Instron Model 8802, 8803, 8804, 8805 and 8806 Load FramesInstron Model 8802, 8803, 8804, 8805 and...

InstronModel 8802, 8803, 8804, 8805 and 8806Load Frames

Reference Manual - Pre-Installation

M21-28800-70 Revision B

www.instron.com

Electromagnetic Compatibility

Where applicable, this equipment is designed to comply with International Electromagnetic Compatibility (EMC) 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

Proprietary Rights NoticeThis document and the information that it contains are the property of Instron Corporation. Rights to duplicate or otherwise copy this document and rights to disclose the document and the information that it contains to others and the right to use the information contained therein may be acquired only by written permission signed by a duly authorized officer of Instron Corporation.

© Copyright 2001 Instron Corporation

iii

Preliminary Pages

General Safety Precautions

Materials testing systems are potentially hazardous.

Materials testing involves inherent hazards from high forces, rapid motions and stored energy. You must be aware of all moving and operating components that are poten-tially hazardous, particularly the actuator in a servohydraulic testing system or the moving crosshead in an electromechanical testing system.

Whenever you consider that safety is compromised, press the Emergency Stop button to stop the test and isolate the testing system from hydraulic or electrical power.

Carefully read all relevant manuals and observe all Warnings and Cautions. The term Warning is used where a hazard may lead to injury or death. The term Caution is used where a hazard may lead to damage to equipment or to loss of data.

Ensure that the test set-up and the actual test you will be using on materials, assem-blies or structures constitutes no hazard to yourself or others. Make full use of all mechanical and electronic limits features. These are supplied to enable you to prevent movement of the actuator piston or the moving crosshead beyond desired regions of operation. Limits provide protection for your specimen and machine and reduce potential hazard.

The following pages detail various general warnings that you must heed at all times while using materials testing equipment. You will find more specific Warnings and Cautions in the text whenever a potential hazard exists.

Your best safety precautions are to obtain training in the testing equipment that you are using and to read your Operating Instructions and Reference Manual(s) to gain a thorough understanding of that equipment.

Preliminary Pages M21-28800-70

iv

Warnings

Hazard - Protect electrical cables from damage and inadvertent disconnection.

The loss of controlling and feedback signals that can result from a disconnected or damaged cable causes an open loop condition that may drive the actuator or crosshead rapidly to its extremes of motion. Protect all electrical cables, particularly transducer cables, from damage. Never route cables across the floor without protection, nor sus-pend cables overhead under excessive strain. Use padding to avoid chafing where cables are routed around corners or through wall openings.

High/Low Temperature Hazard - Wear protective clothing when handling equipment at extremes of temperature.

Materials testing is often carried out at non-ambient temperatures using ovens, fur-naces or cryogenic chambers. Extreme temperature means an operating temperature exceeding 60 °C (140 °F) or below 0 °C (32 °F). You must use protective clothing, such as gloves, when handling equipment at these temperatures. Display a warning notice concerning low or high temperature operation whenever temperature control equipment is in use. You should note that the hazard from extreme temperature can extend beyond the immediate area of the test.

Crush Hazard - Take care when installing or removing a specimen, assembly or structure.

Installation or removal of a specimen, assembly or structure involves working inside the hazard area between the grips or fixtures. Keep clear of the jaws of a grip or fixture at all times. Keep clear of the hazard area between the grips or fixtures during actuator or crosshead movement. Ensure that all actuator or crosshead movements necessary for installation or removal are slow and, where possible, at a low force setting.

Hazard - Do not place a testing system off-line from computer control without first ensuring that no actuator or crosshead movement will occur upon transfer to manual control.

The actuator or crosshead will immediately respond to manual control settings when the system is placed off-line from computer control. Before transferring to manual control, make sure that the control settings are such that unexpected actuator or cross-head movement cannot occur.

v

Preliminary Pages

Warnings

Robotic Motion Hazard - Keep clear of the operating envelope of a robotic device unless the device is de-activated.

The robot in an automated testing system presents a hazard because its movements are hard to predict. The robot can go instantly from a waiting state to high speed operation in several axes of motion. During system operation, keep away from the operating envelope of the robot. De-activate the robot before entering the envelope for any pur-pose, such as reloading the specimen magazine.

Hazard - Set the appropriate limits before performing loop tuning or running waveforms or tests.

Limits are included within your testing system to provide a safe way of limiting actua-tor movement. Failure to set these limits appropriately could result in injury to person-nel or damage to equipment.

Electrical Hazard - Disconnect the electrical power supply before removing the covers to electrical equipment.

Disconnect equipment from the electrical power supply before removing any electri-cal safety covers or replacing fuses. Do not reconnect the power source while the cov-ers are removed. Refit covers as soon as possible.

Rotating Machinery Hazard - Disconnect power supplies before removing the covers to rotating machinery.

Disconnect equipment from all power supplies before removing any cover which gives access to rotating machinery. Do not reconnect any power supply while the cov-ers are removed unless you are specifically instructed to do so in the manual. If the equipment needs to be operated to perform maintenance tasks with the covers removed, ensure that all loose clothing, long hair, etc. is tied back. Refit covers as soon as possible.

Hazard - Shut down the hydraulic power supply and discharge hydraulic pressure before disconnection of any hydraulic fluid coupling.

Do not disconnect any hydraulic coupling without first shutting down the hydraulic power supply and discharging stored pressure to zero. Tie down or otherwise secure all pressurized hoses to prevent movement during system operation and to prevent the hose from whipping about in the event of a rupture.


vi

Warnings

Hazard - Shut off the supply of compressed gas and discharge residual gas pressure before you disconnect any compressed gas coupling.

Do not release gas connections without first disconnecting the gas supply and dis-charging any residual pressure to zero.

Explosion Hazard - Wear eye protection and use protective shields or screens whenever any possibility exists of a hazard from the failure of a specimen, assembly or structure under test.

Wear eye protection and use protective shields or screens whenever a risk of injury to operators and observers exists from the failure of a test specimen, assembly or struc-ture, particularly where explosive disintegration may occur. Due to the wide range of specimen materials, assemblies or structures that may be tested, any hazard resulting from the failure of a test specimen, assembly or structure is entirely the responsibility of the owner and the user of the equipment.

Hazard - Ensure components of the loadstring are correctly preloaded to minimize the risk of fatigue failure.

Dynamic systems, especially where load reversals through zero are occurring, are at risk of fatigue cracks developing if components of the loadstring are not correctly pre-loaded to one another. Apply the specified torque to all loadstring fasteners and the correct setting to wedge washers or spiral washers. Visually inspect highly stressed components such as grips and threaded adapters prior to every fatigue test for signs of wear or fatigue damage.

vii

Preliminary Pages

Table of Contents

Chapter 1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Purpose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Chapter 2 Responsibilities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1Customer Responsibilities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Site Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2Three-Phase Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2Single-Phase Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2Water Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3Floor Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3Noise Suppression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3Cable Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3Pipe Runs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Instron Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5Insurance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5Initial Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Chapter 3 Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Load Frame - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2Two-Column Load Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3Four-Column Frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8Hydraulic Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13Electronic Control Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15


viii

Load Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15Hydraulic Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16Electronic Control Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20Air Cushion Isolators (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21Air Blast Coolers (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22Power Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

Chapter 4 Lifting and Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1Load Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Raising the Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2Transporting the Frame using a Fork-Lift Truck . . . . . . . . . . . . . . . . . . . . . . . 4-6

