the crosshead. The clips can be attached to the column. The clips have an adhesive backing. CAUTION Starrett recommends that you turn power on your FMM system OFF when connecting your load cell sensor.
4.5.4 INSTALLING BASE CLEVIS ASSEMBLY Your FMM frame’s base has a metric threaded adapter plate with threaded M4, M6, M10 and M12 holes. The plate attaches to the FMM tester’s base with four mounting screws and washers. You may loosen the four screws on the base adapter plate to align the load cell or force gage to the center line of your testing fixture. NOTE Starrett offers an optional base adapter plate with imperial threads. The threaded holes on this adapter plate are #10-32, 5/16-18, 1/4-28 and 1/2-20. The Base Clevis is used to fit your testing fixtures.The Base Clevis has either an M6 or M12 male threaded screw connector. To attach the Base Clevis, screw the Base Clevis into the base hole.
Metric Base Adapter Plate
5.000
M4 X 0.7
Ø0.550 THRU
4.250
Ø1.200 0.190
M10 X 1.5 - 6H
M10 X 1.5 - 6H
Ø0.150 X 82.0°
M12 X 1.75 - 6H Ø0.430 X 82.0°
Ø0.370 X 82.0°
3.000 2.500 2.000
M6 X 1 - 6H
Ø0.225 X 82.0°
A
A
0.750
M6 X 1
0.000
4.250
5.000
2.500
3.000
0.750
2.000
0.000
Imperial Base Adapter Plate
5.000
#10-32
Ø0.550 THRU
4.250
Shown: SPK-BLC-BLOCK
Ø1.200 0.190
10-32 UNF-28
5/16-18 UNC-28
1/2-20 UNF-28
REF.
DESCRIPTION
3.000 2.500 2.000
1 2 3 4 5 6
Block, BLC Load Cell
Reducer Bushing, M12 to M6 (for BLC-2 thru BLC-200)
1/4-28 UNF-28
Screw, Socket Head,M6 x 1 x 25mm
Washer, Flat, M6 Washer, Flat, M12
A
A
0.750
1/4-28
Screw, Socket Head, M12 x 1.75 x 25mm (for BLC-500 only)
0.000
4.250
5.000
2.500
3.000
0.750
2.000
0.000
6
3
5
4
2
1
Shown: SPK-BLC-BLOCK Components
Shown: Base Adapter Plate with Clevis Assembly
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4.5.5 INSTALLING TESTING FIXTURES Test fixtures feature a 15.9mm diameter attachment. This attachments slides onto the Base Clevis and Load Cell Clevis. The test fixture is secured to the Clevis adapter using a 8mm grip pin. Both Clevis devices include two (2) locking rings. Use the rings to tighten the clevis to the sensor, base and test fixture. If testing is performed using a force gage, you may also use non-clevis test fixtures. Simply screw the testing fixture into the base adapter plate and align the force gage stem to the center line of the test fixture.
4.6 USING ANTI-SKID MOUNTING CLIPS You may secure the FMM test frame to your workbench using the anti- skid mounting clips (p/n L1-FMMCLIP). The clips attach to the feet on the FMM tester. The clips can then be screwed down onto your work bench. NOTE Anti-skid clips should always be used on extended travel models: FMM-110X, FMM-330X and FMM-550X.
REF.
DESCRIPTION
10 15 16
Bench Clip Bracket
Screw, Socket Head M6 x 1 x 12mm
Washer, Locking, M6
10
16
15
Shown: Clevis Assemblies used on Base Adapter Plate and on BLC Load Cell Sensor for affixing test fixtures
Shown: Location for mounting Bench Clips to FMM base plate
Shown: Base Clevis Adapter Kit (SPK-CLEVIS-L) includes clevis, locking rings (2), grip pin and spanner wrench
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5.0 FMM CONTROLS This section will describe the controls used with your FMM force measurement system to perform tests. 5.1 POWER SWITCH The main power switch for your FMM frame is located on the back of the machine. • Connect the machine to a source power outlet. • Turn the On/Off switch to the ON position to operate. • When your machine is not being used, turn the power switch to the OFF position.
