M10-94400-1
Issue C April 1995

InstronModel 4400
Universal Testing System

Operator’s Guide

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

© Copyright 1995 Instron Corporation

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Amendment Incorporation Record
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Amendment Incorporation Record
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Preliminary Pages

Materials testing systems are potentially hazardous.
Materials testing involves inherent hazards from highforces, rapid motions and stored energy. You must beaware of all moving and operating components which
are potentially hazardous, particularly the actuator in a
servohydraulic testing system or the moving crossheadin 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 toequipment or to loss of data.
Ensure that the test set-up and the actual test you will
be using on materials, assemblies or structures constitutes no hazard to yourself or others. Make full use of
all mechanical and electronic limits features. These aresupplied for your safety to enable you to prevent movement of the actuator piston or the moving crosshead beyond desired regions of operation.
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 gain a thorough understanding of the equipment by reading your instruction manuals and to always use good judgement.

vPreliminary Pages

M10-94400-1

Warning
Disconnect the electrical power supply before removing the covers to electrical equipment.
Disconnect the equipment from the electrical power supply before removing any electrical safety covers or replacing fuses. Do not reconnect the power source while
the covers are removed. Refit covers as soon as possible.
Disconnect power supplies before removing the covers to rotating machinery.
Disconnect the equipment from all power supplies before removing any cover which gives access to rotatingmachinery. Do not reconnect any power supply while
the covers 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 thecovers removed, ensure that all loose clothing, long hair,etc. is tied back. Refit covers as soon as possible.
Shut down the hydraulic power supply anddischarge hydraulic pressure before disconnecting 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 duringsystem operation and to prevent the hose from whipping
about in the event of a rupture.

viPreliminary Pages

Warning
Shut off the supply of compressed gas anddischarge residual gas pressure before disconnecting any compressed gas coupling
Do not release gas connections without first disconnecting the gas supply and discharging any residual pressure
to zero.
Use protective shields or screens if any possibility exists of a hazard from the failure ofa specimen, assembly or structure undertest.
Use protective shields whenever a risk of injury to operators and observers exists from the failure of a test specimen, assembly or structure, 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 theowner and the user of the equipment.
Protect electrical cables from damage andinadvertent disconnection.
The sudden loss of controlling and feedback signals
which can result from a disconnected or damaged cablecauses an open loop condition which 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 suspend cables overhead underexcessive strain. Use padding to avoid chafing where cables are routed around corners or through wall openings.

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M10-94400-1

Warning
Wear protective clothing when handlingequipment at extremes of temperature.
Materials testing is often carried out at non-ambient temperatures using ovens, furnaces 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 handlingequipment 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.
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 thegrips 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.

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Preliminary Pages

Warning
Do not place a testing system offline fromcomputer control without first ensuring thatno 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 offline from computer control. Before transferring to manual control, make sure that the control settings are suchthat unexpected actuator or crosshead movement cannot
occur.
Keep clear of the operating envelope of arobotic 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. Deactivate the robot before entering the envelope for any
purpose, such as reloading the specimen magazine.

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M10-94400-1

Table of Contents
Chapter

x

Page

1

Introduction
Outline .........................................................................1-1
Introduction ..................................................................1-2
About this Manual ...............................................1-3
Product Support ..................................................1-3
General Characteristics ...............................................1-4
Console Components ..................................................1-7
Front Panel ..................................................................1-8
Main Panel Section .............................................1-8
Display Panel Section .........................................1-10
Limits Panel Section ...........................................1-10
Crosshead Control Section .................................1-11
Internal Status Indicators ....................................1-12
Recorders ...........................................................1-12
Console Internal Functions ..........................................1-14
Central Processing Unit (CPU) ...........................1-14
Crosshead Control Function ...............................1-14
Load Sensor Conditioner ....................................1-14
Strain Sensor Conditioner...................................1-15
IEEE-488 Interface .............................................1-15

2

Specifications
Introduction ..................................................................2-2
Specifications...............................................................2-3

3

Installation
Outline .........................................................................3-1
General Considerations ...............................................3-2

Preliminary Pages

Table of Contents (continued)
ChapterPage

3

Installation (continued)
Console Connections...................................................3-3
Mounting the Console .........................................3-3
Attaching the Console...................................3-3
Mounting the Console Bracket ......................3-4
Connector Panel .................................................3-5
Installing Cables .................................................3-7
Cabling for Optional Equipment ..........................3-9
Cables...........................................................3-9
Analog Output Connector .............................3-9
Opening the Console ...................................................3-11

4

Function Of Controls
Outline .........................................................................4-1
Preliminary Considerations..........................................4-2
Function Of Controls....................................................4-3
Main Panel ..........................................................4-3
Display Section ...................................................4-12
Limits Section .....................................................4-14
Data Storage ...............................................................4-16
Nonvolatile Memory ............................................4-16
System Reset .....................................................4-16
Volatile Memory ..................................................4-16
Resident Test Program Overview ................................4-20
Self Test Routine .........................................................4-23
Self Test - Part 1 .................................................4-23
Self Test - Part 2 .................................................4-24
Self Test Result - No Failures .............................4-24

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Table of Contents (continued)
Chapter

xii

Page

4

Function Of Controls (continued)
Self Test Result - Failures ...................................4-25
Self Test Result Display ......................................4-25
Version Number ...........................................................4-31
Selecting Operating Units ............................................4-32
Switching Units ...................................................4-32
Operating Units for Self Identified Load Cells
and Load Frames................................................4-33
Operating Units for Non-Self Identified Load
Cells and Load Frames.......................................4-34
Area ...................................................................4-35
Energy Units .......................................................4-35

5

System Operation
Outline .........................................................................5-1
Operating Considerations ............................................5-2
Pretest Procedures ......................................................5-3
Turn Instrument On: Warm-up .....................................5-4
Self Test Routine At Power Up ....................................5-5
System Reset At Initial Power Up................................5-7
Load Calibration ..........................................................5-8
Overview ............................................................5-8
Electrical Calibration of Self Identifying
Load Cells ..........................................................5-9
Manual Calibration of Self Identifying
Load Cells ..........................................................5-10
Electrical Calibration of Non-Self Identifying
Load Cells...........................................................5-12

Preliminary Pages

Table of Contents (continued)
Chapter
5

Page

System Operation (continued)
Manual Calibration of Non-Self Identifying
Load Cells ..........................................................5-13
Load Weighing System Balance ........................5-15
Calibration And Balance Errors...........................5-16
Strain Calibration .........................................................5-18
Overview .............................................................5-18
Strain Operating Mode........................................5-18
Strain Gauge Extensometers..............................5-20
Electrical Calibration of Self Identifying Strain
Gauge Extensometers ......................................5-22
Manual Calibration of Strain Gauge
Extensometers ...................................................5-22
Extensometers - Operating Notes.......................5-25
Display Panel...............................................................5-26
Description ..........................................................5-26
Operation ............................................................5-26
Establish Gauge Length ..............................................5-28
Electronic Limits...........................................................5-30
Operating Notes - Limits Panel ...........................5-30
Operation ............................................................5-31
Set Crosshead Travel Limit Stops ...............................5-34
Set Crosshead Speed .................................................5-35
Crosshead Jog Control ................................................5-37
Area Compensation .....................................................5-38
Install Specimen ..........................................................5-42
Set Testing Area ..........................................................5-43
Run a Test ...................................................................5-45xiiiPreliminary Pages

M10-94400-1

Table of Contents (continued)
Chapter
6

xiv

Page

System Options
Overview......................................................................6-1
Introduction ..................................................................6-2
Strip Chart Recorder....................................................6-3
Description ..........................................................6-3
Specifications......................................................6-4
Power Requirements ....................................6-6
Installation...........................................................6-7
Operation ............................................................6-8
Pen Scaling...................................................6-8
Pen Calibration .............................................6-9
X-Y Recorder ...............................................................6-12
Description .........................................................6-12
Specifications......................................................6-13
Installation...........................................................6-15
Power Requirements ....................................6-15
Signal Input Connection................................6-15
Operation ............................................................6-16
Initial Setup ...................................................6-16
Calibration.....................................................6-19
Time Base Operation ....................................6-22
Normal Operation..........................................6-23
Printer ..........................................................................6-24
Description ..........................................................6-24
Installation...........................................................6-24
Operation ............................................................6-25
Printout Format ...................................................6-25
Printer Units ........................................................6-26

Preliminary Pages

Table of Contents (continued)
Chapter
6

Page

System Options (continued)
AC/DC Strain Conditioner............................................6-30
Specifications......................................................6-31
Installation...........................................................6-31
Operation ............................................................6-32
Preset Points ...............................................................6-34
Description ..........................................................6-34
Operation ............................................................6-35
Energy .........................................................................6-37
Description ..........................................................6-37
Operation ............................................................6-37
Cycle Counter ..............................................................6-39
Pip Control ...................................................................6-41
Air Kit Option ...............................................................6-44
Overview .............................................................6-44
Description ..........................................................6-44
Operation ............................................................6-45
Manual Operation .........................................6-46
Grip Control Function Operation ...................6-47
Pretension and Excess Tension Operation ...6-47
Automatic Start Operation.............................6-48
Automatic Release Operation .......................6-49
Set pretension Level .....................................6-49
Set Excess Tension Level .............................6-50
Time Delays ..................................................6-50
Continuous Pretension Testing .....................6-50

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Table of Contents (continued)
ChapterPage

7

Test Check List

8

Maintenance
Overview......................................................................8-1
Introduction ..................................................................8-2
General ...............................................................8-2
Special Maintenance Considerations..................8-2
Preventive Maintenance ..............................................8-3
Cleaning - Control Console.................................8-3
Error Messages ...........................................................8-4
Overview .............................................................8-4
Displaying Error Messages .................................8-4
Rear Panel Indicators ..................................................8-10
Rear Panel Indicators .........................................8-10
General .........................................................8-10
Power Supply Condition Indicators ...............8-11
Green Test LEDs...........................................8-11
Red Activity LEDs .........................................8-12
Red Latch Indicator LEDs .............................8-13
IEEE-488 Interface Indicators .......................8-14
Summary of Operating Sequence forRear Panel Indicators ..................................8-15
Fault Indications ..........................................................8-16

Appendix A Test Planning
Applications .................................................................A-2
Load Requirements .....................................................A-4
Selection Of Grips........................................................A-5

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Preliminary Pages

Table of Contents (continued)
ChapterPage

Appendix A Test Planning (continued)
Establishing Gauge Length..........................................A-7
Selection Of Testing Speed .........................................A-8
Strain Rate...................................................................A-9
Area Compensation .....................................................A-10
Description ..........................................................A-10
Determining Stress Range..................................A-11
Limitations Due To Load Cell Capacity ...............A-12
Chart Magnification......................................................A-14
Appendix B GlossaryxviiPreliminary Pages

M10-94400-1

List of Illustrations
FigurePage

1-1. Functional Block Diagram ............................................1-5
1-2. Control Console Front Panel ......................................1-9
3-1. Console Rear Panel Connectors .................................3-6
3-2. Rear Panel Cable Arrangement...................................3-8
3-3. Access to Interior of Console.......................................3-12
4-1.
4-2.
4-3.
4-4.

Main Panel...................................................................4-3
Display Section ............................................................4-12
Limits Section ..............................................................4-14
Console Section Numbers Assigned toMain Panel Display for Self Test Result ......................4-26
4-5. Coding of Display Results for Self Test Result ............4-27
4-6. Characters Displayed in Self Test Result....................4-27
6-1 Model 4400 X-Y Recorder Panel .................................6-17
6-2. Typical Test Curve with Preset Points..........................6-34
8-1. Rear Panel Indicators .................................................8-12
8-2. Closeup Detail of Console Status andFault Indicators ............................................................8-13

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Preliminary Pages

List of Tables
TablePage
3-1. Series 4400 Console Option Cables............................3-9
3-2 Analog Output Connector Pin Assignments ................3-10
4-1.
4-2.
4-3.
4-4.

Main Panel Functions ..................................................4-3
Display Section Functions ...........................................4-12
Limits Section Functions..............................................4-14
Variables and Functions in Nonvolatile
Memory........................................................................4-17
4-5. Control Console Sections ............................................4-26
4-6. Characters Possible in Self Test Result for
Each Digit of Main Panel Display.................................4-29
4-7. Operating Units for Self-Identified Load
Cells 4-33
5-1. Low Capacity Load Cells Calibration Data ..................5-13
5-2. Transducer Calibration/Balance Errors........................5-17
6-1.
6-2.
6-3.
6-4.
6-5.
6-6.
6-7.
6-8.

Strip Chart Recorder Supplies .....................................6-6
Recorder Line Voltage Selection .................................6-7
Calibration Signal for Load Cells .................................6-10
Recorder Supplies .......................................................6-14
Chart Speed Conversions............................................6-22
Strain Units Printout.....................................................6-26
Energy Units Printout...................................................6-27
Printout with Strain as Independent
Variable........................................................................6-28
6-9. Printout with Extension as Independent
Variable........................................................................6-28

xixPreliminary Pages

M10-94400-1

List of Tables (continued)
Table

Page

6-10. Example Pip Delay Values vs Test Speeds .................6-43
6-11. Air Kit Functions ..........................................................6-46
8-1.
8-2.
8-3.
8-4.

Sections of the Control Console ..................................8-5
Error Messages ...........................................................8-7
LED Error Codes for IEEE-488 Section Tests .............8-14
Fault Indications ..........................................................8-16

A-1. Gripping Techniques ....................................................A-6
A-2. Typical Testing Speed Ranges for Various
Materials ......................................................................A-8xx

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Frontispiece. Series 4400 Universal Testing System

xxii

Introduction

Chapter 1
Introduction
Outline•Introduction . . . . . . . . . . . . . . . . . . . . . . . . Page 1-2•

General Characteristics . . . . . . . . . . . . . . . Page 1-4•

Console Components . . . . . . . . . . . . . . . . . Page 1-7•

Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . Page 1-8•

Console Internal Functions . . . . . . . . . . . . Page 1-14

The Instron Series 4400 Universal Testing Instruments areelectromechanical systems employing the latest printed circuit board technology to provide a small, light and efficienttesting system. This manual describes the functions and operation of the Control Console. Other manuals include
Load Frame operating instructions for each of the Series
4400 systems and an IEEE Interface User’s Guide.
This chapter describes:
The features and functions of the Series 4400
Systems••

The physical layout of the system•

Some of the optional accessories available for thesystem1-1

Introduction

M10-94400-1

Introduction
The Instron Series 4400 Universal Testing Instrument isa materials testing instrument designed to test thestrength of a wide variety of materials. The system ismade up of a load frame, in which a specimen of thetest material is mounted, that applies a tension or compression load to the specimen, and a control console thatprovides the calibration, test setup, and test operating
controls. The control console is compact enough tomount directly on the load frame, eliminating the needfor a separate support table or workbench.
The Series 4400 Control Console includes an operator’s
front panel with controls that offer complete communications with the system through a numeric keypad, pushbutton selection switches and Liquid Crystal Displays(LCDs).
The Console front panel is divided into sections according
to functional groupings of controls. For example, a Main
section contains a numeric keypad and digital display fordata input, a Limits section sets up the electronic limits,
and a Display section contains LCD displays of real-timevalues of test parameters. These panel sections are described more fully later in this chapter.
Optional interfacing is available for an X-Y or a strip chart
recorder, a printer, and a programmable computer. These
options may be specified with your initial order or added
later to expand the capabilities of your testing system.

1-2

Introduction

The purpose of this manual is to provide a basic understanding of the Control Console and its principles of operation. It contains specifications, cable installation,
component and control descriptions, operating details
for both basic and optional features, and maintenance.
Appendices contain an introduction to materials testing
and a glossary of terms related to materials testing.

Introduction

About this Manual

In addition to this manual, there is also a manual covering the installation, maintenance, and parts list for theload frame. Accessories, such as the strip chart and X-Yrecorders, printer, and most grips and extensometers,come with their own separate instruction manuals.

Product Support
If you encounter any problems with using or maintaining your testing instrument, or if you want to order accessories or parts, you can obtain answers to yourquestions or place orders by calling Instron Service, using the list below:
In the United States:

1-800-473-7838

In Canada:

1-800-461-9123

In all other regions of the world:

Nearest InstronService Office

A listing of international Instron Sales and Service offices, including addresses and telephone numbers, canbe found on the back cover of this manual.

1-3General Characteristics

M10-94400-1

General Characteristics
The Series 4400 control system is made up of two major
subsystems: a crosshead drive and control system, thatapplies tensile or compressive loading to a specimen;
and a highly sensitive load weighing system, that measures the loading of a specimen. Figure 1-1 is a functional
block diagram showing the interfacing of these two systems, and the signal flow within the overall instrument.
During a test, results occur as tracked (instantaneous)values of load, extension and strain or, after a test, as
stored break and peak values of these parameters. Totalenergy and load and energy values at preset points arealso available as stored parameters. Several choices ofanalog and digital output devices are available as options for viewing and recording test results.
The control console provides control, data acquisitionand data readout functions for the load frame. All operations are directed by a microprocessor-based central
processing unit (CPU). The crosshead control network
allows programmable crosshead speeds and provides
digital control of the crosshead position. The operating
mode of the console data entry and readout functions
can be in English, metric or SI units, as selected by aswitch. A status indicator on the main panel shows thesystem of units selected.
The action of the moving crosshead during a test - stop,
return, or cycle - can be controlled manually by pushbutton switches, or automatically by the functions provided
by the Limits feature. These functions may be based on
the applied load, extension or strain, or to a detected
specimen break.
1-4

Introduction

General Characteristics

Figure 1-1.

Functional Block Diagram
1-5

General Characteristics

M10-94400-1

A CPU-controlled sensor conditioner in the load weighing system allows calibration and balance procedures tobe performed automatically, after you initiate them at
the front panel. The sensor conditioner provides both an
unranged analog and an automatically ranged digitalload signal output suitable for several types of optional
readout devices.
Optional readouts for test results include interfacing for
an X-Y recorder, a strip chart recorder, and an 80 character-width printer.
The console also has provisions for an IEEE-488 interface. This is a General Purpose Instrument Bus (GPIB)
which allows remote supervisory control of test procedures through a programmable computer.

1-6

Console Components
The Series 4400 Control Console contains a single
printed circuit board on which are mounted all of theelectrical components, including the front panel
switches and displays, and rear panel connectors.

Introduction

Console Components

The console printed circuit board is the interface for allconnections to the console. The interconnecting cablesfrom the load frame and load cell, and cabling from optional recorders, printers, and strain measuring devices
plug into connector locations on the rear of the board.
Since the console receives its electrical power from ad.c. power supply in the load frame, there is no need forbulky power supplies and cooling fans, and thus a compact size has been achieved.
The Console itself is mounted on the load frame bymeans of a special bracket. A friction locking device on
the bracket rides in grooves in the crosshead column covers on the load frame, allowing the console to be moved
to any convenient working height. The bracket is symmetrical, allowing the console to be mounted on either
the right-hand or left-hand column on the frame.
The main components of the control console are shownin Figure 1-2. Access to the interior of the console is described in Chapter 4.

1-7

Front Panel

M10-94400-1

Front Panel
The Front Panel (Figure 1-2) is divided into four major
sections. The Main section contains a numeric keypad
for data entry of system setup parameters, an LCD display for the numeric input, pushbuttons for such functions as crosshead speed selection, and gauge length
setting, among others. The Display section contains
LCD displays of real-time values of Load, Extension,and Strain, while the Limits section sets electronic limits
for the system. The last section is the Crosshead Control
section, in which manual controls for crosshead positioning are located.

Main Panel Section
The Main Panel section consists of test function entry
keys, a numeric keypad and a 4-digit LCD display.
Status indicators on the left-hand side of the panel, whenlit, signify that a fault has occurred. The current units(S.I., English, metric) in use by the testing system arealso shown in this area. The panel provides the following functions:• Load cell calibration

1-8•

Crosshead speed selection•

Gauge length•

Area compensation•

Testing area definition•

Strain transducer calibration•

Printer operation•

IEEE bus enable/disable•

Special Software - Diagnostics

Introduction

Front Panel

Figure 1-2.

Control Console Front Panel
1-9

Front Panel

M10-94400-1

Display Panel Section
The Display Panel section contains three 4-digit LCD
displays and control keys to allow load, extension, andstrain to be tracked during a test, and the peak and breakvalues of these parameters to be observed. All values arecomputed and saved at the end of each test and may beviewed as needed during and after the test. An indicator
lamp shows the active selection key.