Electronic Control Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9Hydraulic Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Type 3410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10Type 3411 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10Type 3420 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10Type 3470 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Air Cushion Isolators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Chapter 5 Essential Services. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1Electrical Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Load Frame and Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2Hydraulic Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2Impedance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3Voltage and Frequency Variations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Hydraulic Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4Water Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Cooling Water Flow Rates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

ix

Preliminary Pages

Water Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9Water Quality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10Noise Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

xi

Preliminary Pages

List of Illustrations

Figure 3-1. Two-Column Load Frame Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3Figure 3-2. Load Frame Daylight Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7Figure 3-3. Four-Column Load Frame Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8Figure 3-4. Load Frame Daylight Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11Figure 3-5. Air Blast Cooler Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22Figure 4-1. Lifting a Two-Column Load Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3Figure 4-2. Lifting a Four-Column Load Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5Figure 4-3. Maximum tilt angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6Figure 4-4. Transporting the Frame on a Pallet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7Figure 4-5. Transporting the Frame with forks under the Crosshead . . . . . . . . . . . . . . . . 4-8Figure 4-6. Lifting the Type 3410 Hydraulic Power Supply. . . . . . . . . . . . . . . . . . . . . . . 4-11Figure 4-7. Lifting the Type 3411 Hydraulic Power Supply . . . . . . . . . . . . . . . . . . . . . . . 4-12Figure 4-8. Lifting the Type 3420 Hydraulic Power Supply. . . . . . . . . . . . . . . . . . . . . . . 4-13

xiii

Preliminary Pages

List of Tables

Table 3-1. Two-Column Load Frame Dimensions / mm (in)(Refer to Figure 3-1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Table 3-2. Two-Column Frame Overall Height / mm (in). . . . . . . . . . . . . . . . . . . . . . . 3-5Table 3-3. Two-Column Frame Daylight Dimensions

(See Figure 3-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6Table 3-4. Four-Column Load Frame Dimensions / mm (in)

Actuator in Table (Refer to Figure 3-3). . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9Table 3-5. Four-Column Frame Overall Height / mm (in) . . . . . . . . . . . . . . . . . . . . . 3-10Table 3-6. Four-Column Frame Daylight Dimensions (see Figure 3-4). . . . . . . . . . . 3-12Table 3-7. Crated Hydraulic Power Supply Dimensions (Types 3410 and 3411) . . . 3-13Table 3-8. Crated Hydraulic Power Supply Dimensions(Type 3420) . . . . . . . . . . . . 3-13Table 3-9. Type 3410 and 3411 Hydraulic Power Supply Dimensions . . . . . . . . . . . 3-13Table 3-10. Type 3420 Hydraulic Power Supply Dimensions . . . . . . . . . . . . . . . . . . . 3-14Table 3-11. Type 3470 Hydraulic Power Supply Dimensions . . . . . . . . . . . . . . . . . . . 3-14Table 3-12. Electronic Control Equipment Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 3-14Table 3-13. Two-Column Frame Weight and Stiffness . . . . . . . . . . . . . . . . . . . . . . . . 3-15Table 3-14. Four-Column Frame Weight and Stiffness . . . . . . . . . . . . . . . . . . . . . . . . 3-15Table 3-15. Types 3410 and 3411 Hydraulic Power Supply Weights . . . . . . . . . . . . . 3-16Table 3-16. Type 3420 Hydraulic Power Supply Weights . . . . . . . . . . . . . . . . . . . . . . 3-16Table 3-17. Type 3470 Hydraulic Power Supply Weights . . . . . . . . . . . . . . . . . . . . . . 3-16Table 3-18. Electronic Control System Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17Table 3-19. Maximum Earth Fault Loop Impedance (Zs) for circuit supplying

electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18Table 3-20. Air Cushion Isolator Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21Table 3-21. Air Blast Cooler Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23Table 3-22. Air Blast Cooler Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24Table 3-23. Air Blast Cooler Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24Table 5-1. Maximum Earth Fault Loop Impedance (Zs) for circuit supplying

electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3Table 5-2. Hydraulic Hose Sets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4Table 5-3. Hose Thread Ends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5Table 5-4. SAE Hose Fitting to Actuator Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6Table 5-5. SAE Hose Fitting to Hydraulic Power Supply

(Types 3410 and 3411) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6Table 5-6. Extended Drain Hydraulic Pipe Run Dimensions . . . . . . . . . . . . . . . . . . . . 5-7


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Table 5-7. Cooling Water Flow Rate Requirements for Type 3410 and 3411 Hydraulic Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Table 5-8. Cooling Water Flow Rate Requirements for Type 3420 Hydraulic Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Table 5-9. Cooling Water Flow Rate Requirements for Type 3470 Hydraulic Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Table 5-10. Types 3410 and 3411 Hydraulic Power Supply Ventillation Requirements 5-10Table 5-11. Type 3420 Hydraulic Power Supply Ventillation Requirements . . . . . . . . 5-10Table 5-12. Type 3470 Hydraulic Power Supply Ventillation Requirements . . . . . . . . 5-10Table 5-13. Types 3410 and 3411 Hydraulic Power Supply Noise Levels . . . . . . . . . 5-11Table 5-14. Type 3420 Hydraulic Power Supply Noise Levels . . . . . . . . . . . . . . . . . . 5-11Table 5-15. Type 3470 Hydraulic Power Supply Noise Levels . . . . . . . . . . . . . . . . . . 5-11Table 5-16. Recommended Environmental Specifications . . . . . . . . . . . . . . . . . . . . . 5-12

1-1

Intro

duct

ionChapter 1

Introduction

Outline

This chapter describes the purpose of this manual and outlines the services and utilities necessary for installing the Model 8800 Testing System.

Purpose

The purpose of this manual is to detail the various requirements that must be met for the correct installation of the Model 8800 Servohydraulic Testing System. This will ensure that the full range of services are available to the correct specification, and that all necessary checks are completed before delivery of the system.

Terminology

The following terms are used within this manual:

STD — Standard height Frame

EXT — Extra height Frame

EXT-EXT — Extra-extra height frame

Note: All references to “gallons” refer to U.S. gallons (3.78 litres), not U.K. gallons (4.54litres).

M21-28800-70

1-2

2-1

Resp

onsi

bilit

ies

Chapter 2Responsibilities

Outline

The purpose of this chapter is to detail the responsibilities of both the customer and Instron to ensure that the proposed testing area is suitable for the installation and operation of the testing system.

Customer Responsibilities M21-28800-70

2-2

Customer Responsibilities

It is the responsibility of the customer to ensure that all required support services are available, and that all necessary checks are made to allow the correct installation of the testing system.

These services and checks are detailed in this chapter.

Site Plan

A site plan must be available, which indicates the proposed positioning of the load frame and control console. A copy of the site plan should be sent to the Instron Area Office in advance.

Three-Phase Power Supply

The hydraulic power supply requires a three-phase supply of 220V, 380/420V or 460V, at either 50Hz or 60Hz as specified for the type of power supply ordered.

Note: Different pump motors are used for 50 Hz and 60Hz supplies — the frequency is not variable.

The supply should be terminated with a suitably-rated, lockable, fused isolator as near as possible to the hydraulic power supply, and with access to adequate earthing terminations. This must still be accessible once the hydraulic power supply has been installed. Refer to Chapter 5, Essential Services, for details of the earthing requirements. The electrical connection to the hydraulic power supply must be of flexible sheathed cable, chosen to suit local regulations to be supplied by the customer.

Single-Phase Power Supply

Single phase power point, 230 V ±10% at 50 Hz, or 115 V ±10% at 50/60Hz as required, must be available for mains supply to the load frame, and for general use.