5.2 EMERGENCY STOP SWITCH The Emergency Stop Switch is located on the left-hand side of the FMM base. This switch interrupts power to the electrical drive system and brings the system to a stop as quickly as possible. CAUTION Engaging the Emergency Stop Switch does not remove power to the system. When the Emergency Stop Switch is engaged, power to the drive system is interrupted. No crosshead movement is possible. When operated, the Emergency Stop Switch locks down into a closed position. The crosshead movement is disabled. To reset or disengage the Emergency Stop Switch, press down and turn counter-clockwise. The switch will release upwards and return power to the drive system. 5.3 JOG KEYS The Jog Keys lets you move the crosshead UP and DOWN. When using the Jog Keys, pressing the key cause the crosshead velocity to increase from zero to full velocity (40 inches per minute / 1016mm per minute) in about 3 seconds. You may restrict the maximum velocity using the L1 Motion Settings. JOG UP - press the up portion of the switch to cause the crosshead to move upward. Release the switch to stop motion. JOG DOWN - press the down portion of the switch to cause the crosshead to move downward. Release the switch to stop motion.
Shown: Power On/Off Switch on back of FMM
Display
Emergency Stop Switch
Jog Keys Up/Down
Selector Knob
Shown: FMM Front Panel Controls
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5.4 DISPLAY The FMM test frame may be operated manually, using the jog keys or automatically using the DFC Controller or the L1 software with a personal computer. When the FMM is operated manually, the FMM display shows the currently selected crosshead speed. The crosshead speed is selected using the Selection Knob. The crosshead speed may be displayed in either inch/minute or mm/minute units of measure. When the FMM is operated using a DFC Controller, the FMM display shows that the FMM is connected to the DFC Controller. Crosshead speed is set from the DFC Controller and not from the FMM test frame. When the FMM is operated using the L1 software with a personal computer, the crosshead speed is set from the personal computer and the L1 software. The crosshead speed is not selected using the FMM Selection Knob. 5.5 SELECTION KNOB The Selection Knob functions when the FMM test frame is being operated manually, i.e., using the jog keys. Rotating the Selection Knob increases or decreases the set speed for the crosshead. The crosshead speed may be set between 40.0 inch/minute (999.9 mm/min) and 0.02 inch/min (1.0 mm/min).
5.5.1 SELECTING UNITS OF MEASURE You may change crosshead velocity units of measure between inch/ minute and mm/minute. To change units, press and hold the Selection Knob. The display will indicate the selected units of measure for velocity. 5.5.2 SELECTING CROSSHEAD VELOCITY Rotate the Selection Knob clockwise to increase the crosshead velocity setting. Rotating the Selection Knob counter-clockwise decreases the crosshead velocity. When the FMM test frame is operated manually using the jog keys, the crosshead will move up or down at the speed indicated in the FMM display. 5.6 SETTING TRAVEL LIMITS Limit Switches are located on the center bar of the column and used to restrict crosshead travel. Position your upper and lower travel limit switches so that they are approximately 2-3 inches above/below where your crosshead will stop during a normal test procedure. These travel limits will stop the crosshead should the crosshead come into contact with one of the limits.
Shows DFC is connected to the FMM frame
Shows current units for velocity
DFC con. mm/min 200.0
Press to manually move crosshead upward
Press to manually move crosshead downward
Press and Hold to change units Rotate to change velocity setting
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6.0 OPERATION The following sections will provide you with general guidelines for using your FMM force measurement system. Starrett recommends that you received professional training by an authorized Starrett Representative prior to operating your testing system. 6.1 FORCE GAGE OPERATION - DFG The DFG force gage may be used as a force indicator with the FMM tester. All FMM control is performed using the FMM tester, including setting the test speed, controlling the direction of testing (tension or compression) and for controlling crosshead velocity. NOTE The DFG cannot control the crosshead movement. The DFG cannot be used for automatic load limit test methods.
6.2 FORCE GAGE OPERATION - DFC Using the DFC force controller, the entire test setup and control of the FMM tester is performed using the gage. The DFC is used to specify the test method, including the direction of test, the crosshead travel and exceptions that can abort a test should an event occur. The DFC, when used with the FMM tester as the controller, can perform these types of common test methods: • Load Limit Test • Distance Limit Test • Break Limit Test NOTE For complete details on using the DFC force gage with your FMM Tester, please refer to the DFC User Manual. LOAD LIMIT TESTING The DFC force gage can be used as a controller for Load Limit testing. The DFC is used to specify the direction of the test (tension or compression), the target load that defines the end of test, and the crosshead travel to the target load setpoint. Once the test is completed, the DFC will display the Load Limit and the Distance the crosshead traveled to the limit. 6.2.1
Tests Test Mode Load Type
Shown: DFG force gage for manual testing
Tension 50.00 6.000
Target Speed
Tests Test Mode Break Type
Shown: DFC Test Setup Menu for Load Limit Test using FMM Test Frame
6.2.2 DISTANCE LIMIT TESTING The DFC force gage can be used as a controller for Distance Limit testing. The DFC is used to specify the direction of the test (tension or compression), the target distance that defines the end of test, and the crosshead travel to the target load setpoint. Once the test is completed, the DFC will display the Distance Limit and the Load and Maximum Load measured during the test.