Limits Panel Section
The Limits Panel section allows you to specify what action
the system takes when maximum and minimum values ofload, extension or strain occur during a test. The electronic
Limits function acts to protect valuable specimens, grips,
and test fixtures from the effects of crosshead overtraveland possible collision.
You should always set limits and assign a crosshead action before starting a test. Enter limits values using the
keypad and view them on the Main Panel Display.
Descriptions of the Limits Panel control functions arefound in Table 4-3.
The Limits Panel section allows a crosshead action to be
specified that is independently based on the following
limit conditions during a test:
LOAD - minimum, maximum
EXTENSION - minimum, maximum
STRAIN - minimum, maximum
BREAK - detection

1-10

Front Panel

STOP - stop crosshead at current position.
RETURN - return crosshead to gauge length.
CYCLE - change direction of crosshead motion at
the limit.
OFF - no action

Introduction

The action assigned to a limit can be:

An indicator lamp lights at the active limit and at the related crosshead action key. A STATUS indicator lamp is lit
whenever a limit is set to control a crosshead action. Whenever a STOP or RETURN action occurs as the result of alimit, the related STATUS lamp flashes.

Crosshead Control Section
The crosshead control keys, located at the bottom of the
Front Panel are used for manually controlling crossheadfunctions. The STOP, UP, DOWN and RETURN keys
each have an associated indicator lamp which is lit when
the function of the key, as described below, is controlling the crosshead.
STOP - crosshead stops.
UP - crosshead moves up at programmed speed.
DOWN - crosshead moves down at programmed
speed.
RETURN - crosshead returns at a speed which increases exponentially to maximum and then decreases exponentially to stop crosshead at gauge
length.

1-11

Front Panel

M10-94400-1

Internal Status Indicators
A series of Light Emitting Diode (LED) indicators aremounted on the circuit board inside the console, but are
visible through a window cutout in the rear panel. These
indicators report the condition of power supply voltages,
the pass/fail condition of some CPU functions during the
Self-Diagnostic Test, and on the activity of CPU circuits
during normal operation. Refer to Chapter 8, Maintenance, for a detailed description of the Status LEDs.

Recorders
You have a choice of using an X-Y recorder or a strip
chart recorder as a readout device. The X-Y recorder allows two test parameters, often Load versus Strain, to beplotted against each other. A strip chart recorder, on theother hand, plots one parameter versus time. Since crosshead speed can be converted directly into time, thespeed of the strip chart can be correlated with crosshead
speed and a plot of a test parameter, such as Load orStrain, versus crosshead speed can be obtained.
Load and strain ranging are performed at the front panelof the recorder itself. This allows you to select an operating range for each parameter from a predefined list ofgain factors. The operating range of the recorder is defined as the percentage of the maximum capacity of theinstalled load cell that causes a full scale reading on therecorder.
The specific recorders available for the Series 4400 Testing System are:XY/YT Plotter

1-12

Cat. No. 2310-901

Front Panel

Double Pen Strip Chart RecorderCat. No. 2310-905

Introduction

Single Pen Strip Chart Recorder Cat. No. 2310-904

1-13

Console Internal Functions

M10-94400-1

Console Internal Functions
In addition to the operator interface and cabling interface functions described previously, the console circuitboard provides a number of internal functions to complete the testing system. These functions include a Central Processing Unit (CPU), a Crosshead Control
function, a Load Sensor Conditioner, a Strain Sensor
Conditioner, and an IEEE-488 Interface function. These
functions are described in the following sections.

Central Processing Unit (CPU)The CPU is a computer chip that provides the main processing functions for the console. A digital bus originating in this section allows communication with andcontrol of all other operations, including optional interfacing for peripheral devices. Battery backup in this section allows nonvolatile parameter storage.

Crosshead Control Function
This function provides the interfacing between the load
frame and console for the crosshead control signals. The
encoder output signal provides crosshead position (extension) information that is conditioned and thecrosshead position (extension) determined by the functions in this section. An error signal is developed whenthe extension is compared with the commanded
crosshead speed and fed back to the crosshead drive system.

Load Sensor Conditioner

1-14This function provides interfacing between the loadtransducer (load cell) and the console. Functions that
this section supplies are excitation to a load cell, processing of its output signal, and providing calibrated analog
and digital load weighing information to the console andreadout devices.

Introduction

Console Internal Functions

Strain Sensor Conditioner
This function is located on an optional plug-in board andis similar to the Load Sensor Conditioner. It provides interfacing between strain measuring extensometers andthe console, and is available as an AC Strain Conditioner (Catalog No. 2210-863). This conditioner is usedwith strain gauge extensometers, rationalized long-travel
extensometers, and linear variable displacementtransducers (LVDTs). An AC/DC version (Catalog No.
2210-865) is used with video extensometers and highresolution digital (HRD) automatic extensometers.

IEEE-488 Interface
This function allows a Series 4400 testing system to be
remotely controlled by an external personal computer
through a General Purpose Instrument Bus (GPIB). This
microprocessor-based pc board interacts directly with
the CPU, thus enabling a supervisory program to control
console and load frame functions. The external computer must be able to transfer program messages to andreceive measurement messages and status from the test
instrument. Complete programming information is supplied with the IEEE-488 interface option kit.

1-15

Console Internal Functions

1-16

M10-94400-1

•Introduction . . . . . . . . . . . . . . . . . . . . . . . . Page 2-2•

Specifications. . . . . . . . . . . . . . . . . . . . . . . Page 2-3This chapter lists physical and electrical specifications
for the Series 4400 Control Console. Load Frame specifications and specifications for the system as a whole are
given in the load frame manual.

Specifications

Chapter 2
Specifications

2-1

Specifications

M10-94400-1

Introduction
The following table lists physical and electrical specifications for the Series 4400 Control Console. Specifications for the Load Frame and its components are givenin the load frame manual.
Since system specifications depend, to a large extent, on
the system transducers (load cell, extensometers, etc.) inuse, and the load capacity of the load frame, it is not possible to list system specifications for all possible combinations of load frames and transducers.
The generalized specifications in this chapter will help
you to determine whether your system will meet your individual testing requirements. If you have any questions
about specifications, your regional Instron Sales Engineer will be happy to assist you.

2-2

Specifications

Specifications
Main Panel
Display Panel
Limits Panel
Load Sensor Conditioner
RS-232 Interface
Options:
Strain Sensor Conditioner
IEEE-488 Interface
Strip Chart Recorder
X-Y Recorder
Printer

Specifications

Components
Standard:

Power Requirements+5 Vd.c.
+15 Vd.c.
-15 Vd.c.
(All voltages supplied from Load Frame, must be free of
spikes, surges, or sags exceeding 10% of the averagevoltage)
Operating Performance
Load Weighing Accuracy±0.01% of full scale or ±0.5% of reading (whichever isgreater) ±1 count on the load display.
Load weighing system meets or surpasses the following
standards: ASTM E4, BS1610, DIN 51221, ISO 7500/1,
EN10002-2, AFNOR AO3-501

2-3

Specifications

M10-94400-1

Strain Measurement Accuracy±0.05% of full scale or ±0.5% of reading (whichever isgreater) ±1 count on the strain display
Strain measurement system meets or surpasses thefollowing standards: ASTM E83, BS3846, ISO 9513,
EN1002-4
Environmental Requirements
Operating temperature:+10 to +38 °C (+50 to +100°F)(other ranges available on request)
Storage temperature:-40 to +60 °C (-40 to +140°F)
Relative Humidity:
10% to 90% non-condensing
Atmosphere:
Use in normal laboratory conditions.
Note:

2-4

Protective measures may be required if excessive dust, corrosive fumes, electromagnetic
fields or hazardous conditions are present.

Specifications

Structural foam
Cleanable mylar surface
with silicon rubber switches.

Dimensions
Height:Width:
Depth:

406.4 mm (16 in.)
280 mm (11 in.)58.2 mm (2.3 in.)

Weight2.7 kg (6 lb) approx.

Specifications

Materials
Enclosure:
Keyboard:

2-5

Specifications

2-6

M10-94400-1

Chapter 3
Installation•

General Considerations . . . . . . . . . . . . . . . Page 3-2•

Console Connections . . . . . . . . . . . . . . . . . Page 3-3•

Opening the Console . . . . . . . . . . . . . . . . . Page 3-11

This chapter contains instructions for installing the Series 4400 Console on the load frame and for cabling optional accessories. Installation instructions for the load
frame itself are contained in the load frame instruction
manual.

Installation

OutlineYou will use this chapter to find out how to:• Connect system cables•

Mount the Console•

Open the console for servicing

3-1

General Considerations

M10-94400-1

General Considerations
Installation of a basic Series 4400 testing instrument is
described in the load frame manual for the system. This
chapter describes how to access the interior of the console and install cabling for optional devices. The basic
cables, Load and Frame, are installed at the factory.
As part of the preparation for a testing routine, you
should connect any cabling required for peripheral readout and control accessories before powering up the system. These accessories include strain measuring devices,a recorder, printer and a computer. Any panels or circuitboards required to use these accessories have usually
been installed previously at the factory.

3-2

Console Connections

Console Connections
The Series 4400 Console is attached to a console mounting
bracket that is, in turn, mounted on one of the load frame
columns, either directly in grooves in the column cover (table models) or on an extension of the column cover (floor
models). On floor model load frames, the column cover extension can be mounted on either the right-hand or lefthand load frame column, specified at the time of purchase,but this can be changed later, if necessary. The console isattached to the mounting bracket with screws, and thebracket can rotate around a vertical axis to provide a comfortable viewing angle for the console.
Attaching the Console

Installation

Mounting the Console

The console mounting bracket is in two parts; a sliding
bracket that attaches to the load frame, and a pivot
bracket that attaches to the Control Console. A 15° tilt
bracket is also provided so that the console can be tilted
back from vertical for more comfortable operation.
Attach the console to the pivot bracket first, then attach
the pivot bracket to the sliding bracket. The whole assembly is then mounted on the load frame. Use the following procedure to assemble all parts:(a) Place the console against the pivot bracket, and alignthe mounting holes. (If you wish to use the 15° tilt
bracket, attach it to the console before attaching theconsole to the pivot bracket).

3-3Console Connections

M10-94400-1(b) Insert a socket head cap screw in each of the four
mounting holes and hand tighten.
(c) With all screws in place, tighten the screws evenly
until all are secure.
(d) Attach the sliding bracket to the pivot bracket using
the pins provided.
(e) Lightly tighten the thumbscrews (these will be tightened firmly when the console is mounted on the load
frame and a comfortable viewing position has been
selected).
Mounting the Console Bracket

To mount the console on the load frame column:(a) Place the console bracket against the side of the column (or column extension) so that the T-nuts of thefriction devices are in the grooves of the load frame
column cover.
(b) Slide the bracket up or down in the groove to a convenient height for comfortable operation. Tighten
both friction knobs by hand, but avoid over-tightening.
(c) Loosen the rotational securing screws and rotate thebracket to one of four positions for a comfortableviewing angle. Tighten the thumbscrews firmly, but
do not over-tighten.
(d) Go to the next section to install cables.

3-4

Console Connections

Connector Panel

TEST - Connector used by Instron Service personnel for testing the IEEE-488 interface. An IEEE-488
Service Test printed circuit board, which is available
only to service personnel, is required to run this test.
IEEE 488 - the connector for cabling from the IEEE
compatible digital interface to a programmable computer.

Installation

The connector panel for the Series 4400 Control Console (Figure 3-1) is located on the rear of the console
unit. The components on this panel are described below.
The load frame, load cell, strain channel and recorder cables connect directly to the console at connectors provided for the purpose. All of the connectors are standard
D-shell connectors.

RS-232 OUT - a connector used mainly for output
to a printer with an RS-232 interface capability. Can
also be used for other RS-232 devices.
FRAME - a connector for cabling between the load
frame and the control console.
STRAIN - a connector for cabling from a strain
measuring extensometer.
ANALOG OUT - the parallel outputs of the signals
used for recorder operation, made available for signal monitoring purposes on devices such as a recorder.
LOAD - a connector for cabling from the load celltransducer.

3-5Console Connections

Figure 3-1.

3-6

M10-94400-1

Console Rear Panel Connectors

Console Connections

POWER - the d.c. connector for control console
main power. The input voltage to the console is supplied from the load frame, where a d.c. power supply is located that provides d.c. power for the entire
system.
mm/IN/SI switch - a 3-position rocker switch forsetting the operating units (S.I., English, or metric)of parameters in the load and extension channels.

For Series 4400 systems, cabling to the console includes
cables for load frame interface, a load cell, an extensometer, and a d.c. power cable. In addition, options
such as a recorder, a printer and a computer also connect
to the rear panel of the console, using the cables provided with these options.

Installation

Installing Cables

To install cables:(a) Match the individual cables with their proper connectors on the rear panel of the console (see Figure 3-1).
(b) Press the cable connector into its mating connector
on the rear panel. Use a small screwdriver to insert
and tighten the cable connector screws. If you do not
do this, cables may fall off during a test.

Caution
Do not allow the cables to droop ina haphazard manner from the rearof the console.

3-7

Console Connections

M10-94400-1(c) When all cables have been connected, dress the cables
into the cable clips provided on the console mounting
bracket, as shown in Figure 3-2. This will ensure thatthe cables will not catch on the load frame, grips, or
testing fixtures while the crosshead is moving.

Figure 3-2.

3-8

Rear Panel Cable Arrangement

Console Connections

Cabling for Optional Equipment
CablesTable 3-1.
OPTIONALACCESSORY
X-Y Recorder
Strip Chart
RecorderExtensometers(all types)
Printer
Computer

Series 4400 Console Option Cables
CABLE ASSEMBLYCONSOLECONNECTOR

A570-26

ANALOG OUT

A570-26

ANALOG OUT(Supplied with
Extensometer)(Supplied with Printer)
144-1-35

Installation

For Series 4400 systems, a recorder, printer and computer connect directly to the rear panel of the console, using the cables provided with these options (see Table
3-1). The cables for load and strain measuring devices
plug into connectors on the devices themselves, as described in the system load frame manual. Thus, you usually will not have to open the console as part of theinstallation procedure.

STRAIN
RS-232IEEE

Analog Output Connector

The Analog Output connector on the rear panel of theconsole is used to connect to a chart recorder, a strip
chart recorder, or other data acquisition device. This connector is a 9-pin, miniature, female “D” connector, thathas the pin assignments shown in Table 3-2.

3-9

Console Connections

Table 3-2.

M10-94400-1

Analog Output Connector Pin Assignments

Pin Number

SignalMetal Shell

Chassis Ground

1

Load

2

Strain3

No Connection

4

Pip

5

Run

6

Analog Ground

7

Analog Ground8

Digital Ground9

No Connection

The pinout appears as follows, looking at the connector:
5 4 3 2 1
9 8 7 6
The Load and Strain output pin signals are ±10 volts,
relative to Analog Ground. +10 volts corresponds to tension full scale.
The PIP pin connection is an active low TTL signal relative to Digital Ground. The signal is driven by a contact
closure fed into the Pip Jack on the console.
The Run pin connection is an active high TTL signal
relative to Digital Ground. The signal goes high when atest is running.
3-10

Opening the Console

Opening the Console
Under normal conditions, it should not be necessary to
open the console. There are no user-serviceable components or adjustments inside the console case, but if itshould become necessary to check for loose internal connections or wiring, or to install an option board, you can
open the console as follows (also see Figure 3-3):

Do not remove covers from the console without first shutting off main
power and disconnecting the a.c.
power cable at the load frame.

Installation

Warning(a) Disconnect all cables to the rear of the console. Label all
cables before removing them for identification, if necessary.
(b) Remove the console from its mounting bracket by removing the three screws in the rear cover of the console.
(c) To open the console, remove six screws located on
the rear panel of the console.
(d) Place the console face down on a work surface. Liftthe rear cover off of the console.
(e) The main printed circuit board is attached to the backof the front panel with six screws. The keys and pushbuttons are part of three rubber stampings sandwiched
between the printed circuit board and the front panel. If
you are replacing a key or pushbutton, you must replace the entire rubber sheet containing that key.
3-11

Opening the Console

Figure 3-3.

M10-94400-1

Access to Interior of Console(f) Reassemble the console in reverse order of the steps
to disassemble. Be sure to replace all screws.
(g) Remount the console on its mounting bracket.
(h) Reinstall cabling removed in step (a). Be sure totighten all connector screws to prevent connectors
from falling loose during operation.

3-12

Chapter 4
Function Of Controls•

Preliminary Considerations . . . . . . . . . . . . Page 4-2•

Function of Controls . . . . . . . . . . . . . . . . . Page 4-3•

Data Storage. . . . . . . . . . . . . . . . . . . . . . . . Page 4-16•

Resident Test Program Overview . . . . . . . Page 4-20•

Self-Test Routine . . . . . . . . . . . . . . . . . . . . Page 4-23•

Version Number . . . . . . . . . . . . . . . . . . . . . Page 4-31•

Selecting Operating Units . . . . . . . . . . . . . Page 4-32

This chapter describes the function of front panel controls and how data resulting from a test is saved. It thendescribes the Self-Test routine and how you can use it tomake sure your system is operating properly. The chapter then describes how to select and change system operating units.

Function ofControls

Outline4-1Preliminary Considerations

M10-94400-1

Preliminary Considerations
The purpose of this chapter is to provide details of theoperational features of the Series 4400 Control Console,
so the application of each device and its purpose in thecalibration and operation of the system will be understood.
The operational capabilities of a Series 4400 testing instrument depend upon the installed options and the peripheral readout and control devices that have been
selected to be used with the system. Complete installation instructions are supplied with any option orderedlater to expand a system.
This chapter contains the function of all controls and indicators on the main panel that supply the operator interface to the instrument. Also included are descriptions of
the system data storage capability and self-test feature.

4-2

Function Of Controls

Function Of Controls

Figure 4-1.
Table 4-1.
CONTROL or
INDICATOR
Numeric Keypad

Main Panel

Function ofControls

Main Panel

Main Panel Functions
FUNCTION(a)Numeric Keys, 0 through 9, allow entry of:
1. Value of calibration signal for manually calibratransducers.
2. Desired crosshead speed.
3. Area compensation value.
4. Maximum and minimum electronic limits forload,extension, and strain.
5. Preset points.

4-3

Function Of Controls

Table 4-1.
CONTROL or
INDICATOR
Numeric Keypad(continued)

M10-94400-1

Main Panel Functions (continued)
FUNCTION(b) +/- key defines the values of load, extension,and strain as + for tension testing and - for compression testing. This key is also used when entering the electronic limits.
(c)REJect key allows the rejection of an incorrect
input on keypad before pressing ENTER key.
(d)ENTER key must be pressed to change any
system variable entered on keypad or to complete a transducer calibration or balance.

4-4

Display

A 4-digit display used to view system variables in therange from .0001 to .9999. “EEEE” is shown if an
overflow of the display register occurs. A “——” is shown
when the system is uncalibrated and no valid data canbe read. “LOSS” is shown if the non-volatile memory is
reset to a default state. All keypad entries (0-9, +/-) areread on this display.

AT G.L.

Gauge length indicator LED is lit whenever crosshead is at
gauge length. Lamp flashes when power is initially turnedon, or a momentary power loss occurs to indicate a loss ofgauge length information. Pressing G.L..RESET key ormoving crosshead by pressing UP, DOWN, RETURN or
JOG stops the flashing.

G.L. RESET

Gauge length reset key, when pressed, causes current
crosshead position to be entered as the gauge length. Also,
any EXTENSION readout will be set to zero. Pressing thiskey causes the AT G.L. LED to stop flashing.

Function Of Controls

Table 4-1.
CONTROL or
INDICATOR
AREA
SET
≠1

Main Panel Functions (continued)
FUNCTION
Enables an area compensation circuit which divides both
displayed load value and output voltage to a recorder by
a set value between 1.000 and 9.999. When this key ispressed, the SET LED lights and an area value can beentered on the keypad.

TESTING AREA
BELOW XHEADABOVE XHEAD

Defines the location in the load frame (above/below
crosshead) to be used for specimen testing. Thisfunction is necessary for the proper operation of cycling
limits and pneumatic grips. To change this function, theS1 key must be enabled and “SL” must be on the Main
Panel Display (refer to SI KEY description). The BELOWXHEAD or ABOVE XHEAD LED lights to indicate theselection.