Water Supply

If you require a water-cooled hydraulic power supply, a water supply must be available, together with sufficient piping. Chapter 5, Essential Services, details the water supply rate, quality and temperature requirements for the various types of pump.

2-3

Customer Responsibilities

Resp

onsi

bilit

ies

Ventilation

If you require an air-cooled hydraulic power supply, then adequate ventilation is essential. Chapter 5 details the ventilation requirements for the various types of hydraulic pump.

Air blast coolers are available if necessary.

Floor Loading

The site floor should be checked for weight loading. The local architect or flooring specialist should be consulted.

The maximum weights of the load frames and console are given in Chapter 3, Specifications. Remember that in high performance installations large dynamic loadings may occur, thus the load capacity should be in excess of three times the combined weight of the system and operator.

Cyclic and shock loads may require the use of anti-vibration mountings.

Noise Suppression

When siting the hydraulic power supply, consideration should be given to the noise emission level. It is usually more convenient if the hydraulic pump is sited in a separate room adjacent to the operating location. If special rooms have to be built, materials suitable for sound insulation should be used. Chapter 5, Essential Services, details the noise emission levels for the various types of hydraulic power supply.

Cable Specification

The local electricity supply authority should be consulted for advice on cable specifications, with consideration being given to motor start up current surges. Chapter 5, Essential Services, gives advice on maximum current levels for various types of hydraulic power supply.

Pipe Runs

All hydraulic pipe runs must be clean to Thermal Control Class 2 (U.K.) or ISO Solid Contaminant Code 13/10 (U.S.A.) or NAS Class 4. Details of the required standard are given in all individual hydraulic power supply manuals.

All pipe runs should be tested to the following pressures:

• Pressure line — 560bar (8000psi)

Customer Responsibilities M21-28800-70

2-4

• Return line — 140bar (2000psi)

• Drain line — 20 bar (150 psi)

Cleanliness and pressure checks should be carried out immediately before installation is started. It should be noted that higher proof pressure may be required to meet local standard practice, or the demands of the customer’s insurers.

When the hydraulic pump is to be situated at a distance greater than 6metres from the load frame, steel pipe runs should be provided. Refer to Chapter 5, Essential Services, for details of the requirements for drain line bore and maximum pipe run length. Instron can supply the flexible pipes for both ends of the pipe run in either 3 or 6 metre lengths.

Where steel pipes are used, it will be necessary to clamp the pipe to avoid excess noise and vibration, especially when operating the testing system with large actuator excursion. The pipes should be clamped firmly in rubber cushion blocks.

Hoses must have adequate packing to avoid chafing and must be firmly supported by clamps when routed other than along the floor.

Handling

Unless specifically arranged otherwise, it is the customer’s responsibility to arrange for off-loading, unpacking and moving the testing system to the final operating location. This includes insurance and safety responsibilities.

2-5

Instron Responsibilities

Resp

onsi

bilit

ies

Instron Responsibilities

The equipment and services provided by Instron as part of the contract to supply the 8800 Series Testing System are as given below. Where special conditions apply, the corresponding equipment and services should be the subject of a separate and specific quotation.

Insurance

Instron will provide insurance cover from the manufacturing site in the U.K. to the customer’s premises in the U.K.. In the U.S.A. insurance cover from the manufacturing site to the customer’s premises is usually the responsibility of the carrier. Outside of these areas all purchase orders must indicate specifically which party is to effect marine insurance cover. In the absence of this indication, Instron will arrange insurance cover at the customer’s expense.

Handling

On arrival at the customer’s premises, Instron will, upon special request, supervise the off-loading and transportation onto the site, this being a special condition as mentioned above.

Installation

Once components are on the site and in position, Instron will be responsible for making all electrical and hydraulic connections between the load frame, hydraulic power supply and control system. Where steel pipes are used for hydraulic connections, Instron will connect both ends of such runs with flexible hoses as ordered by the customer.

Hydraulic System

Instron will provide the first fill of all necessary oils and lubricants, and will be responsible for carrying out flushing of the hydraulic system where a complete system has been supplied. If the customer’s own hydraulic oil installation is used, Instron will not connect until the required standards of cleanliness have been achieved by the customer at their expense. In those cases where the customer desires to use an existing hydraulic supply or has incorporated steel pipe runs in a package system but has not flushed the system to ISO Solid Contaminant Code 13/10 (U.S.A.), NAS Class 4, or Thermal Control Class 2 (U.K.). Instron will, upon special request, carry out flushing and contamination checks on such systems.

Instron Responsibilities M21-28800-70

2-6

Note: Flushing and contamination checking equipment for new or existing installations may be purchased from Instron.

Initial Operation

Having made all necessary connections, Instron will be responsible for running up the system and for a calibration check and customer demonstration. Following the initial demonstration of the equipment, further training can be given to the customer by initially contacting the local Instron area office who will be happy to advise.

Documentation

Instron will provide all necessary documentation. Further copies may be supplied as itemised on the customer’s order.

3-1

Spec

ifica

tion

Chapter 3Specification

Outline

This chapter details the specifications of the testing system components. This is to ensure that you have chosen a suitable site for your testing system.

Dimensions M21-28800-70

3-2

Dimensions

Load Frame - General

There are several different configurations of table height, column length and actuator mounting height available to suit customer requirements. Standard or extra height columns, standard or extra height tables and table or crosshead mounted actuators are available for all frame sizes.

Daylight dimensions and table height measurements for the two-column load frames are independent of the location of the actuator, but for the four-column frames these dimensions are dependent upon the actuator position.

Figures 3-1 to 3-4, and Tables 3-1 to 3-8 detail the dimensions of the Series 8800 Load Frames.

3-3

Dimensions

Spec

ifica

tion

Two-Column Load Frame

Refer to Table 3-1

Figure 3-1. Two-Column Load Frame Dimensions


3-4

Table 3-1. Two-Column Load Frame Dimensions / mm (in)(Refer to Figure 3-1)

Dimension Description

Frame Type

8802 B1 8802 B2 8803 B1 8803 B2

A Column Spacing 664 (26) 664 (26) 778 (31) 788 (31)

B Column Diameter

76 (3) 76 (3) 101 (4) 101 (4)

C Column Length 1780 (70) 2240 (88) 2240 (88) 1680 (106)

D Crosshead Depth

275 (11) 275 (11) 350 (14) 350 (14)

E Crosshead Length

200 (8) 200 (8) 275 (11) 275 (11)

F Crosshead Width 1030 (41) 1030 (41) 1230 (48) 1230 (48)

G Table Depth 150 (6) 150 (6) 200 (8) 200 (8)

H Table Length 300 (12) 300 (12) 380 (15) 380 (15)

J Table Width 870 (34) 870 (34) 1030 (41) 1030 (41)

K Table Height 910 (36) 1115 (44) 1015 (40) 1220 (48)

L Overall Width 1060 (42) 1060 (42) 1270 (50) 1270 (50)

M Overall Length 1120 (44) 1120 (44) 1220 (48) 1220 (48)

N Base Width 120 (5) 120 (5) 150 (6) 150 (6)

P Base Depth 80 (3) 80 (3) 100 (4) 100 (4)

R Hole Diameter 14 (0.6) 14 (0.6) 18 (0.7) 18 (0.7)

3-5

Dimensions

Spec

ifica

tion

Note: For the B3 height option, the column lengths are as follows:8802 – 2640mm (104 in).8803 – 3040mm (120 in).

If air cushion isolators are fitted, add 89 mm (3.5 in) to dimension K.