Tension 20.00 50 51.00
Min Break % Drop Speed
Shown: DFC Test Setup Menu for Break Limit Test using FMM Test Frame
Tests Test Mode Off Load Distance Break
6.1.1 MANUAL OPERATION Operate the FMM tester using the jog keys when using the DFG force gage. 6.1.2 AUTOMATIC OPERATION There is no automatic operation when using the DFG force gage. If automatic operation is needed, use either the DFC force controller or the L1 software.
Shown: DFC Test Setup Menu for Distance Limit Test using FMM Test Frame
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6.2.3 BREAK LIMIT TESTING The DFC force gage can be used as a controller for Break Limit testing. The DFC is used to specify the direction of the test (tension or compression), the target break limits that define the end of test, and the crosshead travel to the target load setpoint. Once the test is completed, the DFC will display the Distance Limit and the Load and Maximum Load measured during the test. 6.3 L1 SYSTEM OPERATION For maximum testing flexibility, control and consistency, Starrett recommends using the FMM digital force tester with our L1 software. Using the L1 software, common test methods can be setup quickly and performed easily, within seconds. The L1 software uses intuitive fill- in-the-blank templates for these common test methods. Just fill in the specific requirements for your test method and perform testing efficiently and consistently. For more detailed information about all the available features and functions of our L1 software, please read our L1 Software User Manual, or ask your Starrett representative for a demonstration.
6.3.1 LOAD LIMIT TESTING Perform go to Load Limit test methods. Simply specify the test direction (tension or compression), specify the target load and specify the crosshead velocity. 6.3.2 LOAD HOLD TESTING Perform a Load Hold test method for determining creep or relaxation. Simply specify the test direction (tension or compression), specify the target load, specify the hold duration and specify the crosshead velocity. The hold duration may be specified for up to 72 hours. 6.3.3 DISTANCE LIMIT TESTING Perform go to Distance Limit test methods. Simply specify the test direction (tension or compression), specify the target distance and specify the crosshead velocity. 6.3.4 DISTANCE HOLD TESTING Perform a Distance Hold test method for determining creep or relaxation. Simply specify the test direction (tension or compression), specify the target distance, specify the hold duration and specify the crosshead velocity. The hold duration may be specified for up to 72 hours. 6.3.5 CYCLE COUNT TESTING Perform a Cycle test method for a count, i.e., number of cycles. Simply specify the test direction (tension or compression), specify the target cycle limits, you may specify a dwell period for each limit, specify how many cycles (counts) and specify the crosshead velocity to each limit. You may cycle for up to 99,999 cycles. 6.3.6 CYCLE DURATION TESTING Perform a Cycle test method for a duration, i.e., time duration for cycles. Simply specify the test direction (tension or compression), specify the target cycle limits, you may specify a dwell period for each limit, specify how many cycles (counts) and specify the crosshead velocity to each limit. You may cycle for up to 99,999 seconds (72 hours).
Shown: L1 Break Test Graph Profile
Shown: FMM Test Frame operating with L1 Tablet and L1 software
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6.4 SYSTEM STARTUP Prior to starting your FMM force measurement system, ensure that you understand the operating and safety features of your system. Also, always verify operating controls prior to use. • Ensure that all cables are properly installed and securely connected. • Turn power to the FMM frame and L1 tablet to the ON position. • Allows your system to warm-up by allowing the system to stabilize after a 15 minute warm=up period. • Launch the L1 tablet software. • Create and perform your force measurement testing with exceptional ease and accuracy. • Contact your Starrett Representative for assistance if needed. 6.5 SETTING CROSSHEAD TRAVEL LIMITS Your FMM frame has two crosshead travel limits located on the center bar of the column. These limit switches are intended to protect the crosshead from traveling too far in either direction. NOTE Always set the crosshead travel limits at the desired location before starting a test. Failure to set these crosshead limits may result in injury due to unexpected crosshead motion and damage to your load cell sensor and testing fixture. Set the upper and lower crosshead travel limits after you have established the crosshead starting position for your test, but before you being testing. Each travel limit operates as an adjustable block. Each limit has a thumbscrew that you tighten and release by hand. Loosen the thumbscrew so that the limit moves freely up or down on the column. Slide the limit up/down on the column to the desired position. Both limits should be positioned just beyond the normal travel distances for your test. When the crosshead reaches the maximum pre-set travel, the limit switch actuator contacts one of these stops. This causes the crosshead to stop its motion. NOTE Your L1 software also contains travel protection for your crosshead. These should be used in addition to your mechanical crosshead travel limits. Within the L1 software, all Quick Test setups and your Tension and Compression stages, contain CONDITIONAL SETTINGS. Included in these settings is the ability to stop the crosshead when a distance limit is reached. Should the crosshead contact either the upper or lower travel limit, the test will stop and the crosshead will stop moving. If this happens, use the jog switch on the your FMM frame base to move the crosshead off the limit stop. Press the DOWN direction on the jog switch to move the crosshead off the upper limit. Press the UP direction on the jog switch to move the crosshead off the lower limit. The crosshead motion arrows on your L1 tablet will display and animate when the crosshead is in motion.