SPEED

Allows a desired crosshead speed to be entered on the
numeric keypad. If the load frame has not been
identified, the display will show “——” when this key ispressed.

LOAD CAL

Initiates a load cell calibration procedure. The LOAD
CAL key LED is lit during calibration or when a load
calibration relay is closed. A flashing LED indicates acalibration error. A test cannot be started during acalibration procedure, and calibration is locked out
during a test.

Function ofControls

After the ENTER key is pressed, if the value of area
compensation is other than 1.000, the ≠1 LED lights andthe SET LED stays on. Area compensation is
temporarily set to 1.000 during a load cell calibration
procedure. The default value of area compensation is
1.000.

4-5

Function Of Controls

Table 4-1.
CONTROL or
INDICATOR

Main Panel Functions (continued)
FUNCTION

LOAD BAL

Sets a load cell balance, or zero, during a calibration
procedure or when balancing out the tare of grips andfixtures before starting a test. The LOAD BAL key LED islit during a balance operation or if a load calibration relay
is closed. A flashing LED indicates a calibration orbalance error. A test cannot be started during a balance
operation, and the balance function is locked out during
a test.

STRAIN CAL

Initiates an extensometer calibration procedure. The
STRAIN CAL key LED is lit during calibration or when an
extensometer calibration relay is closed. A flashing LED
indicates a calibration error. A test cannot be started
during a calibration procedure, and calibration is locked
out during a test.

STRAIN BAL

Sets an extensometer balance, or zero, during acalibration procedure or when balancing out the tare ofgrips and fixtures before starting a test. The STRAIN
BAL key LED is lit during a balance operation or if a load
calibration relay is closed. A flashing LED indicates acalibration or balance error. A test cannot be started
during a balance operation, and the balance function islocked out during a test.

METRIC

Status indicators that show the operating units for theload and strain channels. The indicator that is lit shows
the current status of the units, as determined by the
positioning of a switch mounted on the rear connector
panel of the console. The selection of units determines
the scaling of displays and the input to a recorder. Afterswitching units, the Main Panel display will show
“LOSS”, indicating that nonvolatile memory is reset tothe default state and stored test data is lost. Load andstrain channels must be recalibrated and all electronic
limits reset.

ENGLISHSI

4-6

M10-94400-1

Function Of Controls

CONTROL or
INDICATOR

Main Panel Functions (continued)
FUNCTION

LOAD

Fault indicator that lights when a load overrange (102%or greater of load cell maximum capacity) occurs. The
crosshead stops and the indicator flashes until theoverload is cleared by pressing the UP or DOWN key ora JOG key on the load frame, whichever direction
decreases the measured load.

TRAVEL

Fault indicator that lights when the overtravel limits forthe moving crosshead are actuated. The crosshead is
stopped when this indicator is lit.

MOTOR

Fault indicator that functions as described below. This
indicator is lit steadily for the following conditions:
1. Motor drive enabling sequence (5 sec. duration).
2. Motor drive cannot be enabled.
3. Load frame cannot be identified.
4. Load frame power supply failure.
5. Crosshead second level travel limit tripped.
6. Emergency stop switch tripped.
This indicator flashes for the following conditions:
1. Drive motor overheats.
2. Drive loop failure (stall, etc.)
The MOTOR status indicator will remain on (steady or
flashing) after the condition/fault is cleared, except after the
5-sec motor drive enable sequence. Perform the key
sequence [S1] [1] [ENTER] to restore the indicator tostandby (off) condition.

TIMER

Function ofControls

Table 4-1.

Fault indicator that lights when the CPU malfunctions and a
special circuit shuts off the crosshead drive motor. Usually,
momentarily shutting down the system power clears thiscondition. This LED also lights if the +/- 15 Vd.c. console
power supply fails.

4-7

Function Of Controls

Table 4-1.
CONTROL or
INDICATOR

M10-94400-1

Main Panel Functions (continued)
FUNCTION

POWER

Fault indicator that lights if a momentary power failure
occurs. Momentarily shutting down system power clears
this condition.

PRINT

Obtain a printout of the current test at any time, or a
printout of the last test when no test is running.

IEEE

Status indicator that is lit when an IEEE-488 option is set
to receive keyboard commands from an external
computer. The indicator does not light if the IEEE option
is not installed.

S1

Enables or disables system options, as follows:(a)System reset option - clearing of nonvolatilememory. Press S1, then 0 and ENTER on keypad.
This sequence clears the nonvolatile memory,setting all variables to a default state, and thereby resetting the system to a known condition.
Also, any previously stored data will be lost. The
Main Panel Display will show “LOSS” after this typeof reset key sequence is entered.
(b)System reset option - no clearing of nonvolatilememory. Press S1, then 1 and ENTER on the keypad. This sequence is a“warm restart” of thesystem which is used to to reset certain fault
conditions, without resetting nonvolatile memory to
the default state; that is, all previously enteredparameters will remain in storage. An exception iswhen this sequence is used to enable a change insystem operating units.

4-8

Function Of Controls

CONTROL or
INDICATOR
S1Main Panel Functions (continued)
FUNCTION(c) Diagnostic Monitor - Press S1, then 2 and ENTER
on keypad. This sequence initiates the diagnostic
troubleshooting routine which is part of the Resident Test Program for the Series 4400 console(refer to Resident Test Program for details andexiting procedure).
Note
The Diagnostic Monitor feature should be used byqualified maintenance personnel only.
(d) Energy option - press S1, then 3 and + /- on the
keypad. With an optional printer installed, this sequence provides an energy printout after a test.
The Main Panel Display must show “SL 3" for thisoption to be enabled, and”SL-3" to be disabled,which is the default condition. The key sequence[S1] [3] [ +/- ]...[ +/- ] toggles between these two
conditions. (See Item (g) below for the selectionof the Energy Integration Variable.)

Function ofControls

Table 4-1.

(e)Preset Point option - press S1, then 4 and +/-. Thissequence provides a printout of load and energy
at three preset points (PPT1, PPT2, PPT3) versus an
independent variable after a test. These values
can be used to determine modulus of elasticity.
(See Item (f) below for the selection of independent variable.) The Main Panel Display must show
“SL 4" for this option to be enabled and ”SL-4" to bedisabled, which is the default condition. The key
sequence [S1] [4] [ / ]...[ / ] toggles between
these two states.

4-9

Function Of Controls

Table 4-1.
CONTROL or
INDICATOR
S1(continued)

M10-94400-1

Main Panel Functions (continued)
FUNCTION(f) Set Preset Point Values - if the values of the Preset
Points (PPT1, PPT2) are to be other than the default values as shown in Table 4-5, then the following key sequences are used to enter new values(where PPT1 and PPT2 are indicated, enter theactual numerical value on the keypad of the
independent variable: Extension in inches or millimeters, or strain in percent):[S1] [41] PPT1 [ENTER][S1] [42] PPT2 [ENTER][S1} [43] PPT3 [ENTER](g)Select Energy Integration Variable and Preset
Points Independent Variable - the key sequence[S1] [5] [ / ]...[ / ] toggles the selection of energy
and preset points variable between Extension
and Strain (that is, the active strain channel). The
Main Panel Display will show “SL 5" for Extensionand ”SL-5" for Strain. The default variable is Strain,
if this option is installed. If Strain is not installed,then Extension is the default variable.
(h)Autoprint option - press S1, then 6 and + /- on
keypad. With an optional printer installed, thissequence provides an automatic printout eachtime a test ends. The Main Panel Display mustshow “SL 6" for this option to be enabled, and”SL-6" to be disabled (continued) which is thedefault condition. The key sequence [S1] [6][+/- ]...[+/-] toggles between these two conditions.
(i) TESTING AREA enable - press S1, “SL” will show on
the Main Panel Display and the TESTING AREA
function can be changed.

4-10

Function Of Controls

CONTROL or
INDICATOR
S1(continued)

Main Panel Functions (continued)
FUNCTION(j) Air Kit Option – provides automatic grip control
for pneumatic grips. The key sequence [S1][7][+/–]
enables or diables grip control, and the Main Panel
Display shows “SL 7 when enabled and ”SL–7"
when disabled. The key sequence [S1][7][n][+/–],
where “n” is a number between 1 and 4, or[S1][7][v], where “v” is a value entered at the keypad, enables or disables various options underautomatic grip control and sets values for Pretension or Excess Tension Levels (see Chapter 6 fordetails).
(k) Miscellaneous[S1] [8] [+/–]
Cycle Counter Printout[S1] [8] [1]
Cycle Limit[S1] [8] [2]Enter Pip Delay Value[S1] [8] [3]Display Cycles/Pip(l) Firmware Date - [S1] [9] [ENTER] displays the date
the firmware installed on this system.
(m) Cycle Count Display - [S1] [+/–] displays the cycle or pip count in the setup display.

UP
DOWN
STOP
RETURN

Function ofControls

Table 4-1.

The pushbutton switches (keys) used for manuallycontrolling the crosshead. Each key has an LED that is
lit when the function of the key is active.
STOP - crosshead stops.
UP - crosshead moves up at programmed speed.
DOWN - crosshead moves down at programmed
speed.
RETURN - crosshead returns at a speed that
increases exponentially to maximum and thendecreases exponentially to stop the crosshead atgauge length.

4-11

of

Function Of Controls

M10-94400-1

Display Section

Figure 4-2.
Table 4-2.
CONTROL or
INDICATORLOAD
DISPLAY

EXTENSIONDISPLAYSTRAINDISPLAY

TRACK

4-12

Display Section

Display Section Functions
FUNCTION

A 4-digit display which indicates + and - values of load
between .0001 and 9999. The display shows “——” when
the load cell is uncalibrated; is blank without data; andshows “EEEE” when overranged.
A 4-digit display which indicates + and - extension values
between .0001 and 9999 from gauge length. The display
shows “——” if the load frame has not been identified,and is blank if no data is available.
A 4-digit display which indicates strain values between.0001 and 9999. The display shows “——” if the strain
channel is not calibrated, “EEEE” if it is overranged, andis blank if strain is not installed or no data is available.
Sets the displays to show instantaneous values of load,
extension and strain. The displays are updated every 300
msec during a test. The TRACK LED is lit when this key
is active. (Peak and break values are recorded eventhough tracking is active.)

Function Of Controls

PEAK

BREAK

PEAK
BREAK

RESET PEAKS

Display Section Functions (continued)
Sets the displays to show load, extension and strain
values that occur at the peak load during a test. These
values are held on the display at the end of a test. Whena test begins, the displays show current tracking values
until a “peak” load is reached. The PEAK LED is lit when
this key is active.
Sets the displays to show load, extension and strain at
specimen break, where break is defined as just prior to
break detection. When a test begins, the displays areblank and remain blank until the break criteria is met. The
BREAK LED is lit when this key is active.
Sets the LOAD display to show the peak load value for atest and the EXTENSION and STRAIN displays to show
values that occur at specimen break. The LED at this key
is lit when the key is active.
This key is used during a test to reset the stored peakvalues of load, extension, and strain to the values at thecurrent load. The peak storage is then continuously
updated to the values at the next peak load that occurs
during the remainder of the test. This key does notchange which values are selected to be displayed(Break, Peak, or Track) and it is functional only when atest is in progress.

Function ofControls

Table 4-2.

4-13

Function Of Controls

M10-94400-1

Limits Section

Figure 4-3.

Table 4-3.
CONTROL or
INDICATORLOAD MAX/MIN
EXTENSION MAX/MINSTRAIN MAX/MIN
BREAK

OFF
STOP
RETURN
CYCLE

4-14

Limits Section

Limits Section Functions
FUNCTION

Electronic limits which permit an action to be
independently assigned to the maximum and minimum
values of load, extension or strain, or to detect break. An
LED to the left of each key lights when the key ispressed. This shows that the key has enabled thenumeric keypad and a limit value can be entered andviewed on the display (except BREAK, as this has an
unknown numeric value). If the Recorder is installed, the
STRAIN limits are functional only if STRAIN is selected
for the X-axis of the X-Y recorder.
Crosshead actions that can be selected to occur at theelectronic limits. The actions are:OFF - no action
STOP - stop crosshead when limit occurs
RETURN - return crosshead to gauge length
CYCLE - change crosshead travel direction
Whenever a limit key LED is lit, a CROSSHEAD ACTION
key LED is lit also. To change the action, press a different
key.

Function Of Controls

STATUS
LEDs

Limits Section Functions (continued)
A rectangular STATUS LED is located to the right of the
BREAK key and one each between the LOAD,
EXTENSION, and STRAIN MAX/MIN limit keys. When alimit or break detection is selected to cause a crossheadaction (except OFF), the related STATUS LED lights.
When either a STOP or RETURN action occurs, the
STATUS LED will flash and stay flashing until recycled bystarting a new test.
If the current value of load, extension or strain is beyond
the assigned limit ranges, then the crosshead control key(UP or DOWN) which would increase the out-of-range
error is disabled. If this disabled key is pressed, thecrosshead will not move and the related limit status LED
flashes. The flashing continues until the enabled key (UPor DOWN) is pressed and the crosshead is moved in a
direction to decrease the out-of-range error.

Function ofControls

Table 4-3.

4-15

Data Storage

M10-94400-1

Data Storage
Nonvolatile Memory
The data storage capability of a Series 4400 control console includes a nonvolatile memory; that is, data remains in storage, even though main power is removed,
due to battery backup. The retention period of the nonvolatile memory, with a fully charged battery, is up toninety days without refreshing.
The variables and system functions stored in nonvolatilememory are shown in Table 4-4. Listed in the table is thedefault value or condition of each variable or function.
These default values are restored whenever the system isreset by the key sequence described below.

System ResetTo reset the system, press S1 on the Main Panel, thenpress 0 and ENTER on the keypad. The nonvolatilememory will be cleared, including data from a previous
test, and all variables, limits and system functions will
be reset to their default values, as shown in Table 4-4.
The Main Panel Display will show “LOSS”.

Volatile Memory
The following variables or system functions are volatile; thatis, the value of the variable or function condition will be restored to a default state whenever main power is removed:

4-16

Data Storage

Variables and Functions in Nonvolatile Memory

VARIABLE or FUNCTION

DEFAULT VALUE or CONDITION

Crosshead Speed

0

Area

1.000

Calibration (Both Zero and Scale)

Uncalibrated

Testing Area

BELOW XHEAD

Peak/Track/Break

TRACK

Load Limit Action(Both MAX and MIN

0/OFF

Extension Limit Action(Both MAX and MIN)

0/OFF

Strain Limit Action(Both MAX and MIN

0/OFF

Break Action

OFF

Break Storage
LD, EX, SN, EN

0 (Blank display)

Peak Storage
LD, EX, SN, EN

0 (Blank display)

Preset Points
Extension (in.)
Extension (mm)Strain (%)

PPT1
1
20
100

Function ofControls

Table 4-4.

PPT2
3
60
300

PPT3
10
200
1000

4-17

Data Storage

Table 4-4.

M10-94400-1

Variables and Functions in Nonvolatile Memory(continued)

VARIABLE or FUNCTION

4-18

DEFAULT VALUE or CONDITION

Preset Points Independent
Variable

Strain (active channel)

Energy Independent Variable

Strain (active channel)

Autoprint Option

Disabled(Reenter S1 - - - sequence)

Preset Points Printout

Suppressed(Reenter S1 - - - sequence)

Energy Printout

Suppressed(Reenter S1 - - - sequence)Data Storage

The tracked variables are never stored, but are updated
every 50 milliseconds during a test.

Function ofControls

The Gauge Length will also default to present crosshead
position whenever main power is removed.

4-19

Resident Test Program Overview

M10-94400-1

Resident Test Program Overview
The Series 4400 control consoles contain a Resident
Test Program which is a feature designed to provide support for several levels of automatic testing of the console. This test program includes a Self Test Routine, aCyclic Self Test and a Diagnostic Monitor.
Note:

The Self Test Routine is a basic test intended
to inform you of the operational status of thesystem console, and is fully described in
Chapter 5. The Cyclic Self Test and Diagnostic
Monitor are intended for use by qualified maintenance personnel as troubleshooting aids, so
this section provides only a brief description ofthese features.

The Self Test Routine is performed automatically whenmain power is applied to the system. Its purpose is toprovide you with an initial survey of the operating condition of the console. It tests the console hardware and prevents the startup of normal operation if there are failureson the basic circuit board in the console.
When main power is applied to the Series 4400 system,
all lamps (LEDs) on the front panel of the console lightand all displays (LCDs) show a number. This action
lasts several seconds and allows you to make a visualcheck of these functions. After the first part of this test,
the Main Panel Display shows a coded number which indicates the operational status of the major functional sections of the console. The coded number also indicates
whether an option is installed or not.

4-20

Resident Test Program Overview

If all circuit boards pass the self test, the coded number
disappears and normal operation can begin. If not, the resulting number on the Main Panel Display remains andonly a continuation of the Resident Test Procedure canbe run.

The Cyclic Self Test is identical to the Self Test Routine
previously described, except that it is continuously repeated. Its purpose is to assist in locating intermittent
failures by long term testing of the console functions.
When the test is stopped, all failures occurring during
the running period can be identified by interpreting theresulting number that appears on the Main Panel Display.
Note:

The Cyclic Self Test is for use by qualified
maintenance personnel. If it is started accidentally (by pressing S1 twice when the Self Test
Routine number is displayed), it can be exited
to resume normal operation, if there are no
failures, by pressing ENTER on the keypad
whenever the Self Test number is again displayed.

Function ofControls

If an installed optional board contains severe faults, as
determined by the Self Test, it may be shown as not installed, thereby permitting normal operation to begin. A
board designated as not installed by the Self Test is also
considered absent by the operating program and its associated features are disabled.

The Diagnostic Monitor is the main troubleshooting
mode of the Resident Test Program. It provides interaction with console circuits via front panel controls, and al-

4-21

Resident Test Program Overview

M10-94400-1

lows a detailed list of errors to be scanned which can directly indicate component failures.
Note

The Diagnostic Monitor is for use by qualified
maintenance personnel, but limited use is described in Chapter 9 for the readout of error
messages.

If the Diagnostic Monitor mode is entered accidentally(by pressing S1 once when the Self Test Routine
number is displayed, or by pressing S1 then [2] on the
keypad during normal operation), the word HELP willappear on the Main Panel Display. This mode can be exited to resume normal operation, if there are no failures,by either pressing REJ (Reject) or by the following procedure:
Press S1 to enter the Cyclic Self Test, wait until the Self
Test result number is displayed, then press ENTER on
the keypad.

4-22

Self Test Routine

Self Test RoutineThis section provides information about the automatic
self test feature of the Series 4400 console.

Self Test - Part 1
Apply main power to the console using the system
power switch on the loading frame. Within 2 seconds,
all front panel LEDs light at the same time, including
the status indicators and the crosshead control panel
switch LEDs. Also, at the same time, all front panel displays (LCDs) show the following numeric coding for 5
to 10 seconds.

Function ofControls

The Self Test Routine consists of two parts as describedin this section. It is initiated when power is applied tothe control console, and cannot be bypassed. The purpose of the Self Test Routine is to assure that the console performs reliably before allowing normal operation(also refer to the Calibration Overview, page 5-8). The
duration of the self test is only several seconds, and it requires no operator input or interaction other than observation of the results of the two-part sequence. If there
are no failures indicated, normal operation can start immediately after the test.

-1.8.8.8.8
During this first part of the self test, you should scan thepanels and check that all LEDs light and all LCDs display the proper number. If service is required, report theexact condition.

4-23

Self Test Routine

M10-94400-1

Self Test - Part 2
After the first part of the Self Test Routine, all LEDs turnoff and the LCDs become blank. This condition persistsfor 2 to 5 seconds. During this second part, you should
again scan the panels and check that all LEDs go off and
LCDs are blank. DO NOT press any of the crosshead control switches, as a short circuit test occurs during this part.
When the Self Test Routine has been completed, the Main
Panel Display shows a four-digit test result, as described in
the Section “Self Test Result Display”. All other LCDs
should be blank and LEDs should be off, except as described in the operating procedures of Chapter 6.