Table 3-2. Two-Column Frame Overall Height / mm (in)

Frame Configuration Frame Type

Actuator in Table 8802 8803

Std Table, B1 Column 2790 (110) 3355 (132)



Ext Table, B1 Column 2995 (118) 3560 (140)



Actuator in Crosshead 8802 8803

100 kN Frame, B1 Column 3606 (142) N/A



250 kN Frame, B1 Column 3626 (143) 4191 (165)

250 kN Frame, B2 Column 4086 (161) 4631 (182)

250 kN Frame, B3 Column 4486 (177) 4991 (197)

500 kN Frame, B1 Column N/A 4245 (167)




3-6

Note: If air cushions are fitted, add 89 mm (3.5 in).The figures shown for the actuator in the crosshead are based upon the ±125 mm (5 in) stroke actuator. For the ±75 mm (3 in) actuator, subtract 204 mm (8 in) from the height. For the ±50 mm (2 in) stroke actuator, subtract 306 mm (12 in) from the height.

Table 3-3. Two-Column Frame Daylight Dimensions(See Figure 3-2)

Dim Description

Frame Type

8802 8803

A Load Cell Depth 50 KN (11 kip)100 KN (22 kip)250 KN (55 kip)500 KN (110 kip)

97 (3.8)97 (3.8)128 (5.0)

N/A

N/AN/A

128 (5.0)232 (9.1)

B Piston Length Retracted

100 KN (22 kip)250 KN (55 kip)500 KN (110 kip)

66 (2.6)66 (2.6)

N/A

N/A66 (2.6)68 (2.7)

C Hydraulic Grip Depth 100 KN (22 kip)250 KN (55 kip)500 KN (110 kip)

132 (5.2)195 (7.7)

N/A

N/A195 (7.7)265 (10.4)

D Pre-Load Washer Depth

M30 x 2M48 x 2M72 x 3

27 (1.1)27 (1.1)

N/A

N/A27 (1.1)48 (1.8)

E Table Height StdExt

910 (38.5)1115 (43.9)

1015 (40)1220 (48)

F X-Head To Table Distance

Min (std)316 316 316 231 231 231

(12.4) (12.4) (12.4) (9.1) (9.1) (9.1)

Max (std)1515 1975 2375 1900 2340 2700

(59.6) (77.6) (93.5) (74.8) (92.1) (106)

Min (ext)111 111 111 16 16 16

(4.4) (4.4) (4.4) (0.6) (0.6) (0.6)

Max (ext)1515 1975 2375 1900 2340 2700

(59.6) (77.8) (93.5) (74.8) (92.1) (106)

COLUMN LENGTH B1 B2 B3 B1 B2 B3

3-7

Dimensions

Spec

ifica

tion

Note: For dimension ‘G’ (see Figure 3-3), calculate thus:‘F’ (Max or Min) – (A+B+2C+2D).

Figure 3-2. Load Frame Daylight Dimensions


3-8

Four-Column Frames

Refer to Table 3-4

Figure 3-3. Four-Column Load Frame Dimensions

3-9

Dimensions

Spec

ifica

tion

Note: If air cushion isolators are fitted, add 89 mm (3.5 in) to dimension L.

The figures for overall width are measured at the crosshead. The width at the base varies as follows:

8804 - 1015 mm (40 in)8805 - 1175 mm (46 in)8806 - 1330 mm (52 in)

The height for base mounted tables varies as follows:8805 - 300 mm (12 in)8806 - 500 mm (20 in)

Table 3-4. Four-Column Load Frame Dimensions / mm (in)Actuator in Table (Refer to Figure 3-3)

Dim DescriptionFrame Type

8804 B1 8804 B2 8805 B1 8805 B2 8806 B1 8806 B2

A Column Spacing 664 (26) 664 (26) 788 (31) 788 (31) 822 (32) 822 (32)

B Column Spacing 306 (12) 306 (12) 410 (16) 410 (16) 514 (20) 514 (20

C Column Diameter 76 (3) 76 (3) 102 (4) 102 (4) 152 (6) 152 (6)

D Column Length 2240 (88) 2640 (104) 2680 (106) 3040 (120) 2810 (111) 3310 (130)

E Crosshead Depth 254 (10) 254 (10) 305 (12) 305 (12) 305 (12) 305 (12)

F Crosshead Length 558 (22) 558 (22) 712 (28) 712 (28) 940 (37) 940 (37)

G Crosshead Width 1030 (41) 1030 (41) 1230 (49) 1230 (49) 1400 (55) 1400 (55)

H Table Depth 150 (6) 150 (6) 200 (8) 200 (8) 345 (14) 345 (14)

J Table Length 558 (22) 558 (22) 712 (28) 712 (28) 940 (37) 940 (37)

K Table Width 870 (34) 870 (34) 1030 (41) 1030 (41) 1145 (45) 1145 (45)

L Table Height 1005 (40) 1240 (49) 1160 (46) 1360 (54) 1656 (65) 1856 (73)

M Overall Width 1080 (43) 1080 (43) 1325 (56) 1325 (56) 1500 (59) 1500 (59)

N Overall Length 1000 (39) 1000 (39) 1220 (48) 1220 (48) 1500 (59) 1500 (59)


3-10

Note: a. If air cushion isolators are fitted, add 89 mm (3.5 in).

b. The figures shown for the actuator in the crosshead are based upon the 250 mm (10 in) (±125 mm (±5 in)) stroke actuator. For the 150 mm (6 in) (±75 mm (±3 in)) stroke actuator, subtract 204 mm (8 in) from the height.For the 100 mm (4 in) (±50 mm (±2 in)) stroke actuator, subtract 306 mm (12 in) from the height.

Table 3-5. Four-Column Frame Overall Height / mm (in)

Frame Configuration Frame Type

Actuator In Table 8804 8805 8806

Std Table, B1 Column 3270 (129) 3875 (153) 4516 (178)

Std Table, B2 Column 3670 (145) 4235 (167) 5016 (198)

Ext Table, B1 Column 3505 (138) 4075 (160) 4716 (186)

Ext Table, B2 Column 3905 (154) 4435 (175) 5216 (205)

Actuator In Crosshead 8804 8805 8806

Std Table, B1 Column 4235 (167) N/A N/A

Std Table, B2 Column 4635 (183) N/A N/A

Ext Table, B1 Column N/A 4110 (162) 4675 (184)

Ext Table, B2 Column N/A 4470 (176) 5175 (204)

3-11

Dimensions

Spec

ifica

tion

Figure 3-4. Load Frame Daylight Dimensions


3-12

Table 3-6. Four-Column Frame Daylight Dimensions (see Figure 3-4)

Dim DescriptionFrame Type

8804 8805 8806

A Load Cell Depth

500 KN (110 kip) 1000 KN (220 kip) 2500 KN (550 kip)

232 (9.1) N/A N/A

232 (9.1) 360 (14.2)

N/A

N/A 360 (14.2) 450 (17.7)

B Piston Length

Retracted

500KN (110kip) 1000 IKN (220 kip) 2500 KN (550 kip)

118 (4.6) N/A N/A

68 (2.7) 303 (11.9)

N/A

N/A 443 (17.4) 421 (16.6)

C Hydraulic Grip Depth

500 KN (110 kip) 1000 KN (220 kip) 2500 kn (550 kip)

265 (10.4) N/A N/A

265 (10.4) 345 (13.6)

N/A

N/A 345 (13.6) No Data

D Pre-Load Washer Depth

M72 x 3 M100 x 4 M150 x 4

48 (1.9) N/A N/A

48 (1.9) 60 (2.4)

N/A

N/A 60 (2.4) 60 (2.4)

E Table Height Base Std Ext

N/A1005 (39.6) 1240 (48.8)

300 (11.8) 1160 (45.7) 1360 (53.5)

500 (19.7) 1656 (65.2) 1856 (73.1)

FX-Head To

Table Distance

Min (base) N/A N/A 930 930 730 730

(36.6) (36.6) (28.7) (28.7)

Max (base) N/A N/A 2375 2375 2505 3005

(93.5) (93.5) (98.6) (118.3)

Min (std) 207 207 52 52 0 0

(8.1) (8.1) (2) (2)

Max (std) 1986 2386 2735 2735 2505 3005

(78.2) (93.9) (107.7) (107.7) (98.6) (118.3)

Min (ext) 0 0 0 0 0 0

Max (ext) 1986 2386 2735 2735 2505 3005

(78.2) (93.9) (107.7) (107.7) (98.6) (118.3)

Column Length B1 B2 B1 B2 B1 B2

3-13

Dimensions

Spec

ifica

tion

Hydraulic Power Supply

The following tables detail the dimensions for the different types of hydraulic power supply that may be supplied with the 8800 Testing System.