Upper Travel Limit
Lower Travel Limit
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6.6 SETTING GRIP PROTECTION Grip protection is an L1 software feature. Grip protection is not available when using either the DFC or DFG force gage. Grip protection allows you to set a maximum load that protects you from accidently overloading your testing fixture. With the grip protection feature, you specify a maximum load. If this load is achieved during a test, the test will abort and the crosshead will stop. NOTE Use the Grip Protection feature within your L1 tablet and software to protect your test fixture for inadvertent overloading.
Using the L1 software, the L1 tablet’s load bar graph and sensor symbol (on the header) will display a color to depict the amount of load being measured by the sensor relative to the sensor’s rated capacity. When the color YELLOW is being displayed, you should use caution. When the color RED is being displayed, you should use extreme caution and be prepared to stop your test. When your sensor is measuring between 0 and 75% of its rated capacity, the bar graph will display GREEN. When your sensor is measuring between 76% and 90% of its rated capacity, the bar graph and sensor symbol will display YELLOW. When your sensor is measuring above 90% of its rated capacity, the bar graph and the sensor symbol will display RED. NOTE • Observe the load bar graph indicator and sensor symbol when performing a test. If the bar graph and sensor symbol display RED, be prepared to stop the test to protect your load cell sensor from an overload condition. • Your L1 software also contains load protection for your load cell sensor. Within the L1 software, all template setups and your Tension and Compression stages, contain CONDITIONAL SETTINGS. Included in these settings is the ability to stop the crosshead when a load limit is reached. It is recommended that you use the Load Condition.
6.7
LOAD CELL PROTECTION
Shown: L1 Software Grip Protection Setup
Load cell protection is an L1 software feature. Load cell protection is not available when using either the DFC or DFG force gage. Mechanical overload protection is standard on both the Starrett DFC and DFG force gages. The gages’ sensors have mechanical overload protection up to 200% of the sensor’s rated capacity. Your BLC load cell sensors have mechanical overload protection. The BLC sensors have mechanical overload protection up to 150% of the sensor’s rated capacity. Within the L1 software in the LOADS Setting, there is a feature called “Maximum Load Allowed”. This feature lets you scale your load cell to help prevent accidental overloading. Refer to the L1 Software Manual for more information on this feature. The DFC and DFG force gages display the active load being placed on the internal load cell. A bargraph on the gage displays in color. When the gage is operating between 1 and 75%, the bar graph is GREEN. When the load is at 76 to 90%, the bar graph is YELLOW. When the measured load exceeds 90%, the bar graph displays in RED. If you apply a load greater than the sensor’s rated full scale, the display will flash RED indicating you should immediately relieve the load being applied to the sensor.
Shown: L1 Software Maximum Load Allowed Load Cell Protection
6.8 STARTING A TEST Before starting a test we recommend the operator perform the following pre-test checks: • Verify that the system is properly installed and all preparation is complete. • You are using a calibrated BLC load cell sensor. • You have properly set the upper and lower crosshead travel limits. • You have set appropriate CONDITIONAL SETTINGS in your L1 tablet for Distance and Load Limits. • Verify that your test setup parameters are set in accordance with your testing requirements. • Your operator has reviewed the manual for the control system and L1 tablet and are familiar with all safety and operating features.
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6.8.1 STARTING USING FMM TEST FRAME When using the FMM tester in manual mode, you start your test by pressing either the up or down jog key. When using the DFG force gage, position your crosshead manually. Next, attach the sample being tested to the test fixtures. 1. Position the travel limit where you want to end your test. 2. Using the control knob to select your test speed. 3. Zero the force gage. 4. Press and Hold the jog key. The crosshead will move at the specified speed until the limit switch is reached. The crosshead will stop. You can then read the measured load from the DFG force gage and the distance traveled using the ruler on the FMM column. 6.8.2 STARTING USING DFC FORCE CONTROLLER The DFC force controller contains three common test methods that allow you to automatically perform a test using the FMM tester. When the DFC controller is used, you setup the test limits, crosshead velocity and any exception limits required. 1. Zero the DFC. 2. Press the Start/Stop softkey on the DFC controller. 3. The crosshead will move at the specified speed and to the limits specified in your test method. When the test has concluded, the DFC will display the measured load and the distance at the load.