Self Test Result - No Failures
The four-digit test result, which appears on the Main Panel
Display after the Self Test Routine, disappears after about
5 seconds if no board failures are detected. Normal system
operation can then begin, as described in Chapter 6. Also,
operation can begin more quickly, if desired, by pressing
ENTER on the keypad before the test result disappears.
The REJECT and S1 keys are active when the test result
is displayed, but would not normally be used at thistime. Pressing REJECT recycles the Self Test Routine,and pressing S1 activates the Diagnostic Monitor whichshould be used only by qualified maintenance personnel.
In the case of no failures, the test result is useful only indetermining what optional circuit boards are installed in
the console. This can be interpreted from the descriptionof the test result in Section “Self Test Result Display”. If
this information is necessary, record the test result at this
time.
4-24

Self Test Routine

Self Test Result - Failures
When failures have been detected during the Self Test,
the test result shows on the Main Panel Display. However, normal operation cannot be started and pressing
ENTER on the keypad has no effect. Record the test result, as it provides important service information.

It is possible that no failures will occur when the Self
Test Routine is rerun, but a failure on the first run indicates a possible marginal condition which you should report.
Pressing the S1 key will activate the Diagnostic Monitor
which is used to further investigate the cause of any failures detected during the self test. This mode should be
used only by qualified maintenance personnel.

Function ofControls

In the case of failures, where one or more bad circuitboards have been found, only two keys are active on thefront panel of the console, REJECT and S1. If you press
REJECT, the Self Test Routine restarts in the same manner
as if main power was switched off and then on. (An exception to this is the POWER and TIMER indicators. If these
LEDs were lit before recycling the self test, then retesting
can occur only if main power is switched on and off.)

Self Test Result Display
The four-digit test result, displayed at the end of the Self
Test Routine, is designed to show the three possible conditions of the one main and two optional circuit boardsin the control console (refer to Table 4-5). These conditions are 1) Good, 2) Bad or, in the case of options, 3)
Not Used. This application of the Main Panel Display isdone by addressing each segment of the LCD figures.
4-25

Self Test Routine

M10-94400-1

1

6

7

8

2

3

4

5

Figure 4-4.

Console Section Numbers Assigned to Main
Panel Display for Self Test Result
Each half of each digit in the display represents a functional section in the console. The top halves are assigned
to optional sections and the bottom halves to basic sections (except Nos. 4, 7, and 8), as shown in Figure 4-4.
The numbers in each digit correspond to the listing in
Table 4-5.

Table 4-5.

Control Console Sections

Section No.

Functional Name

Basic or Option

1
2
3
*4
5
6
*7
8

IEEE-488 Interface
Central Processing Unit (CPU)
Crosshead Control(Not Used)
Load Sensor Conditioner
Strain Sensor Conditioner(Not Used)(Not Used)

OptionBasic
Basic-BasicOption––*Section No. 4 is not included in the Resident Self Test feature. It always shows in the Self
Test as “good” even though this section is not used. Sections 7 and 8 will always show as“Not Used”.

4-26

Self Test Routine

The method in which each half digit of the display iscoded to represent a functional section condition is bydeleting a segment of the digit for a “good” or “bad” indication, or by displaying all segments if a section is not
used. This is shown in Figure 4-5.

BAD

GOOD

Figure 4-5.

NOT
USED

Coding of Display Results for Self Test Result

Function ofControls

As a result of the coding, the four digits in the display
can be one of the characters shown in Figure 4-6 (an exception is shown in Table 4-6).

Figure 4-6.

Characters Displayed in Self Test Result

Table 4-6 shows all of the possible characters that could
appear in each digit of the 4-digit Main Panel Display.
Any combination of these characters could make up the
Self Test Result. Table 4-6 also indicates, within eachhalf character, the functional section number and its condition that caused the half character. The examples below show possible self test results and the meaning of
each.

4-27

Self Test Routine

Example No 1. All sections in use and all good.

Example No 2. IEEE Board not in use andCrosshead Control Section bad.

4-28

M10-94400-1

Self Test Routine

Characters Possible in Self Test Result for
Each Digit of Main Panel Display
1st Digit

2nd Digit

3rd Digit

4th Digit

1G

6G

*NOT
POSSIBLE

2G

3G

*NOT
POSSIBLE

1NI

6NI

7NI

8NI

2G

3G

*4

5G

1B

6B

2G

3G

*NOT
POSSIBLE*NOTPOSSIBLE

1G

6G

2B

3B

*NOT
POSSIBLE*NOTPOSSIBLE

1NI

6NI

8NI

2B

3B

*NOT
POSSIBLE

1B

6B

2B

3B

Function ofControls

Table 4-6.

5B
*NOT
POSSIBLE*NOTPOSSIBLE

Notes

4-29

Self Test Routine

4-30

M10-94400-1

Version Number

Version Number
The system firmware, which is the resident program that isstored in non-volatile memory, has been updated on several occasions over the life of the Model 4400 Testing System. In order for some of the option functions and featuresdescribed in Chapter 6 to work properly, the firmware
must have a certain version date. This requirement is notedin the description of the options in Chapter 6.
To determine the version date of your firmware, use thefollowing key sequence at the front panel of the console:

When the S1 and 9 are pressed, the setup display on theMain Panel shows “SL 9". Then, when the 1 is pressed,
the display shows the month and year of the installedfirmware:“12–93"
If the firmware has been customized just for your system, a leading minus sign is added to the displayed date:

Function ofControls

S1, 9, ENTER“–12–93"4-31

Selecting Operating Units

M10-94400-1

Selecting Operating Units
Switching Units
The operating units (English, metric, S.I.) in use in a Series 4400 system is controlled by the position of theunits selection switch, marked “mm/IN/SI” located on
the rear panel of the console. The switch is a rocker
type; depressing the left-hand side sets the units to metric, the center position is English units, and depressing
the right-hand side sets the units to SI.
You should normally set the units selection switch before
powering up the system. When system power is applied, thechoice of units is shown by the units indicator on the Main
Panel. If this switch has been changed since the last time thesystem was powered up, the Main Panel Display shows“LOSS”. This indicates that nonvolatile memory is reset tothe default state and stored test data is lost.
Note

You must recalibrate the load and strain channels and reset the electronic limits if “LOSS”
appears on the display panel.

If you change the units selection switch position withpower applied to a calibrated system, the front panel
units indicator will not change. You must perform ONEof the following procedures to make the units change
valid:(a) Cycle main power off then on.
(b) Enter the system reset sequence: Press S1, then press[0] and [ENTER] on the keypad.

4-32

Selecting Operating Units(c) Enter the “warm start” sequence: Press S1, thenpress [1] and [ENTER] on the keypad.
After you switch units and perform one of the above procedures, the Main Panel display will show “LOSS”, indicating that nonvolatile memory is reset to the default
state and stored test data is lost.
Note

After you change operating units for a calibrated
system, you must recalibrate the load and strain
channels and reset all limits (Load, Extension,and Strain).

Operating Units for Self Identified Load Cells
and Load Frames

Table 4-7.

Operating Units for Self-Identified Load Cells

PARAMETERENGLISHMETRIC

S.I.

*Load

LB
KLB
MLB

GF
KGF
KKGF

N
KN
MN

Extension

IN

MM

MM

Speed

IN/MIN

MM/MIN

MM/MIN

Function ofControls

The units that are used for load, extension and speed arelisted in Table 4-7.

Legend for Table 4-7:
LB = pounds
N = Newtons
KLB = LB x 10
KN = N x 10
MLB = KLB x 10
MN =K N x 10
GF = grams force IN = inches
KGF = GF x 10
MIN = minutes
KKGF = KGF x 10 MM = millimeters

4-33

Selecting Operating Units

M10-94400-1

The units shown in Table 4-7 provide the scaling for the
Display Panel and recorder options, and are the units
that appear on a printout of test results.
Note

When Area Compensation is not equal to
1.000, the load signal to the LOAD display andrecorder are scaled by 1/AREA (normalized).
A printout will show load units/Area, e.g., LB/A.

The units in use depend upon the selection of English,
metric or S.I. type, as described in the previous section.
The units shown for load and extension appear only if
the load cell and load frame, respectively, are self-identified.

Operating Units for Non-Self Identified Load Cells andLoad Frames
If the load cell (or load frame) in use is not self-identified, then the units for load (or extension and speed)
print as:“LD” for Load“EX” for Extension“SP” for Speed
If the load cell in use is not self-identified, the scaling of
the load parameter for the LOAD display, recorder andprinter options depend upon the full scale value of thecell; you enter the full scale value during the calibration
procedure. Also, if Area Compensation is not equal to
1.000, load is scaled by 1/Area and LD/A would beprinted.

4-34

Selecting Operating Units

If the load frame is not self identified, then the scalingof the extension parameter for the EXTENSION display,recorder and printer options and the speed parameter depend upon the units in use (inches or millimeters); youmust record this separately.

Area
There are no units associated with Area Compensation(AREA on the Main Panel). A printout of test results always lists Area values. This feature is fully described on
page 5-38.

The units shown on a printout of Energy depend upon
the current units in use for load and extension (English,
metric, S.I.). Also, energy units are printed as being divided by Area (1/A) whenever Area is not equal to
1.000.
Energy units consist of the combination:
X ∗

YZ
A

Function ofControls

Energy Units

where:

X = units of Load (LB, etc.)
Y = variable of distance (Extension or Strain)
Z = units of distance (in., etc.)
A = 1/Area (used when A = 1.000)

4-35

Selecting Operating Units

M10-94400-1

Examples of Energy units printout:

4-36

English units

LB*EX in./A

Metric units

kGf*EX mm/A

S.I. units

N*EX mm/A

Chapter 5
System Operation•

Operating Considerations . . . . . . . . . . . . . Page 5-2•

Pretest Procedures . . . . . . . . . . . . . . . . . . . Page 5-3•

Turn Instrument On: Warm-up . . . . . . . . . Page 5-4•

Self Test Routine At Power Up . . . . . . . . . Page 5-5•

System Reset At Initial Power Up. . . . . . . Page 5-7•

Calibration . . . . . . . . . . . . . . . . . . . . . . . . . Page 5-8•

Display Panel . . . . . . . . . . . . . . . . . . . . . . . Page 5-26•

Establish Gauge Length. . . . . . . . . . . . . . . Page 5-28•

Electronic Limits . . . . . . . . . . . . . . . . . . . . Page 5-30•

Set Crosshead Travel Limit Stops . . . . . . . Page 5-34•

Set Crosshead Speed . . . . . . . . . . . . . . . . . Page 5-35•

Crosshead Jog Control Unit. . . . . . . . . . . . Page 5-37•

Area Compensation . . . . . . . . . . . . . . . . . . Page 5-38•

Install Specimen. . . . . . . . . . . . . . . . . . . . . Page 5-42•

Set Testing Area. . . . . . . . . . . . . . . . . . . . . Page 5-43•

Run a Test. . . . . . . . . . . . . . . . . . . . . . . . . . Page 5-45

SystemOperation

OutlineThis chapter details the procedures involving pretest parameters common to all tests. Additional procedures for
system options can be selected from Chapter 6.
5-1

Operating Considerations

M10-94400-1

Operating Considerations
A typical test worksheet, which enables you to preplan atest program, is included in Chapter 7. With the blankspaces filled in where applicable, the worksheet serves
as a permanent record for future reference. This record
is important even for repetitive testing routines during
which parameters may remain unchanged for a period oftime. Even though most parameters are stored in the nonvolatile memory, these would revert to a default value if
you enter the system reset sequence, [S1] [0] [ENTER].
Appendix A to this manual provides supplementary information if you need assistance in planning a materials
testing procedure. A section on the introduction to testing contains details about determining load requirements, establishing gauge length and choosing a testing
speed.
Appendix B is a glossary of mechanical properties andtests for materials testing applications which you can reference for specific materials testing terms.

5-2

Pretest Procedures

Pretest Procedures
The Test Setup Procedures in the following list help you
to prepare your Series 4400 testing system to run basic
tension and compression tests. Follow the procedures sequentially, since many of them require that other procedures be performed first. Each listed procedure iscovered in detail later in this chapter. Refer to Chapter 4
if you need further explanations of control or display
functions. Chapter 6 provides operating procedures for
optional accessories.
1. Install a load cell (Refer to load frame manual)
2. Install grips (Refer to grips manual)
3. Connect accessories (page 3-9)
4. Set operating units switch (page 4-32)
5. Turn instrument on (page 5-4)
6. Monitor Self Test (page 5-5)
7. System reset (page 5-7)
9. Set Display Panel displays (page 5-26)
10. Set gauge length (page 5-28)
11. Set Electronic Limits (page 5-30)
12. Set crosshead limit stops (page 5-34)

SystemOperation

8. Calibrate and Balance system (page 5-8)

13. Set crosshead speed (page 5-35)
14. Set Area Compensation (page 5-38)
15. Install test specimen (page 5-42)
16. Set testing area (page 5-43)
17. Start test (page 5-45)
5-3

Turn Instrument On: Warm-up

M10-94400-1

Turn Instrument On: Warm-up
To turn on power to the Series 4400 instrument, set themain power switch on the load frame to ON. The complete testing system receives power, but any external accessories, such as a recorder or a printer, must be turnedon separately.
When power is applied to the system, an automatic Self
Test Routine runs as described on page 4-23.
You must allow a warm-up period of at least 15 minutes
to assure load cell stability. This warm-up period is also
necessary whenever you change a load cell.
Note

5-4

In some cases, grips and fixtures may have to beinstalled on the load frame after calibration, depending upon the procedure used and the typeof load cell installed.

Self Test Routine At Power Up

Self Test Routine At Power Up
The following sequence occurs during the automatic self
test of the Series 4400 system when main power is applied. Monitor this routine closely, as it provides assurance of the reliability of the system before proceedingwith test programs. (Refer to page 4-23 for details of
this feature and user interaction.)(a) Turn instrument on. Scan all sections of the Front
Panel during the Self Test Routine and observe thefollowing action:(1) All LEDs light, including the control switches
and backlit status indicators, and all displays
show “-1.8888” for up to 10 seconds.

(3) The Self Test Result shows on Main Panel Display for up to 5 seconds, then disappears (seeNote below). If the Self Test Result remains on
the display, then the system cannot be operated
and corrective maintenance is required.
Note

You can repeat the Self Test Routine by pressing
the Reject key (REJ) on the keypad during the time
when the Self Test Result shows on the Main Panel
Display. This allows you to observe the LED test
again, and, if a fault condition is random or spurious, may allow a Self Test Routine to pass asecond try. If a second try is required often, it
could indicate a marginal condition or an intermittent failure.

SystemOperation(2) All LEDs go out and all displays are blank for up
to 5 seconds.

5-5Self Test Routine At Power Up

M10-94400-1(b) After a successful Self Test, observe the following
actions (depending upon options installed):(1) On the Main Panel:a. The STOP switch is lit.
b. The display is blank, or it shows “LOSS” if theoperating units or the strain mode has beenchanged before turning power on.
c. The AT G.L. LED is flashing.
d. An operating units status indicator is lit.
e. A TESTING AREA indicator is lit.
(2) On the Display Section of the panel:a. A display mode selection key LED is lit.
b. If no prior values were stored, the displays
show:
LOAD, “——”; EXTENSION, “.000";STRAIN, ”——".
(3) On the Limits Section of the panel, a Limits
Status LED may be lit.
The particular LEDs and indicators that are lit at the endof a Self Test Routine vary depending upon the state of
the system. That is, variables and functions may not beat the default state (refer to Table 4-5) due to a previous
test which would be stored in the nonvolatile memory.
If you enter the System Reset sequence as described on
page 5-7, the default state is restored.

5-6

System Reset At Initial Power Up

System Reset At Initial Power Up
When you initially power up your Series 4400 system,
we recommended that you enter a System Reset sequence at the end of the Self Test Routine. This ensuresthat system data storage is at the default state (Table 4-5).
To enter a System Reset:
Press S1 on the Main Panel,then press “0" and ”ENTER" on the keypad.

SystemOperation

The Main Panel Display shows “LOSS” after this sequence, which indicates that any previously stored conditions and data are lost.

5-7

Load Calibration

M10-94400-1

Load Calibration
Overview
The Load Measurement function of the Series 4400 System
consists of a precision load cell transducer, mounted on theload frame crosshead, and a Load Sensor Conditioner, located on a section of the console printed circuit card.
The calibration procedure precisely calibrates the load
weighing system for the load cell in use. The systemthen is able to provide an accurate load signal which is
automatically ranged during a test over 100% (X1), 50%(X2), 20% (X5) and 10% (X10) ranges of the load cellmaximum capacity.
A 15 minute warm-up period with system power on andall circuits functioning, must be allowed before performing the calibration procedure. This assures that load cell
creep is at a minimum.
The calibration procedure you use depends on the type of loadcell installed. Load cells can be one of the following types:(a) Self identifying and electrically calibrated.
(b) Self identifying and manually calibrated.
(c) Non-self identifying and electrically calibrated.
(d) Non-self identifying and manually calibrated.
The procedures for calibrating all four types of loadcells are given in this section. These procedures, for themost part, require you to enter simple key sequences.

5-8

Load Calibration

Calibration also completes an operating reliability check of the
Load Sensor Conditioner (see Self Test Routine, on page 4-23).
The system responds to a bad calibration procedure byflashing the BAL or CAL LEDs. If either of these LEDs
flash, you must correct the error before proceeding. The
section “Calibration and Balance Errors” on page 5-16
includes a table of possible causes and solutions.
A test cannot be started while the LOAD CAL or LOAD
BAL LED is lit, and the calibration and balance functions are locked out while a test is running.
Note

Instron recommends that you check calibration atleast once a day during continuous operation ofyour testing system.

Electrical Calibration of Self Identifying Load Cells

Note

When electrically calibrating a self identifying
load cell, the balance operation is performed
automatically.

(a) Press LOAD CAL key. The Main Panel Display
shows the maximum capacity of the cell and theLOAD CAL LED lights.

SystemOperation

To calibrate the load weighing system with a self identifying electrically calibrated tension or compression loadcell installed:(b) Press ENTER on the keypad. After about 6 seconds,
the LOAD CAL LED goes out and the display goesblank indicating that calibration is completed. (Go to“Balance Load Weighing System” on page 5-15.)

5-9

Load Calibration

M10-94400-1

Manual Calibration of Self Identifying Load Cells
Note

When manually (deadweight) calibrating aload cell, use a precision weight that is traceable to a particular class as defined by the
National Bureau of Standards.

To calibrate the load weighing system manually with aself identifying load cell installed:(a) Do one of the following:(1) If you are using a tension load cell, install a pin orother device in the load cell coupling for hanging
a calibration weight.
(2) If you are using a compression load cell, set thecell on its cap on the base of the load frame. Install an anvil on the load cell coupling.
(b) Press the LOAD BAL key. The LOAD BAL LED
lights.
(c) Press ENTER on the keypad. After about 3 seconds,
the LOAD BAL LED goes out indicating that the balance function is completed.
(d) Hang a calibration weight from the tension cell coupling, or set the weight on the anvil of the compression cell.
Note

5-10

The calibration weight should be equivalent to
no less than 40% of the maximum value of thehighest range to be used of the installed loadcell. Otherwise, the load weighing system may
not be within the specified 1% accuracy.

Load Calibration

EXAMPLE:If a 2518 Series cell is installed and is to be used over its
full capacity in metric units (50 kg), then the calibration
weight should be no less than 20 kg.
(e) Press the LOAD CAL key. The Main Panel Display
shows the maximum capacity of the cell and theLOAD CAL LED lights(f) On the numeric keypad, key in the actual value of thecalibration weight in the system of units in use (S.I.,
English or metric).
(g) Press ENTER. After about 6 seconds, the LOAD
CAL LED goes out and the display goes blank indicating that calibration is completed.
(h) Remove calibration weight and fixture from the loadcell. If you are calibrating a compression cell, installit in the crosshead.

(j) Press ENTER. After about 3 seconds, the LOAD BAL
LED goes out indicating that the balance function is completed (see Load Weighing System Balance on page 5-15.)

SystemOperation(i) Press the LOAD BAL key. The LOAD BAL LED
lights.