The Type 3410, 3411 and 3420 hydraulic power supplies are packed in crates. The crate dimensions are given below.

Table 3-7. Crated Hydraulic Power Supply Dimensions (Types 3410 and 3411)

Hydraulic Power Supply Delivery

litres/min (gal/min)Heightmm (in)

Widthmm (in)

Depthmm (in)

30 (8) 1200 (47) 1030 (41) 1630 (64)

45 (12) 1200 (47) 1030 (41) 1630 (64)

80 (21) 1330 (52) 1580 (62) 2440 (96)

230 (60) 1600 (63) 1740 (69) 3340 (131)

Table 3-8. Crated Hydraulic Power Supply Dimensions(Type 3420)

Hydraulic Power Supply Heightmm (in)

Widthmm (in)

Depthmm (in)

Both capacities use the same shipping crate

1260 (49.6) 1020 (40.1) 810 (31.9)

Table 3-9. Type 3410 and 3411 Hydraulic Power Supply Dimensions



Widthmm (in)

Depthmm (in)

30 (8) 901 (35.5) 930 (37) 1330 (52)

45 (12) 902 (35.5) 930 (37) 1330 (52)

80 (21) 1010 (10) 1250 (49) 2100 (83)

230 (60) 1200 (47) 1625 (64) 3000 (118)


3-14

The Type 3470 Hydraulic Power Supply is supplied uncrated, on a wooden pallet.

Note: A sound enclosure may be used with the 23 l/min hydraulic power supply. The dimensions for this are: Height 1016 mm (40 in), Width 1118 mm (44 in), Depth 966 mm (38 in).

Electronic Control Equipment

The table below details the dimensions of the tower console and front panel controller.

Note: An additional 75 mm (3 in) should be provided at the rear of the console for cooling and cable routing.

Table 3-10. Type 3420 Hydraulic Power Supply Dimensions



Widthmm (in)

Depthmm (in)

12.5 (3.3) 870 (34) 877 (35) 663 (26)

25 (6.6) 1000 (39) 877 (35) 663 (26)

Table 3-11. Type 3470 Hydraulic Power Supply Dimensions



Widthmm (in)

Depthmm (in)

23 (6) 800 (31.5) 787 (31) 724 (28.5)

38 (10) 1092 (43) 1016 (41) 660 (26)

77 (20) 1118 (44) 1346 (53) 965 (38)

Table 3-12. Electronic Control Equipment Dimensions

Equipment TypeHeight

mm (in)Width

mm (in)Depth

mm (in)

Tower 650 (25.6) 280 (11.0) 570 (22.4)

8800 Control Panel (optional)

280 (11.0) 270 (10.6) 300 (11.8)

Actuator Interface Box

130 (5.1) 115 (4.5) 60 (2.4)

Handset 200 (7.9) 130 (5.1) 80 (3.1)

3-15

Weights

Spec

ifica

tion

Weights

Load Frame

Table 3-13 and Table 3-14 give the weight and stiffness data for the 8800 Series Load Frames

Note: The weights specified in these tables are approximate guides only; where possible the weight has been assessed with the heaviest actuator, grips and loadcell for that particular load frame.The measurements for load frame stiffness are calculated with the crosshead set 1000 mm above the machine table.

Table 3-13. Two-Column Frame Weight and Stiffness

Weight and Stiffness dataFrame Type

8802 8803

Weight kg (lb) 1330 (2929) 2450 (5396)

Stiffness kN/mm (lb/in) 585 (3.27 × 106) 1066 (5.9 × 106)

Table 3-14. Four-Column Frame Weight and Stiffness

Weight and Stiffness dataFrame Type

8804 8805 8806

Weight kg (lb) 2952 (6500) 4900 (10790) 10000 (22020)

Stiffness kN/mm (lb/in) 1086 (6.1 × 106) 2102 (1.2 × 107) 4413 (2.5 × 107)

Weights M21-28800-70

3-16


The follwing tables detail the weights appplicable to the various types of hydraulic power supply that may be supplied with the 8800 Testing System.

Note: A sound enclosure may be used with the 23 l/min hydraulic power supply. The weight including the hydraulic power supply will be 318 kg (700 lb).

Table 3-15. Types 3410 and 3411 Hydraulic Power Supply Weights

Hydraulic Power Supply Deliveryl/min (gal/min) Dry Weightkg (lb) Filled weightkg (lb)

12.5 (3.25) 250 (550) 300 (660)

30 (8) 550 (1210) 660 (1452)

45 (12) 550 (1210) 660 (1452)

80 (21) 860 (1892) 1180 (2596)

230 (60) 1805 (3971) 2605 (5731)

Table 3-16. Type 3420 Hydraulic Power Supply Weights


12.5 (3.25) 163 (359) 250 (551)

24 (6.6) 213 (469) 300 (661)

Table 3-17. Type 3470 Hydraulic Power Supply Weights


23 (6) 165 (360) 235 (520)

38 (10) 320 (700) 440 (970)

77 (20) 635 (1400) 920 (2020)

3-17

Weights

Spec

ifica

tion


Table 3-18 details the weights applicable to the various components of the electronic control system.

Table 3-18. Electronic Control System Weights

Equipment Weight kg (lb)

8800 Tower Up to 32 kg (70.5 lb) (i.e. 32 kg fully populated with all optional boards)

8800 Control Panel (optional) 2.2 kg (48.5 lb)

Actuator Interface Box 1 kg (2.2 lb)

Handset approx 200g (6oz)

Power Supplies M21-28800-70

3-18

Power Supplies

Details the reccomended maximum earth fault loop impedance for equipment supplies.

Note: When U0, the nominal voltage to earth (ground) is not 240 V, the tabulated impedance values must be multiplied by U0/240.

The above figures are based upon the IEE Wiring Regulations, Sixteenth Edition 1991, Table 41D. There are no comparable US standards, but the above values may be used as guidelines.

Table 3-19. Maximum Earth Fault Loop Impedance (Zs) for circuit supplying electrical equipment

Fuse Rating (Amps) Zs (Ohms)

6 14.10

10 7.74

16 4.36

20 3.04

25 2.40

32 1.92

40 1.41

50 1.093

63 0.86

80 0.60

100 0.44

125 0.35

160 0.27

200 0.20

3-19

Power Supplies

Spec

ifica

tion

Input Supply: 30A at 100 to 125V in 5V steps, or 13A at 200 to 250V in 10V steps, single phase.

Input Frequency: 50-60 Hz ±5 %.