6.8.3 STARTING USING L1 TABLET When using L1 software, the entire test setup and test operation is performed using the touchscreen on the L1 tablet. When the test is ready to be performed, you simply press the “Start Test” target.
Shown: L1 Software Start Test display
6.9 STOPPING A TEST You may stop a test using hardware controls on the FMM frame, on the DFC Force gage and on your L1 tablet. 6.9.1 STOPPING USING FMM TEST FRAME When using the FMM tester in manual mode, crosshead control is entirely performed using the jog keys. The crosshead will move while the jog key is pressed. To stop crosshead move, you simply stop pressing the jog key. 6.9.2 STOPPING USING DFC FORCE CONTROLLER When using the DFC controller, the crosshead will stop automatically when the test method has concluded or when the user selects the STOP softkey on the DFC controller. If exception limits are used in the test setup, the crosshead will also stop should an exception event occur.
8
50.00mm N
0.05 L D 0.00
mm
8
50.00mm N
Shown: DFC Start Test display
5.55 L D 5.55
mm
Shown: DFC Stop Test display
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6.9.3 STOPPING USING L1 TABLET When using L1 software, the crosshead will stop automatically when the test method has concluded or when the user selects the STOP TEST target on the touchscreen. If exception limits are used in the test setup, the crosshead will also stop should an exception event occur.
7.1.1 DAILY MAINTENANCE CHECKS Starrett recommends that you perform daily maintenance checks on your FMM force measurement system prior to operation. These checks should include the following: • Emergency Stop Switch operation • Jog Switch operation • Start/Stop Switch operation • Crosshead travel limit operations • L1 tablet Start/Stop operation • Cable and Power Cord connections 7.1.2 AUTHORIZED FACTORY MAINTENANCE Starrett recommends that you have an authorized Starrett Service Representative perform at least an annual maintenance on your FMM force measurement system. This maintenance will include:
• Inspection and servicing any loose fittings • Check operation of crosshead travel limits • Check operation of all cables • L1 tablet operation • Software updates (if needed) for your L1 tablet
Shown: L1 Software Stop Test display
• Verification of crosshead travel speed • Verification of encoder distance accuracy • Verification and re-calibration of load cell sensor(s) to ASTM E4 standard 7.1.3 CLEANING Starrett recommends that your FMM force testing system be cleaned weekly or more often if operated in a non-laboratory environment. WARNING • Disconnect power to your FMM force measurement tester and the L1 tablet before cleaning these instruments. • Use a moist, lint-free cloth with very mild detergent (if required) to clean the outside surfaces of your FMM force measurement system. • Read the Care and Cleaning instructions for the L1 tablet and follow the manufacturer’s recommendations. CAUTION • Do not clean with solvents or abrasive cleaning agents. • Do not apply excessive amounts of detergent cleaning agents. Exercise caution when using water or mild cleaning detergents to prevent fluids from getting into electrical contacts or rotating machinery. • Do not use oil to lubricate. • Use low-pressure air to remove dust and debris from tester surfaces. Always protect the column and internal machinery components from dust and debris from getting inside the column. 7.1.4 LUBRICATION Lubrication of the internal ball screw should be performed by authorized Starrett Service Representatives only. 7.2 MAINTENANCE PROCEDURES These general maintenance procedures may be followed for performing the following maintenance checks. These procedures do not require an authorized Starrett Service Representative.
6.10 EMERGENCY STOPPING The Emergency Stop switch is a large, round, red button switch with LED. It is located on the front left-hand side of your FMM frame’s front panel. Press this button to stop the test as soon as possible when a condition develops that could compromise the safety of the operator or that risks damage to your hardware. To release the Emergency Stop, press and turn clockwise.The Emergency Stop switch should return to its OFF position. 7.0 MAINTENANCE Your FMM force measurement tester is a precision instrument designed to perform accurate force measurement testing for a variety of applications. Starrett recommends that you have your system maintained by a factory-trained Starrett Service Representative at least annually. If your system is used in a more demanding application or in a harsh environment, it may be wise to have maintenance performed more frequently. WARNING Dangerous voltages and internal rotating machinery inside the machine may cause bodily injury or damage to the equipment. Personnel not trained in the service of Starrett force testing systems should not remove the covers to gain access to any internal components within your system. 7.1 PREVENTIVE MAINTENANCE Starrett recommends that you periodically inspect, clean and lubricate your FMM force measurement system.
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