5-11

Load Calibration

M10-94400-1

Electrical Calibration of Non-Self Identifying
Load Cells
To calibrate the load weighing system with a non-selfidentifying electrically calibrated tension or compression load cell installed:(a) Press the LOAD BAL key. The LOAD BAL LED
lights.
(b) Press ENTER. After about 3 seconds, the LOAD
BAL goes out indicating that the balance function iscompleted.
(c) Press the LOAD CAL key. The LOAD CAL LED
lights, but the Main Panel Display goes blank indicating that the load cell cannot be identified.
(d) On the numeric keypad, key in the maximum capacity of the highest range of the cell in the system ofunits in use (S.I., English or metric).
(e) Press ENTER.
Note

The calibration point for electrically calibrated
load cells is the maximum capacity of the next
to the highest range of the cell. For the Instron
low capacity tension load cells, this number
would be as shown in Table 5-1 (for example,
200 for the type 2512-101 cell).

(f) On the numeric keypad, key in the value of the calibration point (refer to the Note above) in the systemof units in use (S.I., English or metric).
(g) Press and hold calibration button on the load cell.
Press ENTER.
5-12

Load Calibration

Table 5-1.

Low Capacity Load Cells Calibration DataTENSION CELLCATALOG NO.

MAXIMUM
CAPACITYCALIBRATION
POINT

2512-136

50 g

20 g

2512-101

500 g

200 g

2512-122

5N

2N(h) After about 6 seconds, the LOAD CAL LED goesout and the display goes blank indicating that calibration is completed. Release the calibration button.
(i) Press LOAD BAL key. The LOAD BAL LED lights(j) Press ENTER. After about 3 seconds, the LOAD
BAL LED goes out indicating that the balance function is completed. (Go to “Load System Balance” onpage 5-15.)

Note

When manually (deadweight) calibrating aload cell, use a precision weight that is traceable to a particular class as defined by the
National Bureau of Standards.

SystemOperation

Manual Calibration of Non-Self Identifying
Load Cells

To calibrate the load weighing system manually with anon-self identifying load cell installed:(a) Do one of the following:

5-13

Load Calibration

M10-94400-1(1) If you are using a tension load cell, install a pin orother device in the coupling of the cell for applying a calibration weight.
(2) If you are using a compression load cell, set thecell on its cap on the base of the load frame. Install an anvil on the cell coupling.
(b) Press the LOAD BAL key. The LOAD BAL LED
lights.
(c) Press ENTER. After about 3 seconds, the LOAD
BAL LED goes out indicating that the balance function is completed.
(d) Press LOAD CAL key. The LOAD CAL LED lights,
but the Main Panel Display goes blank indicatingthat the load cell cannot be identified.
(e) On the numeric keypad, key in the maximum capacity of the highest range of the cell in the system ofunits in use (S.I., English or metric).
(f) Press ENTER(g) Hang a calibration weight from the tension cell coupling,or set a weight on the anvil of a compression cell).
Note

5-14

The calibration weight should be equivalent to
no less than 40% of the maximum value of thehighest range to be used of the installed loadcell. Otherwise, the load weighing system may
not be within the specified 1% accuracy.

Load Calibration

EXAMPLE:If a 2518-204 cell is installed and is to be used over its
full capacity in English units (200 lb), then the calibration weight should be no less than 80 lb.
(h) On the numeric keypad, key in the actual value ofthe calibration weight in the system of units in use(S.I., English or metric).
(i) Press ENTER. After about 6 seconds, the LOAD CAL
LED goes out indicating that calibration is completed.
(j) Remove calibration weight and fixture from the loadcell. If you are calibrating a compression cell, installit in the crosshead.
(k) Press the LOAD BAL key. The LOAD BAL LED
lights.
(l) Press ENTER. After about 3 seconds, the LOAD
BAL LED goes out indicating that the balance function is completed.

You may install grips and fixtures before or after calibration, depending upon the type of load cell installed.
Also, you may change grips or fixtures between tests, inwhich case system calibration does not have to be repeated. However, it is necessary to balance out the tareweight of grips and fixtures whenever these are added orchanged and the system has been calibrated.
Note

SystemOperation

Load Weighing System Balance

Always balance a calibrated load weighing
system whenever grips and fixtures are added
or changed.
5-15

Load Calibration

M10-94400-1

To balance the load weighing system:(a) Press the LOAD BAL key. The LOAD BAL LED
lights.
(b) Press ENTER. After about 3 seconds, the LOAD
BAL LED goes out and the balance function is completed. (see next Section if LOAD BAL LED
flashes.)

Calibration And Balance Errors
Your Series 4400 system reports when a problem exists
in a transducer calibrating or balancing procedure. Thiswarning is easily identified by the flashing of the LOAD
CAL or LOAD BAL LEDs for load cells, or the
STRAIN CAL or STRAIN BAL LEDs for extensometers. Also, if the system cannot properly read the identification of an identifiable transducer, the Main Panel
Display is blank.
Table 5-2 shows the probable causes and solutions for a
flashing CAL or BAL LED for either a load or straintransducer, and several other possible calibration problems.

5-16

Load Calibration

Transducer Calibration/Balance Errors

CALIBRATION OR
BALANCE ERRORPROBABLE CAUSESOLUTION

CAL LED flashes after aself identifying transducer iscalibrated automatically

1. Transducer is not connected.
2. Transducer is defective.
3. Transducer interface
board is defective.

1. Check all cable connections.
2. Try another transducer.
3. Run Self Test Routine.

CAL LED flashes after atransducer is mechanicallycalibrated using a weight orcalibration fixture.

1. Transducer is not connected.
2. Transducer is defective.
3. Transducer interface
board is defective.
4. Wrong full scale or calibration setting value
entered on keypad.

1. Check all cable connections.
2. Try another transducer.
3. Run Self Test Routine.

BAL LED flashes after atransducer is calibrated orbalanced. System was unable to balance out tareweight of grips or fixtures.

Tare weight is over 100% oftransducer capacity.

Remove tare weight byusing lighter grips or fixtures.

When LOAD CAL key ispressed: (1) the wrong
value of transducer capacity
appears on the Main Paneldisplay; or (2) No value appears at all.

1. Operating units havenot been changed to
the required type.

1. Check units indicatorfor proper type. If wrong,turn off power, change
units, then turn power on
and recalibrate.
2. Use mechanicalcalibration procedure.

CAL LED remains on.

1. ENTER key was notpressed.
2. Wrong calibration sequence used.

2. Transducer is not selfidentifying.

4. Check all figures andre-enter.

1. Press ENTER.
2. Redo calibration procedure.

SystemOperation

Table 5-2.

5-17Strain Calibration

M10-94400-1

Strain Calibration
Overview
Strain measurement on the Series 4400 system makes
use of an optional Strain Sensor Conditioner board. This
Strain channel can accept a wide variety of straintransducers, including strain gauge extensometers,
LVDT extensometers, Crack Opening Displacementgauges, and several types of specialized extensometers
for specific applications.
The functions of the Strain channel are similar to the
Load Sensor Conditioner described in Chapter 4. The
output is either an unranged, or an automatically ranged,
0 to 10 Vd.c. full scale strain signal. The strain signal canbe monitored during a test, can be used for X-Y recordingof load-strain data, can be used with strain limits to control
crosshead action, and can be used in a printout obtained ofpeak, break and preset point values.

Strain Operating Mode
The operating mode for the Strain channel can be set toeither Percent Strain (%) or, depending on the type of extensometer, to displacement in inches or millimeters.
Note

Always be aware of the strain operating mode
when monitoring the signal, when setting up forstrain recording, and when using strain limits.

To change the strain operating mode, you must change
the setting of a DIP switch on the rear of the console.
This switch is part of a three-section DIP switch locatedbetween the rows of cable connectors at the lower rear
5-18

Strain Calibration

panel of the console (see Figure 8-1). The bottom,
number 3 switch is marked STRAIN UNITS.
To change the position of the Strain Mode switch, push
on one side of the switch with a pointed tool, such as aball point pen. To set the mode to displacement units,
push the switch to the side marked “ON"; and for Percent, push it toward the side marked ”3".
If you change the strain mode setting while the system is
powered down, the Main Panel display shows “LOSS”
when power is applied. This indicates that nonvolatilememory is reset to the default state and stored test data
is lost. Load and strain channels must be recalibrated
and electronic limits reset.
If you change the strain operating mode with power applied to the system, there is no indication on the front
panel. You must perform ONE of the following procedures to make the change valid:(a) Cycle main power off, then on, or(c) Enter the “warm start” sequence: Press [S1], then [1]and ENTER on the keypad.
After you switch the strain operating mode and perform
one of the above procedures, the Main Panel display
shows “LOSS”, indicating that nonvolatile memory is reset to the default state and stored test data is lost.
Note

AS 1

SystemOperation(b) Enter the system reset sequence: Press [S1], then [0]and ENTER on the keypad, orAfter you change the strain operating mode fora calibrated system, you must recalibrate the

5-19Strain Calibration

M10-94400-1
load and strain channels and reset all limits(Load, Extension, and Strain).

Strain Gauge Extensometers
Instron manufactures a host of different types of extensometers and other strain measuring devices, most ofwhich can be used with the Series 4400 Testing System.
In the following sections, the discussion will center on
Instron’s Series 2630 Extensometers, but the calibration
procedures described apply equally well to other typesof extensometers and strain gauges.
The Instron Series 2630 Strain Gauge Extensometers arelightweight units that are provided with clamps for attaching the devices to round or flat test specimens.
These extensometers are available in models coveringhigh and medium magnification ranges, and with initialgauge lengths of 10, 25, or 50 mm (1/2, 1, or 2 in.). Operating instructions are included with each extensometer.
The calibration procedure for an extensometer compares
the strain measuring system of a Series 4400 instrument
against a precise voltage, and sets system calibration for
the extensometer in use. The system then is able to provide an accurate strain signal which is automaticallyranged during a test over 100% (x1), 50% (X2), 20%(X5) and 10% (X10) of the maximum range of the extensometer.
The calibration procedure varies depending upon thetype of extensometer installed and the method used:
1. Self identifying and electrically calibrated.
2. Self identifying and manually calibrated.
5-20Strain Calibration

3. Non-self identifying and manually calibrated.
If the calibration procedure fails for any reason, the system flashes the STRAIN BAL or STRAIN CAL LEDs.
If either of these LEDs is blinking, you must correct theerror before proceeding (refer to page 5-16).
Note

For maximum accuracy of strain measurement, extensometers should be manually calibrated over the range of interest, as describedon page 5-22

The following procedures, describing the calibration ofstrain gauge extensometers, assume that the devices havebeen properly installed and cabled in a Series 4400 system.
An extensometer calibrator with a micrometer
adjustment, such as the Instron High Magnification Extensometer Calibrator with a 25 mm(or 1 in.) range, is required for the manual
calibration procedures.

You cannot start a test while the STRAIN CAL or
STRAIN BAL lamp is lit, and, conversely, the calibration and balance functions are locked out while a test is
running.

SystemOperation

Note

5-21

Strain Calibration

M10-94400-1

Electrical Calibration of Self Identifying Strain
Gauge Extensometers
Note

When electrically calibrating a 2630 Series
self-identifying strain gauge extensometer, thebalance operation is performed automatically.

To electrically calibrate a 2630 Series self-identifying
strain gauge extensometer:(a) Clamp the extensometer onto the specimen at gauge
length, as described in the manual supplied with theextensometer. Allow up to 15 minutes for the extensometer to stabilize after applying excitation.
(b) Press the STRAIN CAL key. The Main Panel Display shows the maximum strain (%) or range (mils ormm) of the extensometer, and the STRAIN CAL
LED lights.
(c) Press ENTER. After about 6 seconds, the STRAIN
CAL LED goes out, the display goes blank and calibration is completed.

Manual Calibration of Strain Gauge Extensometers
To manually calibrate a 2630 Series self-identifying, or
non-self identifying, strain gauge extensometer:(a) Mount spindles on the calibrator that fit the extensometer clamps, and set the calibrator in a vertical position for greatest accuracy.
(b) Adjust the calibrator for minimum displacement(gauge length). Minimize backlash in the mechanism
by going through the zero point and then return.
5-22

Strain Calibration(c) Clamp the extensometer onto the calibrator spindles
at gauge length, as described in the manual suppliedwith the extensometer. Allow up to 15 minutes forthe extensometer to stabilize after applying excitation.
(d) Press the STRAIN BAL key. The STRAIN BAL
LED lights.
(e) Press ENTER. After about 3 seconds, the STRAIN
BAL LED goes out, indicating that the balance function is completed.
(f) Press the STRAIN CAL key. The STRAIN CAL
LED lights. Go to Step 1 or 2 below.
(1) If the extensometer is a self-identifying type, theMain Panel Display shows the maximum strain(%) or range (mils or mm) of the extensometer.
Do not press ENTER.

(g) Adjust the calibrator by one of the following methods:
Note

Adjust calibrator carefully. Do not turn it past
the set point and have to reverse, as backlash
will cause an error.

SystemOperation(2) If the extensometer is a non-self identifying type,
the Main Panel Display is blank. Key in the maximum strain (%) or range (mils or mm) of the extensometer on the keypad. Press ENTER. The
STRAIN CAL LED stays lit.

(1) To calibrate the extensometer over its maximum
strain (or displacement) range, adjust the calibrator to a displacement value which corresponds to
5-23

Strain Calibration

M10-94400-1

full scale. For example: If using an extensometerwith a 1-inch gauge length and a 10% maximum
strain, adjust calibrator to 0.100 inches.
(2) To calibrate the extensometer over a range of interest (most accurate method), adjust the calibrator to the maximum displacement value required.
For example: If using an extensometer with a 1inch gauge length and a 10% maximum strain,
and a 1% strain is the range of interest (refer toNote below), adjust calibrator to 0.010 inches.
Note

Do not calibrate a 2630 Series strain gauge
extensometer below 10% of its full scale range.
Otherwise, the accuracy will not be within specifications.

(h) On the keypad, key in the value set on the calibrator
in Step g, part 1 or 2 above. If the strain operating
mode is displacement, enter the value in millimetersor mils. If the strain operating mode is percent, enter
the percent strain corresponding to the displacementof the calibrator (10.00 for 10%, 1.000 for 1%, etc.).
(i) Press ENTER. After about 6 seconds, the STRAIN
CAL LED goes out, the display goes blank and calibration is completed.
(j) Remove the extensometer from the calibrator andclamp it onto the specimen at gauge length, as described in the manual supplied with the extensometer.
(k) Press the STRAIN BAL key. The STRAIN BAL
LED lights.

5-24Strain Calibration(l) Press ENTER. After 3 seconds, the STRAIN BAL
LED goes out and the balance function is completed.

Strain Gauge Extensometers - Operating Notes
The strain measuring accuracy of a Series 4400 system
is 0.5% of the strain reading, ±1 count, on the display or
the analog output to recorder (± linearity of transducer).
This specified accuracy is valid from the calibration
point of an extensometer down to 2% of maximum
strain (displacement). An extensometer must be recalibrated if the ambient temperature goes outside the range
of +10 to +38°C (+50 to +100°F) after initial calibration.

SystemOperation

After the extensometer has been installed on the specimen, secure the cable so it does not interfere with the
movement of the extensometer. Also, keep the cableaway from the drive motor housing to avoid electrical interference.

5-25

Display Panel

M10-94400-1

Display Panel
Description
The Display Panel at the top of the control console has
three 4-digit LCD displays which allow the current
value of load, extension, and strain to be tracked for observation during a test. The tracking value on each display is not stored at the end of the test.
Additional functions enable the values of load, extension, and strain at peak load and at specimen break to be
saved for viewing on the displays at the end of a test.
The peak and break values are stored in nonvolatile system memory until overwritten by the next test, or when
the system is reset.
When Area Compensation is in use, the gain of the load
signal applied to the LOAD display is divided by the
specimen area value (see page 5-38). Hence, when Area
Compensation is not equal to 1.000, the LOAD display
indicates the normalized value of stress.
Descriptions of the Display Panel control and indicatorfunctions are contained in Table 4-2.

Operation(a) Press the TRACK key to track load, extension andstrain on the displays at any time during a test. The
TRACK LED lights and the three displays show theconstantly changing values while the test is in progress.
The storage of peak and break values is not interrupted
when the TRACK key is pressed. These functions arealways recorded.

5-26

Display Panel(b) Press the PEAK key to set the displays to show load,
extension and strain values that occur at the peak load
during a test. This can be done at any time, either before, during, or at the end of a test when the values are
stored. The PEAK LED is lit when this function is active.
(c) Press the BREAK key to set the displays to show load,
extension and strain values at specimen break. This canbe done at any time, either before, during, or at the endof a test when the values are stored. During a test, thedisplays remain blank until a break condition occurs.
The BREAK LED is lit when this function is active.

(e) Press the RESET PEAKS key during a test to reset
stored peak values of load, extension and strain tovalues at the current load. Peak storage is then updated to values at the next peak load. This key does
not change which values are selected to be displayed(Break, Peak or Track) and is active only during a
test.

SystemOperation(d) Press the PEAK BREAK key to set the LOAD display to show peak load value for a test and the EXTENSION and STRAIN displays to show values at
specimen break. This can be done at any time, either
before, during, or at the end of a test when values are
stored. The PEAK BREAK LED is lit when this function is active.

5-27

Establish Gauge LengthM10-94400-1

Establish Gauge Length
Gauge length is the distance between the contact pointsof the upper and lower grips on the specimen at the startof a test, and establishes the initial length of the specimen. The choice of a suitable gauge length depends
upon the material under test (see Appendix A, Introduction to Testing). To ensure a uniformity in specimen
length, this spacing must be the same for all similar
tests. This requires that the moving crosshead return andstop at a preset limit, or gauge length, at the conclusionof each test.
On Series 4400 systems, gauge length, the current spacing between grips or fixtures, is entered into memory
whenever the G.L. RESET key is pressed. This featureprovides a very accurate gauge length setting.
To set a specific gauge length:(a) Drive the crosshead up or down, as required, using
the JOG keys on the Frame Control Panel. Use aruler to determine the exact spacing between contact
faces of upper and lower grips, or anvil and compression plate.
(b) Press the G.L. RESET key to enter the gauge length
into system memory.
An alternate method to set gauge length is as follows:(a) Carefully bring the grip faces (or anvil and compression plate) together until they just touch, using the
JOG keys.

5-28

Establish Gauge Length(b) Press the G.L. RESET key to reset the EXTENSION
display to zero.
(c) Drive the crosshead up with the JOG key until the required spacing is displayed (in inches or millimeters), and again press the G.L. RESET key to enter
the new gauge length into system memory.
If the AT G.L. LED had been flashing, indicating that a
power shutdown or system reset had occurred, it becomes steady when the G.L. RESET key is pressed. This
LED goes out whenever the crosshead is moved fromgauge length, but relights when the crosshead is returned.
Once gauge length has been set, thecrosshead will always return to this position
upon a RETURN command.

SystemOperation

Note

5-29

Electronic Limits

M10-94400-1

Electronic Limits
You should set the electronic limits and assign a crosshead action to them before starting a test. Enter limits
values using the keypad and view them on the Main
Panel Display.
An indicator lights at the active limit and at the corresponding crosshead action key. A STATUS indicator is
lit whenever a limit is set to control a crosshead action.
The LED flashes after the limit is reached and the action
occurs, except at CYCLE and OFF.

Operating Notes - Limits Panel(1) To enable either the load or strain channel limits, therespective channel must be calibrated.
(2) When system operating units are changed, any Load,
Extension and Strain limits previously set on the Limits Panel default to “0" and the related crosshead action defaults to ”OFF". Any STATUS LED which is
lit to indicate an active load, extension or strain channel limit goes out. Each limit must be reset using values stated in terms of the new operating units, andthe crosshead action selected(3) When the operating mode for the Strain channel ischanged (see page 5-18), any Strain limits previously
set on the Limits Panel default to “0" and the related
crosshead action defaults to ”OFF". The STATUS
LED, which may be lit to indicate that the limits forthe strain channel are active, goes out. Each limit
must be reset using values stated in terms of the new
operating mode, and the crosshead action selected.
5-30

Electronic Limits(4) When Area Compensation is in use, the gain of theload signal actuating the Load Limits is divided by
the normalized mantissa (base number) of the areavalue (see Area Compensation on page 5-38). Hence,
when Area Compensation is not equal to 1.000, theLoad Limits should be set based on the normalized
value of stress.
EXAMPLE:
Maximum stress limit = 100 psi
Area compensation (normalized) = 2.0
Set MAX LOAD LIMIT to 100(Note: Actual load = 200 lb.)
Before setting stress limits, become familiar with thelimitations due to load cell capacity as described in Appendix A.