Line voltagevariation: ±10 %, free from noise and transients.

Note: All ancillary electrical equipment connected to the load frame should be powered from the same electrical supply.

Environmental Conditions M21-28800-70

3-20

Environmental Conditions

Temperature (operating): 5 to 38 °C (41 to 100 °F)

Temperature (storage): -30 to 50 °C (-22 to 122 °F)

Temperature (rate of change): 2 °C (4 °F) per hour. Changes above this rate may affect the performance of this equipment.

Relative humidity: 10 to 90 %, non-condensing.

3-21

Air Cushion Isolators (Optional)

Spec

ifica

tion

Air Cushion Isolators (Optional)

Table 3-20 gives the specification for the different types of air cushion isolators.

Table 3-20. Air Cushion Isolator Specifications

ParameterAir Cushion Isolator Type

SLM-6 SLM-12 SLM-14

Height of Mounting

89 mm (3.5 in) 89 mm (3.5 in) 89 mm (3.5 in)

Diameter of Mounting

61 mm (2.4 in) 95 mm (3.75 in) 138 mm (5.4 in)

Mounting Thread 0.5” - 13 UNC x 0.54” deep

0.5” - 13 UNC x 0.54” deep

0.625” - 11UNC x 0.75” deep

Maximum static load per mount

273 kg (600 lb) 545 kg (1200 lb) 1090 kg (2400 lb)

Minimum static load per mount

68 kg (150 lb) 1236 kg (300 lb) 275 kg (600 lb)

Maximum inflation pressure

6 bar (90 psi) 6 bar (90 psi) 6 bar (90 psi)

Air Blast Coolers (Optional) M21-28800-70

3-22

Air Blast Coolers (Optional)

General

If your hydraulic power supply is air-cooled, it may require an air blast cooler.

An air blast cooler circulates hot oil through an external radiator which has a large fan attached. The fan forces cooling air through the vanes of the radiator, thus cooling the oil quickly and efficiently.

Dimensions

Refer to Figure 3-5 and Table 3-21.

Figure 3-5. Air Blast Cooler Dimensions

3-23

Air Blast Coolers (Optional)

Spec

ifica

tion

Power Requirements

All Air Blast Coolers require three-phase 380/415V at 50 Hz.

Table 3-21. Air Blast Cooler Dimensions

Type

Dimension

A B C D E F G H J K L M N P R S X

BD10485 302.5 605 32 272.5 545 291 460 508 384 180 50 553 - 220 190 1"

BD20660 430 860 38 360 760 410 680 742 431 200 50 770 - 220 190 1.25"

BD30850 505 1010 35 465 930 444 750 810 531 300 60 940 70 260 160 1.5"

BD50850 525 1050 51 475 950 505 860 932 541 300 75 960 100 340 200 2"

BD75930 590 1180 51 540 1080 570 960 1062 646 370 100 1090 120 410 250 2"

BD1001160 680 1360 51 630 1260 660 1140 1242 646 370 100 1270 120 410 250 2"

Air Blast Coolers (Optional) M21-28800-70

3-24

Weight

Specification

* averaged at 1 metre.

Table 3-22. Air Blast Cooler Weights

Type Approximate Dry Weight kg (lbs)

BD10 43 (95)

BD20 86 (190)

BD30 113 (250)

BD50 186 (410)

BD75 311 (685)

BD100 365 (803)

Table 3-23. Air Blast Cooler Specifications

Type Airflow m3/S Motor rpm Motor kW Noise dBA*

BD10 0.94 2700 0.37 84

BD20 1.91 1400 0.55 80

BD30 2.48 1400 0.75 83

BD50 3.21 1400 1.1 80

BD75 3.87 1400 1.5 83

BD100 5.29 1400 2.2 85

4-1

Lifti

ng a

nd

Hand

ling

Chapter 4Lifting and Handling

Outline

This chapter gives you information required for moving the load frame to your desired location and unpacking it.

General

Unless specifically arranged otherwise, it is the customer’s responsibility to arrange for off-loading, unpacking and transporting the equipment to the final site at the customer’s premises. This includes insurance and safety responsibilities.

It is essential to transport the equipment by crane or fork-lift truck from the off-loading site to an area for unpacking, as close as possible to the operating site.

While environmental conditions in the vicinity of the testing equipment are not critical (refer to “Environmental Conditions” on page 3-20), attention should be given to the siting of the equipment in locations where air-borne dust and dirt can be held to a minimum. Floor loading is a major consideration, and a reasonably level floor with a loading capacity in excess of three times the combined weight of the load frame, control system and the operator is required. Ground floor locations are preferred, as the loading capacity is usually sufficient and floor vibrations during testing are minimised.

Warnings.

Ensure that cranes or fork-lift trucks used to move the equipment have adequate load capacity (1.5 × gross weight).

Ensure that slings used are serviceable and are of the correct length and proof loading.

Ensure that the yellow safety collar is clamped under the crosshead whenever the frame is moved.

Ensure that the crosshead clamp bolts have been tightened for transit to a torque of 230 Nm (170 lb ft).

Load Frame M21-28800-70

4-2

Load Frame

Raising the Frame

The 8800 Series Load Frames are packed and mounted horizontally on a pallet, which should remain in position until the frame is at the operating site, where it can then be removed with all other straps, hold-downs and loose packing material.

Caution

Do not use the column eye-bolts to raise the frame. They are to be used for vertical lifting of the frame only.

Two Column Frames

In order to raise the frame to a vertical position, refer to Figure 4-1 and use the following procedure.

a. Ensure that the crosshead is in the lowest position and that the metal sup-port for the columns is fitted.

b. Fit a fibre sling around the top of the columns, below the metal support as shown in Figure 4-1. Ensure that adequate packing material is used to protect the columns.

c. Ensure that the crane or hoist is correctly positioned, and that the pivoting edges of the frame feet are chocked to prevent movement during lifting.

d. Raise the frame to the vertical position.

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Figure 4-1. Lifting a Two-Column Load Frame

TIE BAR MUST BE IN POSITION PRIOR TO

LIFTING AND TRANSPORTATION

YELLOW SAFETY COLLAR

CROSSHEAD CLAMP

CRANE OR HOIST MAXIMUM ANGLE OF

SLING 60°

USE EYE BOLTS FOR VERTICAL LIFTING ONLY. MAXIMUM

ANGLE OF SLING 60°

PROTECTIVE SOFT COLUMN PADS

METAL SUPPORT MUST BE IN POSITION PRIOR TO

LIFTING AND TRANSPORTATION


4-4

Four-Column Frames

In order to raise the frame, refer to Figure 4-2 and use the following procedure.

a. Ensure that the crosshead is in the lowest position, and that the column supports are fitted.

b. Fit the shackles to the crosshead lifting brackets and fit a lifting sling to the shackles as shown in Figure 4-2.

c. Ensure that the crane or hoist is correctly positioned, and that the pivoting edges of the frame feet are chocked to prevent movement during lifting.

d. Raise the frame to a vertical position.

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Figure 4-2. Lifting a Four-Column Load Frame

CRANE OR HOIST CAPACITY 1.5 x GROSS WEIGHT

ENSURE THAT METAL SUPPORTS FOR COLUMNS

ARE IN POSITION AS SHOWN.TO BE REMOVED UPON

INSTALLATION


4-6

Transporting the Frame using a Fork-Lift Truck

There are two methods of transporting the load frame when using a fork-lift truck, and both are described in this section.

Warning

Hazard - Do not allow the frame to become tilted at an angle greater than 10° when transporting across sloping or uneven surfaces.