Operation(a) Press the LOAD, EXTENSION or STRAIN limit
key (MIN or MAX) for the required limit. The related LED lights and the current limit value appearson the Main Panel Display.
(b) Enter the value, and the sign if negative (refer toNotes 1 and 2 below), of the limit on the keypad. The
displayed number flashes until it has been enteredinto the system.
Notes

SystemOperation

To set a limit and a crosshead action on the Limits Panel:

1. If the sign (+ or -) of the output signal of theload cell (or strain transducer) in use is negative (-) with increasing load (or strain), then a

5-31

Electronic Limits

M10-94400-1
limit value (maximum or minimum load or
strain) must also be negative. Press the +/- keyon the keypad to obtain the correct sign whensetting a limit.
2. If the sign (+ or -) of the output signal of theload cell (or strain transducer) in use is negative (-) with increasing load (or strain), theSeries 4400 system considers the most negative value as the minimum load (or strain). For
example: If load limits of -300 lb and -100 lb are
specified for a test, set the minimum load
(LOAD MIN key) to -300 lb, and the maximum
load (LOAD MAX key) to -100 lb.

(c) Press ENTER on the keypad. The number stops flashing.
(d) Press the CROSSHEAD ACTION key for the limit
just entered. Indicator LEDs (ACTION and
STATUS) for the limit will light.
(e) To set a crosshead action to occur at specimen break,press the BREAK key and then a CROSSHEAD ACTION key.
EXAMPLE:
Crosshead to stop at a maximum load of 200 lb, and toreturn to gauge length if specimen breaks.
Enter the key sequence:[LOAD MIN] [2] [0] [0] [ENTER] [STOP] [BREAK][RETURN]
Whenever one of the limit condition LEDs, or the
BREAK LED, is lit, one of the four crosshead action
5-32

Electronic Limits

key LEDs will light. The crosshead action may bechanged by pressing another action key.
Note

If the crosshead action is to CYCLE between
LOAD limits during a compression test and theload cell in use has a positive (+) output signal
for an increase in load (2511-200 series), set
TESTING AREA to ABOVE XHEAD.

You can check the limit settings by pressing each limit
key and reading the setting on the Main Panel Display.

CautionWhen a limit or specimen break causes a crosshead action, the related STATUS LED flashes to inform you
why the action occurred (except at the CYCLE and OFF
actions). The LED continues to flash until the next test
is started.

SystemOperation

Always verify that the limit settingsand crosshead actions are properly set before starting a test. Also,
always ensure that limit settings
are within the maximum capacity of
the load cell in use.

5-33

Set Crosshead Travel Limit Stops

M10-94400-1

Set Crosshead Travel Limit Stops
The crosshead travel limit stops are a safety feature thatyou should set after establishing gauge length and before
starting a test. Refer to the load frame manual for your system for the location of these devices.
If a system failure prevents the crosshead from stopping
automatically at gauge length (or at optional electronic
limits), the travel limit stops will be contacted by an actuator on the crosshead, a limit switch will open, and thecrosshead will stop.

Caution
Always set the crosshead travel
limit stops before starting a test.
Set the upper limit stop to a point just beyond the expected maximum travel (extension) in the UP direction
when tension testing, or just before gauge length whencompression testing. Tighten the stop securely on thelimit switch rod.
Set the lower limit stop to a point just beyond the expected maximum travel (extension) in the DOWN direction when compression testing, or just before gauge
length when tension testing. Tighten the stop securely on
the limit switch rod.

5-34

Set Crosshead Speed

Set Crosshead Speed
The testing (crosshead) speed you select depends upon
the type of material being tested. Some examples of typical speeds are given in Appendix A, Introduction to Testing. Usually, a testing rate is specified as one of thefollowing:• Specimen strain rate in inches per inch per minute(or mm/mm/min).
•

Percentage of specimen extension or compression
per minute.

•As crosshead speed in inches (or mm) per minute.
When selecting a crosshead speed, you should consider thefollowing:• Characteristics of the specimen material.
•

Total elongation or compression of specimen during
the test.

•

Note

If a crosshead speed is entered beyond thespecified maximum range of the Series 4400
system, it is not accepted. The maximum
speed for the system is automatically set.

SystemOperation

Maximum speed of recorder response.
To maintain speed accuracy in a Series 4400 system, do
not exceed the maximum speed at the crosshead loading
shown in the specification for the load frame.

Set crosshead speed as follows:(a) Press the SPEED key. A number appears on the Main
Panel Display (either the default value or a previously set speed appears).
5-35

Set Crosshead Speed

M10-94400-1(b) Enter the required speed on the keypad (up to four
digits and a decimal point). The displayed number
flashes, indicating that it has not been entered into
the system.
(c) Press ENTER. The number stops flashing.
Note

5-36

You can change crosshead speed at any time
during a test by entering the above sequence.

Crosshead Jog Control

Crosshead Jog Control
A Crosshead Jog Control unit is available for moving
the crosshead up and down in small increments or at
slow speed while loading specimens or installing grips
and fixtures. The Jog Control unit is a small, hand-heldbox on the end of a cable, containing a rocker switch.
When the switch is pressed in the direction of the UP arrow, the crosshead will move at a constant speed in an
up direction as long as the switch is held. There is a similar action in the down direction when the switch is heldin the direction of the DOWN arrow.

SystemOperation

The Jog Control parallels the action of the UP and
DOWN switches on the Main Panel, but may be moreconvenient to use since it can be moved close to test
space on the load frame while installing grips or loading
specimens.

5-37

Area Compensation

M10-94400-1

Area Compensation
Area Compensation is a feature of the Series 4400 system that allows the load signal to be calibrated in termsof stress (Load/Area). Thus, specimens of similar material but different cross-sectional area can be tested and a
relationship established between the applied force andthe specimen size. Appendix A, Introduction to Testing,contains a description of area compensation.
A Series 4400 system accepts values of area compensation ranging from 9.999 x 10-50 minimum to 9.999 x
1050 maximum. The default value is 1.000 x 100, as expressed in scientific notation. However, you enter the actual number through the keypad using floating point
format with values ranging between 9.999E-50 to9.999E50. The default value is 1.000E00 in this format.
An area compensation value is entered by two key sequences. The initial sequence enters a base number, or
mantissa, between 1.000 and 9.999. This number is thenormalized value of the specimen cross-sectional area.
EXAMPLE:Specimen cross-sectional area:
A = 0.156 in2 = 1.56 x 10-1
Enter 1.56 (normalized value) as the mantissa.
After the first key sequence, the letter “E” and two digits
appear on the display; this is the current exponent (powerof 10) of the area value stored in nonvolatile memory. The
second key sequence enters the exponent of the area value
in the form of two digits ranging from -50 to 50, where theabsence of the “+” sign denotes a positive number.

5-38

Area Compensation

EXAMPLE:Specimen cross-sectional area:
A = 0.156 in2 = 1.56 x 10-1
Enter -01 as the exponent of the area value.
The load signal output to the LOAD display and to a recorder is divided by the mantissa of the area value only.
Therefore, stress (Load/Area) as indicated by these two
devices is normalized in relation to actual stress. However, with the load sensitivity adjusted in proportion to
specimen size, (area compensated) the recorder scale remains accurately calibrated in terms of stress (force perunit area).

CautionThe parameters of stress (L/A) and energy are printed using the mantissa and exponent of the area value (refer topage 6-26). Thus, actual stress based on the original
cross-sectional area of the specimen can be read directlywith an optional printer.

SystemOperation

Always determine the Maximum Allowable Stress for the load cell in use
to avoid overloads when area compensation is used. (Important - seeAppendix A, page A-12)

Set area compensation by entering the following key sequences:(a) Press AREA key. The SET LED lights, and a number
appears on the Main Panel Display (either the default

5-39

Area Compensation

M10-94400-1

value or the value of a previously set area compensation).
(b) Enter the mantissa (base number) of the desired area
compensation on the keypad. This must be a number
between 1.000 and 9.999, which is the normalized
value of the specimen cross-sectional area. The displayed number flashes, indicating that it has not beenentered into the system.
(c) Press ENTER. If the number entered is not 1.000 andthe exponent is not E00, then the ≠ 1 indicator willlight. The entered number disappears and the display
shows “E” and two digits.
(d) Enter exponent of area compensation number at the
keypad (refer to Note 1 below). This must be anumber between -50 and 50. The system limits larger
numbers to these values. If the required exponent is apositive number, simply enter the number directly. If
the required exponent is a negative number, press the+/- key unless the currently displayed number is already a negative quantity. The number flashes until it
has been entered into the system.
(e) Press ENTER. The exponent disappears and thenumber set in Step (b) reappears. Repeatedly pressing ENTER causes the displayed value to alternate
between the mantissa and the exponent.
Notes

5-40

1. Always record the load (stress) and energy
data stored from a previous test before changing the exponent of the area compensation
value. Otherwise, this data will be in error as it
is immediately assigned the value of a newlyArea Compensation

SystemOperationentered exponent.
2. I f the maximum and minimum load limits areused, they should be reset in accordance with
the increased or decreased load channel sensitivity due to area compensation (the normalized
value only, not the exponent) (see Operating
Note (4) on page 5-31).
3. Area compensation is temporarily set to
1.000E00 (1.000 x 10 ) during a load cell calibration procedure. Any prior set value is restored
when the procedure is completed.

5-41

Install Specimen

M10-94400-1

Install Specimen
Install a test specimen in the grips for tension testing, oron the compression platen or other fixture for compression testing.
The gauge length has been set at this point, so do not
move the crosshead. If the specimen does not fit, either
trim it or change the gauge length. Tighten the upper
grip first. If this causes a preload, do not perform a balance procedure to compensate for it, as this is the initialloading on the specimen.

5-42

Set Testing Area

Set Testing Area
It is important that you set the TESTING AREA function on the Main Panel properly so that the automatic
overload detection circuit will stop a test if the load cellis overranged. If pneumatic grips are being used with an
optional Air Kit, or cycling is to be done using the Limits Section of the panel, it is essential to set the TESTING AREA properly. The default state for the
TESTING AREA function is BELOW XHEAD.

CautionFor normal operation, set the TESTING AREA function
to BELOW XHEAD. This applies to compression loadcells also.
The TESTING AREA function should be changed forone of the following two conditions only:

SystemOperation

Ensure that the TESTING AREA
function is properly set before starting a test. If it is not and a load overrange condition is detected, theLOAD fault indicator flashes but thecrosshead does not stop, and damage to the load cell could occur.

(a) The sign of the output signal of the installed load cell
is positive (+) for compression (applies to 2511-200
Series compression cells only.)

5-43Set Testing Area

M10-94400-1(b) The load cell, except for a 2511-200 series compression
cell, is mounted for testing above the moving crosshead (requires special fixturing).
Note

When using a 2511-200 series compression
cell and the TESTING AREA function is set to
ABOVE XHEAD, any strain extensometerused must also have a positive (+) output whencompressed. If the sign of the extensometer is
not the same as the sign of the load cell, thestrain limits do not function properly. Choose
another extensometer of the proper polarity orcall an Instron Regional Sales and Service
Office for additional extensometers.

To change TESTING AREA, enable it by initially pressing S1. The Main Panel Display shows “SL”. You canpress the TESTING AREA key and change the function
to BELOW AHEAD or ABOVE XHEAD while thiscondition is active.
Note

5-44

The TESTING AREA key stays enabled, with “SL”
remaining on the display, until you enter anotherkey sequence such as: [S1] [0] through [S1] [6],[SPEED] or [AREA].

Run a Test

Run a Test
The output of a test with only a load cell installed is aload signal of 0 to ±10 Vd.c. This signal can be monitored on the Display Section of the panel, and recorded
if an optional Recorder or Printer is installed. These andother optional accessories are described in Chapter 6.

SystemOperation

Start a test by pressing the UP key on the Main Panelfor a standard tension test, or the DOWN key for a standard compression test.

5-45

Run a Test

5-46

M10-94400-1

Chapter 6
System Options•

Introduction . . . . . . . . . . . . . . . . . . . . . . . . Page 6-2•

Strip Chart Recorder . . . . . . . . . . . . . . . . . Page 6-3•

X-Y Recorder. . . . . . . . . . . . . . . . . . . . . . . Page 6-12•

Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 6-24•

AC/DC Strain Conditioner . . . . . . . . . . . . Page 6-30•

Preset Points. . . . . . . . . . . . . . . . . . . . . . . . Page 6-34•

Energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 6-37•

Cycle Counter . . . . . . . . . . . . . . . . . . . . . . Page 6-39•

Pip Control . . . . . . . . . . . . . . . . . . . . . . . . . Page 6-41•

Air Kit Option . . . . . . . . . . . . . . . . . . . . . . Page 6-44

This chapter describes the function of some optional accessories and internal functions that can be used with a
Series 4400 System. Peripheral items may be included
with the system when you purchase it, or added later toexpand its capabilities. Optional internal functions areavailable for specialized testing applications.

System Options

OutlineIntroduction

M10-94400-1

Introduction
The options described in this chapter are either external
accessories that can be added to the system (Recorders,
Printer) or are built into the system (Energy option, Preset Points option, Air Kit option, Pip Control option,etc.). Those that are built into the system are considered
options because they are not necessary for routine operation of the system, but can enhance the functionality ofthe system in special testing situations.
External accessories can be added to the system at any
time. Installation is merely a matter of cabling the accessory to the system, and connectors are provided on theback of the console for these devices. All of these external devices have their own instruction manuals, which
are supplied with them.
Built-in options are activated from the console front
panel. In the sections of this chapter that follow, thesefeatures are described, and operating instructions are
given.

6-2

Strip Chart Recorder

Strip Chart Recorder
Description
The optional Instron Strip Chart Recorder produces aplot of an input signal, usually load or strain, against
time. The chart itself, driven by an internally-timed stepping motor, moves past a recording pen, which, in turn,is driven by the input signal. Since crosshead speed canbe converted directly to time, the resulting plot is thus aplot of load or strain versus crosshead speed.
The recorder has a bi-directional chart with selectable speedsin the internal time drive mode. The range of speeds is 1.0 to
100 cm/min (0.05 to 50 in/min), forward and reverse.
The Recorder is available with one or two input channels (and recording pens). If it has one input channel, theinput to that channel will always be Load. If the recorderhas two input channels, Load will be applied to Channel
1, and Strain to Channel 2.

The Series 4400 system provides an automatic chart stop
signal at a crosshead “return” command. Pipping of thepen (event marker) is possible through a PIP contact on
the recorder connector.
The recorder is supplied with 250 mm wide, metricscaled paper. The paper can be either fan-fold or roll paper. Paper scaled in U.S. Customary units is available

System Options

The input from the Series 4400 system is a -10 to +10
Vd.c. load or strain signal, which is automaticallyranged to full scale by the testing system. Switch-selectable ranges and a variable gain control on the Recorderfront panel can be used for range expansion.

6-3

Strip Chart Recorder

M10-94400-1

from Instron. The recorder can be operated in either English or metric units, switch-selectable on the rear panelof the recorder.

Specifications
The following are the operating specifications for theStrip Chart Recorder:
Measurement Ranges: 1, 2, 5, 10, 20, 50, 100, 200, 500
mv
1, 2, 5, 10, 20, 50 V
Chart Width:

250mm

Roll Paper:

approx. 16m or 25m

Writing System:

Fiber-tip pens

Input circuitry:

AsymmetricRange Expansion:

40% (gain control)

Counter Voltage:

Manually: =100/-100%, contin.

Accuracy:±0.35% (≥ 10 µv)

Linearity of Potentiometer:±0.25%

Reproducibility:±0.25%

Full Scale DeflectionTime:≤0.35 sec.

Maximum Writing
Speed:

1m/secReference Voltage:

Electronically stabilized

Input Impedance
DC Volts, mv Ranges: 30 MΩ

6-4

Strip Chart Recorder

DC Volts, V Ranges: 2 MΩ
AC Volts, mv Ranges: 20 KΩ, in series with 1 µf
AC Volts, V Ranges: 2 MΩ
Permitted Source Impedance
mv Ranges:
20 kΩ
V Ranges:

5 kΩ

Temperature Drift of Zero Line
mv Ranges:
approx. 0.5 µv/K
V Ranges:

approx. 50 µv/K

Long Term Drift:

1 µv/month

Overload Protection:
mv Ranges:
V Ranges:

±60V
±60V

Chart Drive (Crystal Controlled Stepping Motor)
Chart Speeds
1, 2, 5, 10, 20, 50, 100 cm/min
1, 2, 5, 10, 20, 50, 100 cm/hr
1.2, 3, 6, 12, 30, 60 cm/min
1.2, 3, 6, 12, 30, 60, 120 cm/hr(all speeds forward and reverse)
100, 110, 220, 240 Va.c. ±10%

Ordering information for Strip Chart Recorder supplies
is given in Table 6-1

System Options

Input Voltage

6-5Strip Chart Recorder

Table 6-1.

M10-94400-1

Strip Chart Recorder Supplies

Part Number

3750-135
3750-137

3750-136
2750-138
3740-147

3740-148

Description

Fan Fold Paper,
metric units
Fan Fold Paper,
U.S. Customaryunits
Roll Paper, metricunits
Roll Paper, U.S.
Customary units
Pens, redPen 1 for all
recordersPens, blackPen 1 for all
recorders

Quantity

10/box10/box10 rolls/box
10 rolls/box
5 pens/pkg

5 pens/pkg

Power Requirements
The Strip Chart Recorder is set at the factory to accept amain power input of 120 ±10 Va.c., single phase. A 3-wirepower cable for this voltage is included. If the power source
to be used is not 120 ±10 Va.c., the power input switch on
the underside of the recorder can be set for other voltages in
the range of 100 to 240 Va.c. (refer to Table 6-2).
To adapt the Strip Chart Recorder for a different line
voltage, set the input power switch to the proper input
voltage for your location. Be sure the line fuse is the6-6Strip Chart Recorder

Table 6-2.

Recorder Line Voltage Selection
If Line Voltage is:

Set a.c. input connectorto:120 ±10 Vac
100 ±10 Vac
220 ±10 Vac
240 ±10 Vac

proper value for the line voltage in use (see the Recordermanual).
If the Strip Chart Recorder is to be adapted for 200-240
Va.c. operation, you must alter the power cable by installing a male plug on the power cable that is specified
for that power source outlet. Observe the following CEE
wire color code for the cable:
Brown - high (live)
Light Blue - low (neutral)
Green & Yellow - earth/groundTo use the recorder with a Series 4400 system, place therecorder on any horizontal, flat, relatively level work surface near the load frame. The recorder is designed to operate in a horizontal position, so do not prop it up
vertically or on a slant.
Determine the line voltage of the mains supply, and if
necessary, set the line voltage selector on the recorder as
described in the previous section.

System Options

Installation

6-7

Strip Chart Recorder

M10-94400-1

Plug the recorder input cable (A570-26), provided withthe unit, into the ANALOG OUT connector on the rearof the console. Connect the other end of the cable into
the 9-pin D-shell connector on the right-rear corner underneath the recorder.

Operation
The Series 4400 system does not provide any control
functions for the recorder; it merely supplies an analog
data signal which is scaled and plotted by the recorder.
Thus, operation of the recorder is covered in an Operating Instructions Manual supplied with the recorder,
where you will find the necessary control settings, setup,and operating information. The following sections givethe procedures for using the recorder with the Series
4400 Testing System. The procedures given are for a
one pen (single channel) recorder, and thus all values are
given in terms of load. Scaling and calibration procedures for the second channel (Strain) are identical to theload channel procedures.
Pen Scaling

Pen scaling can be set at the recorder so that zero andfull scale fall exactly at the edges of the chart. If thesetwo points are accurate, then the scale divisions printed
on the chart can be used to accurately determine thevalue of all other points on the test curve.
To scale the recorder pen for a load signal:(a) Press the 0 (ZERO) button on channel 1 of the recorder. This removes all input signals and shorts the
input for a no-signal condition.