Figure 4-3. Maximum tilt angle

10° MAXIMUM

TILT ANGLE

4-7

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Transporting the Frame on a Pallet

a. Construct or obtain a pallet which is slightly larger than the base of the frame.

b. With the frame standing in an upright position, use a crane or hoist to lift the frame onto the pallet.

c. Position the fork-lift truck to that the lifting forks can be inserted from the front of the frame.

d. Insert the forks fully under the pallet, and for stability pass a sling of soft fibre around the crosshead and secure it to the fork-lift truck as shown in Figure 4-4.

e. Raise the frame and transport it to the operating site.

Figure 4-4. Transporting the Frame on a Pallet

SLING TIED TO FORK-LIFT TRUCK

PALLET

10° MAXIMUM TILT ANGLE


4-8

Transporting the Frame with the Forks under the Crosshead

a. With the frame standing in the upright position, move the fork-lift truck so that the lifting forks can be inserted from the front of the frame.

b. Place soft padding material onto the forks of the truck to prevent any damage to the paint finish or to the logo on the crosshead.

c. Carefully insert the forks under the crosshead and, for stability, pass a sling of soft fibre around the crosshead and secure to the fork-lift truck as shown in Figure 4-5.

d. Raise the frame and transport it to the operating site.

Figure 4-5. Transporting the Frame with forks under the Crosshead

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The control system components are normally packed in the same crate as the load frame. However, this depends on the frame type and the number of accessories supplied.

Always ensure that all individually packaged items are removed from the main packing crate before making any attempt to lift the frame.

Hydraulic Power Supply M21-28800-70

4-10


Caution

Do not lift the hydraulic power supply with a crane or hoist when there is oil in the tank.

Do not use the motor lifting ring to lift the hydraulic power supply.

Type 3410

Remove the top and side panels of the packing crate and, using the lifting eyes located at each corner of the supply, and a four-sided frame lifting sling as shown in Figure 4-6, raise the hydraulic power supply and transport it to the operating site. Ensure that the sling does not make contact with any power supply component.

Type 3411

Remove the top and side panels of the packing crate and the hydraulic power supply. Using the lifting eyes mounted on the lower frame members and a four-sided lifting sling as shown in Figure 4-6, raise the hydraulic power supply and transport it to the operating site. Ensure that the sling does not make contact with any power supply component.

Type 3420

Four lifting eyebolts are fitted for handling purposes and when the shipping crate is dismantled and support packing removed, the pack may be lifted and positioned by using suitable slings and a hoist which must have a safe working capacity i.e. 1.5 x the gross weight of the hydraulic power supply.

Type 3470

The type 3470 hydraulic power supply is shipped upon an open wooden pallet and should only be handled using a fork-lift truck.

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Figure 4-6. Lifting the Type 3410 Hydraulic Power Supply

Hydraulic Power Supply M21-28800-70

4-12


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Air Cushion Isolators M21-28800-70

4-14

Air Cushion Isolators

The optional air cushion isolators must not be inflated without the weight of the load frame upon them. They are therefore supplied fitted to the load frame, but deflated for shipment.

When the frame is finally positioned at the testing site, they should be sequentially pressurised to an air pressure which must not exceed 6 bar (90 psi). The overall mount height between the frame foot and the floor should be 89 ± 6 mm (3.5 ± 0.25 in).

Caution

Deflate the air cushion isolators before moving the load frame.

If the load frame is subsequently moved, the air cushion isolators must first be deflated. They must be re-inflated after the move is complete.

5-1

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Chapter 5Essential Services

Outline

This chapter details the services required by the 8800 Series Testing System. These must be available at the operating site.

Note: All references to “gallons” refer to U.S. gallons (3.78litres), not U.K. gallons (4.54litres).

Electrical Power Supplies M21-28800-70

5-2

Electrical Power Supplies

Load Frame and Control System

Either 230V ± 10%, 50-60Hz single phase via a three pin connector fused at 13 Amps, or 115 V ± 10% 50/60Hz, single phase via a three pin connector, variable fuse rating.


220 V, 380 - 415 V or 460 V, 50 or 60 Hz dependent upon type, three-phase via an appropriate three-phase isolator.

Caution

The pump used is either a 50 Hz model or a 60 Hz model. Applying the wrong frequency voltage can damage the hydraulic power supply.

The following details on starting currents for hydraulic power supplies provide the user with additional information for ascertaining the correct cabling.

• Type 3410 all models, and Type 3420 12.5l/min model. Direct On-line. Surge currents may reach 6 x full load current for a very short period. Consult the local electrical regulations for details of wiring requirements. Soft-Start apparatus may be purchased.

• Type 3411 all models and Type 3420 24 l/min model. Off-load Star/Delta. Surge currents may reach 2.2 x full load current for a very short period. Consult the local electrical regulations for details of wiring requirements. Soft-Start apparatus may be purchased.

5-3

Electrical Power Supplies

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Impedance Requirements

Table 5-1 details the recommended maximum earth fault loop impedance for equipment supplies.

Note: When U0, the nominal voltage to earth (ground) is not 240 V, the tabulated impedance values must be multiplied by U0/240.

The above figures are based upon the IEE Wiring Regulations, Sixteenth Edition 1991, Table 41D. There are no comparable US standards, but the above values may be used as guidelines.

Voltage and Frequency Variations

Variations in the electrical power supplies to the testing system can cause problems such as dropped or lost data, resets, etc. Any variation in line voltage should be kept within ±10 %, free from noise and transients, while any variation in line frequency should be kept within ± 0.5Hz.

Table 5-1. Maximum Earth Fault Loop Impedance (Zs) for circuit supplying electrical equipment

Fuse Rating (Amps) Zs (Ohms)

6 14.10

10 7.74

16 4.36

20 3.04

25 2.40

32 1.92

40 1.41

50 1.093

63 0.86

80 0.60

100 0.44

125 0.35

160 0.27

200 0.20

Hydraulic Power Supplies M21-28800-70

5-4

Hydraulic Power Supplies

Table 5-2 details the standard hydraulic hose sets that are available from Instron.

Table 5-2. Hydraulic Hose Sets

Low-flow 3 metre hose set (25 l/min) Cat No 3450-035

Pressure Hose 96-1-1166 3/8 in bore

Return Hose 96-1-1103 0.5 in bore

Drain Hose 96-1-1166 3/8 in bore

Low-flow 3 metre hose set (45 l/min) Cat No. 3450-008

Pressure Hose 96-1-1102 0.5 in bore


Drain Hose 96-1-1102 0.5 in bore

Medium-flow 3 metre hose set (230 l/min) Cat No. 3450-009

Pressure Hose 96-1-1060 1 in bore



High-flow 3 metre hose set (500l/min) Cat No. 3450-010


Return Hose 96-1-1104 2 in bore



Pressure Hose 96-1-1167 3/8 in bore


Drain Hose 96-1-1167 3/8 in bore

5-5


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Table 5-3 details the hose thread end type for the hydraulic hose sets listed in Table 5-2.





Medium-flow 6 metre hose set (230l/min) Cat No. 3450-012

Pressure Hose 96-1-1065 1 in bore



High-flow 6 metre hose set (500l/min) Cat No. 3450-013


Return Hose 96-1-1105 2 in bore


Table 5-3. Hose Thread Ends

Hose Bore Thread End Type

3/8 in bore 9/16-18 JIC Female one end,male one end

0.5 in bore 3/4-16 JIC Female one end,male one end

0.75in bore 1 1/16-12 JIC Female both ends

1 in bore 1 5/16-12 JIC Female both ends

1.25 in bore 1 5/8-12 JIC Female both ends

1.5 in bore 1 7/8-12 JIC Female both ends

2 in bore 2 1/2-12 JIC Female both ends

Hydraulic Power Supplies M21-28800-70

5-6

Table 5-4 and Table 5-5 detail the hose fittings at the actuator manifold and at the hydraulic power supply.

If a hydraulic power supply is not ordered from Instron, a hydraulic oil supply of 207 bar (3000 psi) will be necessary. Instron can advise on flow rates required.

The oil temperature must not exceed 50 °C (122 °F), and the recommended filtration requirements are to ISO Contaminant Code 13/10 (U.S.) regulations, NAS Class 4, or Thermal Control Class 2 (U.K.).

When the hydraulic power supply is to be situated at a distance greater than 6 m (20 ft) from the load frame, steel pipe runs should be provided. Table 5-6 details

Table 5-4. SAE Hose Fitting to Actuator Manifold

Fitting Assembly Part Number

Actuator Manifold

Low-Flow Hoses Medium-Flow Hoses High-Flow Hoses

3 metre 6 metre 3 metre 6 metre 3 metre 6 metre

3340-03040 l/min

1477-1072 1477-1072 1477-1073 1477-1073 N/A N/A

3340-03180 /min

1477-1072 1477-1072 1477-1073 1477-1073 N/A N/A

3340-032230 l/min

N/A N/A 1477-1092 1477-1092 1477-1093 1477-1093

Table 5-5. SAE Hose Fitting to Hydraulic Power Supply(Types 3410 and 3411)

Fitting Assembly Part Number


Low-Flow Hoses Medium-Flow Hoses High-Flow Hoses

3 metre 6 metre 3 metre 6 metre 3 metre 6 metre

30l/min 1477-1076 1477-1076 1477-1077 1477-1077 N/A N/A

45l/min 1477-1076 1477-1076 1477-1077 1477-1077 N/A N/A

80l/min N/A N/A 1477-1077 1477-1077 N/A N/A

230l/min N/A N/A 1477-1078 1477-1078 1477-1079 1477-1079

5-7


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the minimum bore of the steel pipe, and the maximum length of the pipe run including the connecting hoses at either end. This is to ensure that the drain fluid back-pressure remains within limits.

Please contact your Instron Sales Office for details of extended run Pressure and Return line dimensions. These vary depending upon frame and hydraulic power supply configurations.

This table assumes that the hydraulic pump and the load frame remain at the same level. Contact Instron for technical advice where another configuration or a greater length of pipe run is required.

Table 5-6. Extended Drain Hydraulic Pipe Run Dimensions

Hydraulic Power Supply Flow Rate

l/min

Pipe

O.D. inches x SWG Bore inches Maximum length

metres (Total)

12.5 10.5 x 18 0.404 19

30 0.75 x 14 0.590 48

45 0.75 x 14 0.590 35

80 0.75 x 14 0.590 24

230 1 x 12 0.790 19

Water Supplies M21-28800-70

5-8

Water Supplies

Cooling Water Flow Rates

Table 5-7 and Table 5-8 show the various flow rates that are required for the different types of hydraulic power supplies.

Table 5-7. Cooling Water Flow Rate Requirements for Type 3410 and 3411 Hydraulic Power Supplies

Hydraulic Power Supply Delivery litres/min (gal/

min)

Cooling Water Flow Rateslitres/min (gal/min)

Water Temperature15 °C (59°F)

Water Temperature 25 °C (77°F)

45 (12) 37 (9.8) 43 (11.3)

80 (21) 67 (17.7) 108 (28.5)

230 (60) 110 (29) 170 (45)

Table 5-8. Cooling Water Flow Rate Requirements for Type 3420 Hydraulic Power Supplies


min)




12.5 (3.3) 11 (3) 30 (8)

25 (6.6) 12 (3.2) 25 (6.6)

Table 5-9. Cooling Water Flow Rate Requirements for Type 3470 Hydraulic Power Supplies


min)




23 (6) 11.4 (3) 13.2 (3.5)

38 (10) 15.1 (4) 25 (4.5)

77 (20) 37.9 (10) 37.9 (10)

5-9

Water Supplies

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Water Pressure

Caution

Do not use solenoid-operated water shut-off valves on the outlet side of the heat exchanges. They cause water hammer effects which may cause internal fractures of the hydraulic power supply, leading to water contamination of the oil.

The recommended water pressure is 2 bar (29 psi) to 7 bar (100 psi).

Water Quality

The efficiency of cooling of the hydraulic power supply oil system is highly dependent upon the quality of the cooling water supply. An analysis of the supply should be obtained from the local water supply authorities, particularly with regard to pH levels and the level of suspended solids. As a minimum standard, the pH level should be within 5.0 to 8.5, and filtration should be provided to screen suspended particles of 0.8 mm or above.

Ventilation M21-28800-70

5-10

Ventilation

Table 5-10, Table 5-11 and Table 5-12 are guides to the air circulation required to cool the hydraulic power supply motor when installed in an enclosed space.

Table 5-10. Types 3410 and 3411 Hydraulic Power Supply Ventillation Requirements


litres/min (gal/min)

Motor Rating kW Cooling Airflow m3/min

12.5 (3.25) 5.5 5.75

25 (6.5) 11 9.5

45 (12) 22.5 13

80 (21) 46.5 20

230 (60) 110 70

Table 5-11. Type 3420 Hydraulic Power Supply Ventillation Requirements

Hydraulic Power Supply Delivery litres/min (gal/min)

Cooling Airflow m3/min

12.5 (3.25) 2.48

25 (6.5) 3.21

Table 5-12. Type 3470 Hydraulic Power Supply Ventillation Requirements


litres/min (gal/min)

Motor Rating kW Cooling Airflow m3/min

23 (6) 11.2 8

38 (10) 18.3 11

77 (20) 37.3 17

5-11

Noise Levels

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Noise Levels

The noise levels of Instron hydraulic power supplies are measured at one metre from the supply. Table 5-13, Table 5-14 and Table 5-15 are typical noise levels only.

It is recommended that the hydraulic power supply is situated remotely from the actual operating location to minimise the nuisance from noise. If sound proofing is used, then it is essential that adequate ventilation is provided to keep the motor and power supply operating temperatures at the correct levels (refer to “Ventilation” on page 5-10). A minimum distance of 600 mm (24 in) of free floor space is required all around the hydraulic power supply to allow for installation and maintenance.

Table 5-13. Types 3410 and 3411 Hydraulic Power Supply Noise Levels

Hydraulic Power Supply Deliverylitres/min (gal/min) Noise Level dB(A)

45 (12) 79

80 (21) 83

230 (60) 95

Table 5-14. Type 3420 Hydraulic Power Supply Noise Levels


12.5 (3.3) 72

25 (6.6) 76

Table 5-15. Type 3470 Hydraulic Power Supply Noise Levels


23 (6) 75

38 (10) 75

77 (20) 80

Environmental Conditions M21-28800-70

5-12

Environmental Conditions

Consideration should be given to the environmental condition in which the testing system is operated or stored. Table 5-16 details the recommended environmental specification which should be complied with to ensure the correct operation of the system.

Table 5-16. Recommended Environmental Specifications

Parameter Specification

Operating Temperature 5 to 38 °C (41 to 100 °F)

Storage Temperature -3 to +50 °C (-22 to +122 °F)

Temperature Rate-of-change 2 °C (4 °F) per hour

Relative Humidity 10 to 90 % non-condensing

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