6-8

Strip Chart Recorder(b) Use the VAR control to set the pen exactly on the leftedge of the chart. This will be more precise if thechart is moving, since the pen will draw a line instead of making a dot.
(c) Select a scale factor on the RANGE switch which
gives full scale deflection of the pen. Check that thepen falls exactly on the right edge of the chart.
Pen Calibration

Pen calibration assures that the pen position coincides
exactly with the load cell signal. The method used tocalibrate the pen depends on the type of load cell in use.
If a self-identifying load cell is installed, the procedure
is to apply a precision calibration voltage to the penchannel by closing the calibration relay, and then adjusting the pen to the chart using the variable control on therecorder. If a non-self identified load cell is installed, aprecision calibration weight is hung from the load celland the pen adjusted with the variable control. The specific procedures are as follows:(b) Adjust the CAL variable control on the recorder to set
the pen to exactly the value of the precision weight.
(c) If a self-identified load cell is installed, the above procedure can be used or, by closing the load cell calibration
relay, a precision load signal will be applied to the recorder (refer to the Note and Example below).

System Options(a) If a non-self identified load cell is installed, hang aprecision weight, within the range of the load cell,from the cell and observe the pen deflection. The
amount of pen deflection depends on the RANGE
switch setting, which sets the chart full scale value.

6-9Strip Chart Recorder

M10-94400-1(1) To close the load cell relay, press the LOAD CAL
key on the Series 4400 front panel, then press 0 and
ENTER. The LOAD CAL and LOAD BAL LEDs
are both lit when this relay is closed.
Table 6-3.
LOAD CELL
MAXIMUM
CAPACITY

50 N
500 N
5 kN
10 kN
50 kN
150 kN
300 kN
600 kN

Calibration Signal for Load Cells*CALIBRATION SIGNAL VALUE - SI EQUIVALENT
NEWTONS

25
250
2 500
5 000
25 00075 000150 000
300 000

POUNDSKILOGRAMS

5.62
56.2
562
1 124
5 620
16 86133 72167 443

2.55
25.49
254.9
509.8
2 549
7 648
15 29630 592*To convert newtons:
1. Multiply by 0.224 808 9
to obtain pounds.

(2) IMPORTANT – After checking pen deflection,
open the calibration relay by repeating the key sequence to close the relay: press LOAD CAL, 0,
ENTER on the keypad. The LOAD CAL and
LOAD BAL LEDs go out. A test cannot be
started when the calibration relay is closed.
Note

6-10

The voltage generated when the load cell calibration relay is closed is the same as would be
produced by an applied load equal to 50% of
the maximum capacity of the cell when using

Strip Chart Recorder
SI units, as shown in Table 6-3. In Metric units,
the calibration voltage is 50.9% of full scale,
while in U.S. Customary units, this voltage is
56.2% of full scale (51.9% for a 600 kN Load
Cell).

EXAMPLE

System Options

Assume a 5 kN (1000 lb, 500 kg) load cell is installed
and English units are in use. A RANGE of 100 is selected for a recorder full scale value of 1000 lb. The pen
will deflect an equivalent of 562 lb. (52.6% of full scale)when the calibration relay is closed. This signal appearson the LOAD display if TRACK is selected.

AS-1

6-11

X-Y Recorder

M10-94400-1

X-Y Recorder
Description
The optional Instron X-Y Recorder is another type of recorder that plots two variables against each other. Unlike
the Strip Chart Recorder, the X-Y Recorder’s chart is stationary, and plots are made with one or two moving
pens. Load versus Strain, Load versus Extension, andLoad versus Time are common plots that are made withthis device.
The Instron X-Y Recorder has single-range X and Y
axes which require -10 to +10 Vd.c. input signals for fullscale. The X-axis has a 38 cm (15 in.) span, and the Yaxis has a 25 cm (10 in.) span. The input on the Y-axis
from a Series 4400 system is a load signal which is automatically ranged to full scale; you can select a gain factor on the Recorder Panel. The X-axis can be set to track
an extensometer signal or the recorder’s internal timebase. Pipping of the pen (event marker) is possible
through a PIP contact on the rear panel connector (referto page 6-41).
The recorder can be operated in English or metric units,
using a front panel switch. A supply of 11 x 17 inchgraph paper, compatible with the calibrated units, is provided with the recorder.
An instruction manual is supplied with the recorder andshould be referred to for unpacking, specifications, paper and pen loading, theory of operation, routine maintenance and troubleshooting procedures.

6-12

X-Y RecorderSpecifications
The following is a complete set of specifications for the
X-Y Recorder:
Calibrated Ranges:
0.5, 1, 2, 5, 10, 20 mv/cm
0.05, 0.1, 0.2, 0.5, 1, 2 V/cm
Variable Range Expansion:

up to 250% (sensitivity increase)

Zero Line Shift:Over entire writing width ±100%

Input Impedance:

2 MΩ

Max. Source Impedance:

5 kΩ

Measuring Error:±0.25%

Temperature Drift ofZero Line:
Max. Input Voltage:

approx. 0.5µv/K, mv ranges
approx. 50 µv/K, V ranges±50 V

Overload capacityof Inputs:±50 V

50 Hz Suppression:

31 dB

60 Hz Suppression:

36 dB

Common-mode
Rejection CMRR:

130 dB @ 1 kΩ

Paper Size:

DIN A4

Usable Writing Area:

210 x 290mm

Pen Type:

HP Pens

System Options

Max. Voltage between
Inputs and Ground:
±50 V

6-13

X-Y Recorder

M10-94400-1

Paper Hold-down:

Electrostatic

Max Writing Speed
X-Axis:Y-Axis:70 cm/sec
100 cm/sec

Cutoff Frequency @ -3dB
X-Axis:1.4 Hz (280 mm)
Y-Axis:3 Hz (200 mm)
Power Consumption
Operating:Standby:

25 VA
10 VA

Input Voltage:

100, 110, 220, 240 Va.c. ±10%

Dimensions (WxHxD) 379.5x150x372 mm
Weight:7 kg approx.

Ordering information for X-Y Recorder supplies isgiven in Table 6-4
Table 6-4.
Part Number

3750-139
3750-140
3750-144
3750-145
3750-146

6-14

Recorder Supplies
Description

Sheet Paper, metricunits
Sheet Paper, U.S.
Customary units
Pens, bluePens, redPens, black

Quantity

100 sheets/pkg
100 sheets/pkg
5 pens/pkg
5 pens/pkg
5 pens/pkg

X-Y RecorderInstallation
Power Requirements

The X-Y Recorder is set at the factory to accept a main
power input of 120 ±10 Va.c., single phase. A 3-wirepower cable for this voltage is included. If the powersource to be used is not 120 ±10 Va.c., the power input
switch on the underside of the recorder can be set forother voltages in the range of 100 to 240 Va.c. (refer toTable 6-2).
To adapt the X-Y Recorder for a different line voltage,
set the input power switch to the proper input voltage foryour location. Be sure the line fuse is the proper value
for the line voltage in use (see the Recorder manual).
If the X-Y Recorder is to be adapted for 200-240 Va.c.
operation, you must alter the power cable by adding amale plug that is specified for that power source outlet.
Observe the following EEC wire color code for the cable:
Brown - high (live)
Light Blue - low (neutral)
Green & Yellow - earth/groundTo use the X-Y Recorder with a Series 4400 system,
plug the cable (A570-26) provided with the unit into theconnector on the underside of the recorder and into the
ANALOG OUT connector on the rear panel of the Series 4400 console.

System Options

Signal Input Connection

6-15

X-Y RecorderNote

M10-94400-1

The recorder must be electrically grounded tooperate properly.

Operation
The Series 4400 system does not provide any control
functions for the recorder; it merely supplies analog data
signals which are scaled and plotted by the recorder. The
following sections give the procedures for using the recorder with the Series 4400 Testing System. The procedures given are for a one pen (single channel) recorder,
and thus all values are given in terms of load. Scaling
and calibration procedures for the second channel(Strain) are identical to the load channel procedures.
Initial Setup

Refer to Figure 2-1 for the function of the Recorderfront panel controls. All controls specified in the following procedures are located on the front panel of the Recorder, unless otherwise noted. Use the following
procedure to set up the initial operating conditions for
the Recorder:(a) Turn on the Recorder by pressing the ON/OFF
switch to the I position. The green light beside the powerswitch comes on.
(b) Select the system of measurement units for the Recorder by setting the INCH/METRIC switch to theunits desired.
(c) Press the STANDBY/M switch to the Down (M) position.

6-16

X-Y Recorder
Calib.
X Axis Controls

Main Control Module

Y Axis Controls

Time Mode

Select.

X Servo Mode

Moves Pen on

Pen moves on X axis as a

Positions pen on the Y axis

Select switch

X axis from left tofunction of an analog signal from ain response to the load force

position to

be addressed for input signals toright at a ratetransducer like an extensometer.

applied to the load cell. If thematch chart

be displayed.

determined by the

The Strain option must be installed

Area button is set to a value other

paperTime Base Selector

for this to function.

than its default value of 1.00, thegraduations

These basic controls must

Switch setting.

pen position can represent Stress.

XTs/inch

125

50

s/cm

50

20 10

25 12.5 5
5

2

1

Y

MAGNIFICATION FACTOR
100 50 20 10

2.5 1.25 0.5 0.25

5

2

1

MAGNIFICATION FACTOR

0.5

100 50 20 10

5

2

1

0.5

0.5 0.2 0.1

ON
STAND
BY

XY

CAL

+

O

CAL

+

O

INCH

YT

VAR

-

M

VAR

-

M

METRIC

1
0
M

START

RESET

MODE

OFF

Stand By/
Measure switch

Pen Lift

Input disabled
pen up-rightPen UpElectrostatic

Calibrate/Variable

paper hold-down

span switch

paper hold-down

Pre-set Mag.

+ Up Y-axis

OFF

Factor ON+ Rt, X-axis

Enable/Disable
Polarity Switch

switchInput Disabled

STAND

PUSHBUTTON UP

BY

CAL

M

VAR

PUSHBUTTON DOWN
Input enabled
Pen to Input
position

Figure 6-1

Pen Down

+

O

-

M

paper hold-down

Adjustable Mag.

- Up Y-axis

ON

Factor ON- Rt, X-axis

Input Enabled

Model 4400 X-Y Recorder Panel

6-17

X-Y Recorder(d) Press the Pen Lift switch to the Up (pen up) position.
(e) Place a sheet of chart paper on the platen of the Recorder with the lower edge of the sheet against thebottom paper stop, and its left edge against the left
paper stop. Press the Paper Hold-down switch to the
Down (On) position.
(f) Press the X-Y/Y-T MODE switch to the Up position
for X-Y operation, or to the Down position for Y-T
operation.
Calibration

Calibration of the Recorder consists of setting the pen
position for zero and full-scale on the chart. Pen calibration assures that the pen position coincides exactly withthe transducer (load cell or extensometer) signal. The
method used to calibrate the pen depends on the type oftransducer in use.
If a self-identifying transducer is installed, the procedure isto apply a precision calibration voltage to the pen channel
by closing the calibration relay, and then adjusting the pen
to the chart using the variable control on the recorder.

When the zero and full scale pen positions fall exactly atthe edges of the chart, the scale divisions printed on thechart can then be used to accurately determine the valueof all other points on the test curve.

System Options

If a non-self identified transducer is installed, a precisioncalibration weight is hung from the load cell, or an extensometer calibrator displaces the extensometer a known
amount, and the pen is adjusted with the variable control.

6-19

X-Y Recorder

M10-94400-1

The X-Axis and Y-Axis Modules are essentially identical and both are calibrated in the same way. Use the following procedure for both types of Modules:(a) Set the polarity switch (+/–) to your required polarity
as follows:
X-Axis:+ (button UP) = increasing signal toward top of chart– (button DOWN) = increasing signal toward bottomof chart
Y-Axis:+ (button UP) = increasing signal toward right ofchart– (button DOWN) = increasing signal toward left ofchart(b) Set the pen to the zero position by pressing the O/M
button so that is pops up to O (Up position). This disables the input and sets the pen to the edge of the chart.
If the pen is not exactly on the edge of the chart (press
the Pen Lift switch to lower the pen to see where it
touches the paper), use the thumbwheel on the Axis
Module to adjust the pen position. Note that the Y-Axis
thumbwheel will move the pen up and down, while the
X-Axis thumbwheel moves it left and right.
(c) After the pen has been zeroed, press the O/M switch
to M. If you fail to do this, you will not be able toread any input signals.
(d) Set the MAGNIFICATION FACTOR switch to 1.
(e) Set the CAL/VAR switch to VAR.
6-20

X-Y Recorder(f) If a self-identified transducer is installed, closing thetransducer calibration relay will apply a precisiontransducer signal to the recorder (refer to the Noteand Example below).
(1) To close the load cell or extensometer relay, press
the LOAD CAL or STRAIN CAL key on the
Model 4400 front panel, then press 0 and ENTER.
The LOAD CAL and LOAD BAL or STRAIN
CAL and STRAIN BAL LEDs are both lit when
this relay is closed.
(2) Using the VAR screwdriver adjustment on the Recorder Module, adjust the pen position exactly tothe calibration voltage.

Note

AS-1

The voltage generated when the load calibration relay is closed is the same as would be
produced by an applied load equal to 50% of
the maximum capacity of the cell when using
SI units, as shown in Table 6-3. In Metric units,
the calibration voltage is 50.9% of full scale,
while in U.S. Customary units, this voltage is
56.2% of full scale (51.6% for 600 kN Load
Cells).

System Options(3) IMPORTANT – After setting pen deflection, open
the calibration relay by repeating the key sequence
to close the relay: press LOAD CAL, 0, ENTER or
STRAIN CAL, 0, ENTER on the keypad. The
LOAD CAL and LOAD BAL or STRAIN CAL and
STRAIN BAL LEDs go out. A test cannot be started
when the calibration relay is closed.

6-21

X-Y Recorder

M10-94400-1(g) If a non-self identified transducer is installed, hang aprecision weight, within the range of the load cell,from the cell, or displace the extensometer with thecalibrator, and observe the pen deflection.
(h) Adjust the CAL variable control on the recorder to
set the pen to exactly the value of the precision
weight or extensometer deflection.
Time Base Operation

You can use the X-Y Recorder in a time-based mode, if desired. The Y-Axis signal is plotted against a recorder-generated time base which can be correlated with crosshead
speed. The time scale can be switch-selected for a range of
0.1 seconds per centimeter to 50 seconds per centimeter or
0.25 seconds per inch up to 125 seconds per inch.
Since the Model 5500 uses chart speeds in units of
inches/minute or centimeters/minute, and the RecorderTime Scale is in units of seconds/inch or seconds/centimeter, Table 6-5 gives speed conversions between the two.
Table 6-5.

Chart Speed Conversions
Chart Speeds

Sec/InIn/Min
Sec/CmCm/Min

0.25
240
0.1
600

0.5
120
0.2
300

1.25
48
0.5
120

2.5
24
1
60

5
12
2
30

12.5
4.8
5
12

25
2.4
10
6

50
1.2
20
3

125
0.48
50
1.2

To set up the Time Base on the Recorder, do the following:(a) Press the X-Y/Y-T MODE switch down to Y-T.

6-22

X-Y Recorder(b) Choose a chart speed that correlates with the Model
4400 testing speed. Look up that speed in Table 6-3
and set the Recorder Time Base Selector switch tothe corresponding speed.
(c) Press the RESET button on the Time Base Module.
The pen will lift and return to the left edge of thechart.
Note

The pen will return automatically when it
reaches the end of its travel.

The Recorder is now ready for testing system operations.
Normal Operation

To record a plot of the Model 4400 Test, do the following:(a) Set up the Recorder as in the previous Sections.
(b) Check that the STANDBY/M switch is in the M position, that the CAL/VAR switch on both X and Y
Modules is in the VAR position, and that the O/M
switch on both X and Y Modules is in the O position.

(d) Press the UP or DOWN button on the Main Panel ofthe Model 4400 Console. In both the X-Y and Y-T
Modes, this starts the test at the load frame and starts
the Recorder.

System Options(c) Press the Pen Lift switch to the Pen Down position.
The pen will not go down immediately, but will godown automatically when the test starts.

6-23

Printer

M10-94400-1

Printer
Description
The printer option for a Series 4400 System provides a
hard copy record of test parameters and results. The
printer features up to 80 characters on a line, which may
consist of letters, numbers, or special symbols, printed at
a rate of about 100 characters per second. The printout
includes the name, value, and units of several parameters, as described on page 6The printer is set up for and supplied with 91/2 x 11 inch
fan-fold paper. Additional pads of paper are available
from Instron.

Installation
To use the printer with the Series 4400 System, plug thesignal cable provided with the unit into the RS-232 connector on the rear panel of the console.
The printer and the Series 4400 System are set up at thefactory for a baud rate of 1200. A baud rate of 300 can beselected, if required. To change the baud rate in the printer,
refer to the manufacturer’s manual provided with the unit.
To change the baud rate in a Series 4400 System requires changing a switch position on a 3-section DIP
switch assembly located on the lower rear of the control
console (see Figure 8-2). The No. 2 switch of the DIP
switch assembly, marked 1200 baud, controls the systembaud rate. The switch is accessed through an opening in
the rear cover of the console. To change to 300 baud,
push down on the OPEN side of the switch with apointed tool, such as a ball point pen.
6-24

Printer

Operation
An operating instructions manual is supplied with theprinter. This section provides the additional procedures
required to use the unit with the Series 4400 System.
(a) To obtain a printout at any time, press the PRINT
key on the Main Panel.
(b) To obtain a printout automatically at the end of atest, enter the key sequence [S1] [6] [+/–] on the keypad. The Main Panel Display must show “SL 6" forthis option to be enabled, and ”SL-6" to be disabled.
Toggle the “+/-” key to set the condition required. A
printout occurs after every test as long as the option
is enabled.
Note

All crosshead commands are locked out during
a printout.

Printout Format
The format of the Printer output consists of up to nine
lines and five fields, depending upon parameters and actions that are included or omitted as described below.

Line 1 – indicates the current active units for Load, Extension, Strain, and Energy. If Strain is not used, theStrain field (No. 4) is omitted.
Line 2 – lists Peak data.
Line 3 – lists Break data. If specimen bread did not occur, line 3 is omitted.

System Options

The printout format is:6-25

Printer

M10-94400-1

Line 4 – Preset Point 1 data. If Preset Points are suppressed, line 4 is omitted.
Line 5 – Preset Point 2 data. If Preset Points are suppressed, line 5 is omitted.
Line 6 – Preset Point 3 data. If Preset Points are suppressed, line 6 is omitted.
Line 7 – Crosshead Speed and Area (Area Compensation)Line 8 – Energy (total). If Energy is suppressed, the Energy field (No. 5) and line 8 are omitted.
Line 9 – Cycle Count/Pip Count.

Printer Units
The units that appear on a printout depend upon the selection of operating units (English, metric, SI). In addition,
the printed units for Strain depend upon the type of extensometer installed (self-identified or non-self identified) andthe strain operating mode (percent or displacement).
The units that will appear in the printout of the Strain
field are shown in Table 6-6.
Table 6-6.
Extensometer Type

Self-identified

Non-Self Identified
6-26

Strain Units Printout
Strain Mode

Percent
Displacement(English)Displacement (metAll

Strain Units

%
MILS
MM
SN

Printer

Besides the system operating units, the printed units forEnergy and Preset Points depend upon the independent
variable (extension or strain), and, if strain is the independent variable, the extensometer type (self-identified
or non-self identified).
The units that appear in the printout of the Energy field
and for Total Energy are shown in Table 6-7.
Table 6-7.
Independent Variable

EXTENSION
EnglishEnergy Units Printout
Extensometer Type

Energy Units(Not Applicable)

Metric

LB*EX IN/A
(Notes 1 and 3)
KGF*EX MM/ASI

KN*EX MM/A

System Options

Notes

6-27

PrinterTable 6-8.

M10-94400-1

Printout with Strain as Independent Variable
LB/A

IN

PEAK =-1.616E02 5.469
BREAK =
-9.745E01 5.482
PPT1 =-2.953E-01
PPT2 =-2.953E-01
SPEED =
5.000 IN/MIN
TOTAL ENERGY =-7.737E00

MILS

LB*SI

23.54
-7.69E00
23.45-7.69E00
10.00-2.870E00
20.00
5.827E00
AREA = 2.00E-01
LB*SI MILS/A

Table 6-8 shows a typical printout with Strain as the independent variable and Strain 1 as the active channel.
Table 6-9 shows a typical printout with Extension as theindependent variable. (Note that AREA is greater than
1.00 in both printouts, so the Load and Energy fields
show division by “A”.)
Table 6-9.

Printout with Extension as Independent Variable
LB/A

IN

PEAK =-2.315E02 3.453
BREAK =
-2.303E02 3.466
PPT1 =-1.830E02 1.000
PPT2 =-1.830E02 3.00
SPEED =
5.000 IN/MIN
TOTAL ENERGY =-7.737E00

6-28

MILS

23.97
24.00

LB*SI

-4.019E02-4.057E02-3.874E01
3.095E02
AREA = 2.00E-01
LB*EX IN/A

Printer

System Options

Notes

6-29

AC/DC Strain Conditioner

M10-94400-1

AC/DC Strain Conditioner
The AC/DC Strain Conditioner Option is an add-on
printed circuit board that allows the use of extensometers, such as the Instron Video Extensometer, the High
Resolution Digital (HRD) Extensometer, and otherstrain transducers that use d.c. excitation and signal processing. This conditioner can also be used as a normal
a.c. conditioner, accepting inputs from Instron’s normalline of extensometers.
In order for the AC/DC Strain Conditioner to operateproperly in the Model 4400 Testing System, the Model
4400 Console must have an updated main printed circuitboard, which has the Instron Part Number A570-66. If
the console has an updated board, there should be asmall sticker on the outside of the console cover withthis part number on it.
The AC/DC Strain Conditioner also requires an updated
version of the system firmware. The firmware must havea date of March, 1994 or later. To determine if your system contains this or a later version, press the key sequence [S1] [9] [ENTER], and a date will appear in themain display. If this key sequence does not work, yoursystem contains an older version of the firmware, and
the AC/DC Strain Conditioner will not work. You can
upgrade your firmware by ordering Catalog Number
3750-064, which will ensure that you receive the latest
version of the Model 4400 Firmware release.

6-30

AC/DC Strain Conditioner

Specifications
AC/DC Strain Conditioner
Catalog Number
2210-865
Input

Differential ±11V maximum
10 Kohm max impedance

Calibration±7 to ±11 Volts, full scale
sum of signal and imbalancemust not exceed ±11 V input
maximum

Input Selection(DC vs AC)

Automatic by jumper in adapter
cable

Installation
If the AC/DC Strain Conditioner Option has not alreadybeen installed, you can do it yourself by following thesesteps:(a) Shut off all electrical power to the system.
(b) Disconnect all cables from the rear of the console.
Tag each cable if you are not sure where they will go
when you replace them.

(d) Lay the console face down on a flat, smooth surface.
Use a cloth or pad under the console if the work surface is rough or dirty.
(e) Remove the six M4 socket head screws that attach
the rear cover to the console case, and retain thesescrews. Lift off the rear cover and set it aside. It is

System Options(c) Remove the console from the load frame by disconnecting the two halves of the mounting bracket.

6-31

AC/DC Strain Conditioner

M10-94400-1

not necessary to remove the mounting bracket fromthe rear cover.
(f) Orient the new Strain Conditioner printed circuit cardso that the four mounting holes in the card align withfour plastic posts protruding from the back of themain printed circuit board. The connector on theStrain Conditioner card should align with the connector labeled X3 on the main board. Press the Strain
Conditioner card onto the posts; when pressed firmly,
the card will “snap” into place – no other mounting
hardware is required. Ensure the connectors matefully.
(g) Replace the rear cover of the console, using the six
M4 socket head screws removed in Step (e).
(h) Remount the console on the load frame and reconnect all cables removed in Step (b).

Operation
There are no specific operating instructions for the
AC/DC Strain Conditioner, since it is operated in thesame manner as a normal Strain channel. There are a
few operating notes, however:•

6-32

When using a DC Extensometer, it must beconnected to the Model 4400 Console with thespecial cable supplied with the conditioner (Catalog
Number 2210-864). This cable has a BNC connector
on one end that connects to the extensometer. Thereis a 25-pin D connector on the other end thatconnects to the STRAIN connector on the rear of theModel 4400 Console. The 25-pin D connector

AC/DC Strain Conditioner

contains jumpers that tell the Model 4400 that a DC
Extensometer is attached.
When using a DC Extensometer, the Strain channel
is calibrated in the same manner as a normal Strain
channel. See the calibration instructions in Chapter
5 of this manual.

System Options

•

6-33

Preset Points

M10-94400-1

Preset Points
Description
The Preset Points option allows you to specify the values of up to three independent variables at three preset
points for recording the values of three dependent variables. Preset Points data is accessible through the RS232 connector on the rear panel, but there is noprovision for displaying it on the front panel. The printermust be available to print out Preset Points data.
The Preset Points are set up to trip on a specific value ofeither extension or strain. When this value is reached,
the system automatically records the values of load andenergy at those points. Figure 6-1 is a typical test curveshowing the data obtainable at preset points.

Figure 6-1.

6-34

Typical Test Curve with Preset Points

Preset Points

Operation
The procedure required to use the Preset Points Option
is to set the independent variable, set the preset point values, and then enable the option to get a printout at theend of a test. The default condition of the independent
variable is the active strain channel or extension if thestrain option is no installed.
To set the independent variable, enter this sequence on
the keypad:[S1] [5] [+/–]The main Panel Display will show either:
SL–5 for Strain, orSL 5 for Extension
Toggle the [+/–] key until the required display appears.
The key sequence [S1] [5] [+/–].....[+/–] also
toggles the Energy integration variable between extension and strain.

The default values of the Preset Points (PPT1, PPT2,
PPT3) are:
PPT1
Extension (in.) 1
Extension (mm) 20
Strain (%)
100

PPT2
3
60
300

PPT3
10
200
1000

To set other values within the range of the load or straintransducer in use, enter the key sequences:[S1] [41] PPT1 [ENTER]

System Options

Note

6-35

Preset Points

M10-94400-1[S1] [42] PPT2 [ENTER][S1] [43] PPT3 [ENTER]
Where PPT1, PPT2, and PPT3 are indicated, enter theactual numerical value of the independent variable; Extension in inches or millimeters; or Strain in either percent, mils, or millimeters.
To obtain a printout of load and energy (refer to the next
section, “Energy”) at the preset points, enter the key sequence:[S1] [4] [+/–]The Main Panel Display will show either:
SL–4 to suppress printout, or
SL 4 to enable printout.
Toggle the [+/–] key until the required display appears.
The printed values are always expressed in the current
operating units.
Note

6-36

The key sequence [S1] [4] [+/–] does not disable the Preset Point function of the IEEE-488
supervisory program.

Energy

EnergyDescription
The Energy option allows you to obtain, at the end of atest, the total energy under the load curve, the values at
Peak and Break, and the values at three preset points. Energy is defined as the integral of composite load (analog
load divided by analog area) and extension or strain. Recorded values may range from 1.000E-04 to 2.147E05.
Energy data is accessible through the RS-232 connector
on the front panel. The printer must be available to print
out Energy data.

Operation
The procedure required to obtain energy readouts is to
set the independent variable, and then enable the energy
option so a printout can be obtained at the end of a test.
The default condition of the independent variable isstrain, but extension becomes the independent variable if
strain is not used.
To set the independent variable, enter the following sequence on the keypad:[S1] [5] [+/–]

SL–5 for Strain, orSL 5 for Extension
Toggle the [+/–] key until the required display appears.
This action also toggles the independent variable for Preset Points.

System Options

The Main Panel Display will show either:

6-37

EnergyM10-94400-1

To obtain a printout of energy values at the end of a test,
enter the key sequence:[S1] [3] [+/–]The Main Panel Display will show either:
SL–3 to suppress printout, or
SL 3 to enable printout
Toggle the [+/–] key until the required display appears.

6-38

Cycle Counter

Cycle Counter
A Cycle Counter function is another feature of theModel 4400 Console that counts and displays crosshead
reversals of direction. Each time the crosshead changes
direction as a result of a limit action, a key press at theconsole, or an IEEE Command, the cycle count is incremented by 0.5 counts. Keep in mind that a full cycle ofcrosshead motion includes two crosshead reversals; one
when it reaches the end of its travel in a positive direction, and another when it reaches the end of its travel ina negative direction. The count is reset to zero at thestart of each test, and the maximum count is 9999.
A count of Pip events (see the next Section “Pip Control”) is also maintained. This count is set to zero at thestart of a test, and increments by one for each Pip sensed.
A cycle count limit is also available. This limit willcause the crosshead to stop when the count limit isreached. This action is not programmable, and a RETURN action is not available. A cycle limit value ofzero indicates no action (i.e., the limit is ignored).
The front panel can display both the cycle count and thePip count. The selection of which counter to display is
performed with a [S1] [8] [+/–] key sequence. as follows:“S8 3 = display Pip CountTo see the selected display, press [S1] [+/–]. The setup
display on the Main Panel shows the selected countvalue until some other key is pressed which takes over

System Options“S8–3" = display Cycle Count (default)

6-39

Cycle Counter

M10-94400-1

the setup display. Simply press [S1] [+/–] again to returnto the count display.
The cycle limit action can be set on the front panel bypressing [S1] [8] [1] . When the S1 and 8 are pressed,
the setup display will show “S1 8". When the 1 ispressed following this, the current limit value will beshown. A new value can be entered at this time.
The cycle count and the Pip count can be included in theprintout report from the printer. To enable the counterline in the printout, press [S1] [8] [+/–], as follows:
S1–8 = disable Counter printout (default)
S1 8 = enable Counter printout
The printout line appears as:
CYCLES = 123.5

6-40

PIPS = 40.00

Pip Control

Pip Control
The capability of event marking the load signal while itis being recorded is provided through the use of a PIP
jack on the rear connector panel of the testing system. A
pip control device connected to the PIP jack will produce a small, rapid, vertical deflection, or “pip”, of therecorder pen. The resulting mark on the chart serves as aconvenient reference or “event marker” for indicating
points of interest on a load-elongation curve for a test
specimen.
A pip control device can be one built into an extensometer, or as simple as a hand-held button switch. Control
device options include a Remote Manual Pushbutton (Instron Catalog No. 2310-516), an Instron XL Elastomeric
Extensometer, or an Instron Incremental Extensometer.

A pip filter is included in the Pip Control circuit to suppress spurious pips from such devices as the Incremental
Extensometer. When the Pip signal is sensed going fromthe open condition to the closed condition, as when aconductive band of the Incremental Extensometer firstpasses under the contacts, a pip is reported to the IEEE
Bus and a blanking delay is started. During the delay,
the Pip signal is ignored. When the delay ends, thesearch for the next active transition resumes.
A variable blanking period can be entered, either fromthe front panel or from a computer connected to the

System Options

The pip height is factory set at approximately one chart
division on a 250 mm (10 inch) wide chart. The amplitude is not affected by the automatic ranging of the load
signal.

6-41

Pip Control

M10-94400-1

IEEE Bus. To enter a delay from the front panel, use thekey sequence:[S1] [8] [2]When the S1 and 8 are pressed, the setup display willshow “S1 8". When the 2 is pressed, the current delay
value will be shown. A new value can be entered at thistime.
The delay value is entered in units of seconds with aresolution of 0.005 seconds. The delay is saved in nonvolatile memory. The default value is zero, which allows
Pips to be sensed at the maximum rate. The maximum
rate for reporting of pips is one every 50 milliseconds(the maximum IEEE report rate). The maximum delay is9999 seconds.
By proper selection of the delay, the extra pips due tomomentary loss of contact on the conductive band will
be eliminated. The proper delay is a function of the test
speed and the width of the conductive band. The conductive bands on the Incremental Extensometer are 1/32
inch wide.
For test speeds in inches per minute:
Delay =2Speed

For test speeds in millimeters per minute:
Delay =50
Speed

Table 6-10 gives examples of test speeds versus typical
pip blanking delays.

6-42Pip Control

Table 6-10. Example Pip Delay Values vs Test Speeds
Delay (seconds)
0
0.100
2.000
20.00
9999
Delay (seconds)
0
0.500
1.000
50.00
500.0
9999

System Options

Test Speed (in/min)
above 20201
0.1
below 0.0002
Test Speed (mm/min)
above 1000
100
50
1
0.1
0.005

6-43

Air Kit Option

M10-94400-1

Air Kit Option
Overview
The Air Kit Option is a set of hardware and firmware toprovide control and operation of pneumatic grips in several manual and semi-automatic modes during testing
sessions. It consists of a Pneumatic Control Box, a Footswitch assembly, and interconnecting electrical cables
and air hoses. It does not include the grips or the air supply. The air kit connection on the load frame, internal
wiring, circuits, and firmware are part of the Model
4400. A complete description of the Air Kit, its specifications, installation, manual operation, maintenance, andparts breakdown are all given in the Pneumatic Grip
Control manual, M10-82701-1.
Early Model 4400 Consoles did not have the required
grip control firmware. These systems require a separate
firmware upgrade to operate an aftermarket (not purchased with the testing system) Air Kit Option. If you
are not certain whether your system contains the grip
control firmware, use the grip control key sequences
given later in this section to see if the functions are present.

Description
In the Model 4400, the upper and lower pneumatic grips
are actuated by air pressure controlled by two solenoid
valves in the Pneumatic Control Box. The grips are passive in that they do not require pneumatic or electricalcontrols as part of the grips themselves. In operation, thegrip jaws close when air pressure is applied and the sole-

6-44

Air Kit Option

noid activated, and open when the solenoid valve is deactivated and air pressure released.
The Pneumatic Control Box is mounted on one of thecolumns of the load frame. This unit contains the solenoid valves and a small printed circuit board. It is the
hub of the pneumatic and electrical connections; onehose provides pressurized air, and two hoses provide
controlled pressure to the upper and lower grips. One
electrical cable connects to the footswitch, and anotherconnects to the load frame.
The footswitch assembly contains two foot pedals for
opening and closing the grips. Each pedal operates a momentary electrical switch, which in turn operates the solenoid valves. The role of the CLOSE pedal in theclosing sequence for the grips depends on the mode ofoperation selected, but the OPEN pedal always causes
both grips to open.

Operation

In addition, one other function is the Pretension Hysteresis level, which is set at 50% of the Pretension level.
This value is fixed, and cannot be adjusted.
Grip Control Enable/Disable overrides all of the othersettings. It must be enabled for any of the automatic features to operate. This control provides a convenientmeans of disabling automatic operation while maintaining a combination of automatic settings for later reuse.

System Options

The Air Kit Option operates in several modes, selectedfrom the Console front panel or through the GPIB Computer Interface from an external computer. The functions
are listed in Table 6-11, along with their default settings.

6-45

Air Kit Option

M10-94400-1

Table 6-11.

Air Kit Functions

Setting
Grip Control Enable/Disable
Pretension Enable/Disable
Excess Tension Enable/Disable
Automatic Start Enable/Disable
Automatic Release Enable/Disable
Pretension Level
Excess Tension Level

Default
Disabled
Disabled
Disabled
Disabled
Disabled
00

The Pretension, Excess Tension, Automatic Start, andAutomatic Release functions enable or disable their respective features. They are independent, except that the
Excess Tension function will not operate unless Pretension is also enabled.
The Pretension and Excess Tension levels can be set independently of their respective enable controls, but will
have no effect while disabled.
Manual Operation

The grips can be operated in a fully manual mode if Grip
Control is set to Disabled, or if all of the other functions
are disabled.
As described in the Pneumatic Grip Control manual, in
manual operation, the CLOSE foot pedal is pressed once
to close the upper grip. It is pressed again to close thelower grip. The OPEN foot pedal opens both grips simul-

6-46

Air Kit Option

taneously when pressed. There is no other interaction
with the Model 4400 System in full manual mode.
Grip Control Function Operation

To enable the Grip Control function:(a) Press [S1] [7]. Read the current state of the Grip Control function from the Main Panel Display.
(b) The Main Panel Display will show:“S1 7" if Grip Control is enabled.
”S1–7" if Grip Control is disabled.
(c) Use the [+/–] key to toggle between the enabled anddisabled state.
Pretension and Excess Tension Operation

The operating sequence starts when the material isplaced in the upper grip. The CLOSE foot pedal ispressed to close the upper grip. The material is then fed
through the lower grip and pulled to apply pretension.
When the set level is reached, the lower grip closes automatically. The load signal is monitored until a test starts(by whatever means). If the load falls below the Pretension Hysteresis level, or rises above the Excess Tension

System Options

If the Grip Control function is enabled and Pretension isenabled, the closure of the lower grip is based on obtaining the load level set by the Pretension Level. Further,once the lower grip is closed, the load must stay above
the Pretension Hysteresis level and, if it is enabled, below the Excess Tension level. The load level is measured through the console load weighing system. A loadcell must be installed and calibrated.

6-47

Air Kit Option

M10-94400-1

level, both grips open. Both grips can be opened at any
time by pressing the OPEN foot pedal. Once both grips
are open, a new sequence can begin.
To enable or disable the Pretension function, do the following:(a) Press [S1] [7] [1]. Read the current state of Pretension from the Main Panel Display.
(b) The Main Panel Display will show:“S7 1" if Pretension is enabled.
”S7–1" if Pretension is disabled.
(c) Use the [+/–] key to toggle between the enabled anddisabled state.
To enable or disable the Excess Tension function, do thefollowing:(a) Press [S1] [7] [2]. Read the current state of Excess
Tension from the Main Panel Display.
(b) the Main Panel Display will show:“S7 2" if Excess Tension is enabled.
”S7–2" if Excess Tension is disabled.
(c) Use the [+/–] key to toggle between the enabled anddisabled state.
Automatic Start Operation

When the Grip Control function and Automatic Start are
enabled, the crosshead will start automatically in the direction of increasing load as soon as both grips areclosed (by whatever means).

6-48

Air Kit Option

This is useful with or without Pretension operation. If
Pretension is disabled, the test will start when the footpedal is pressed the second time to close the lower grip.
With Pretension enabled, the test will start when the Pretension Level is reached and the lower grip closes (automatically), provided the load stays within the Pretension
Hysteresis and Excess Tension ranges.
To use Automatic Start:(a) Press [S1] [7] [3]. Read the current state of Automatic Start from the Main Panel Display.
(b) The Main Panel Display will show:“S7 3" if Automatic Start is enabled.
”S7–3" if Automatic Start is disabled.
(c) Use the [+/–] key to toggle between the enabled anddisabled state.
Automatic Release Operation

When both the Grip Control function and Automatic Release are enabled, both grips will open when a test ends
(by whatever means). This avoids the need to press theOPEN pedal to start the next manual or pretension sequence.

(a) Press [S1] [7] [4]. Read the current state of Automatic Release from the Main Panel Display.
(b) The Main Panel Display will show:“S7 4" if Automatic Release is enabled.
”S7–4" if Automatic Release is disabled.

System Options

To use Automatic Release:

6-49

Air Kit Option

M10-94400-1(c) Use the [+/–] key to toggle between the enabled anddisabled state.
Set Pretension Level

To set the Pretension Level, do the following:(a) Press [S1] [7] [5].
(b) After the [5] key has been pressed, read the current
Pretension Level on the Main Panel Display.
(c) To change the Pretension Level, enter the load value
for the Pretension Level on the numeric keypad on
the console. Press [ENTER] to complete the sequence.
Set Excess Tension Level

To set the Excess Tension Level, do the following:(a) Press [S1] [7] [6].
(b) After the [6] key has been pressed, read the current
Excess Tension Level on the Main Panel Display.
(c) To change the Excess Tension Level, enter the load
value for the Excess Tension Level on the numeric
keypad on the console. Press [ENTER] to complete
the sequence.
Time Delays

As mentioned earlier, the grip status feedback to the console is from the solenoid, not the grip faces. A one second time delay is used to allow the grips time to open
and close in the above sequences.

6-50

Air Kit Option
Continuous Pretension Testing

To set up for continuous Pretension testing, do the following:(a) Set a Pretension Level and enable Pretension.
(b) Set an Excess Tension Level and enable Excess Tension (this step is optional).
(c) Enable Automatic Start.
(d) Enable Automatic Release.
(e) Enable Grip Control.
(f) Set a break action of RETURN.

System Options

With these settings, you can run a single test by simply
loading a specimen in the upper grip, press the CLOSE
pedal, apply the Pretension force, and step back while
the test runs.

6-51

Air Kit Option

6-52

M10-94400-1

Test Check List

Chapter 7
Test Check List
This Materials Test Check List is included as an aid for
you to preplan a test program. It can also serve as a record for completed tests. The format of the list is only asuggestion. A different format may better suit the requirements of your particular types of tests.
SPECIMEN

Material (Type, Batch)

Date

Identification No.

Width/Diameter

Thickness

Cross-sectional Area

TEST PURPOSE and CONDITest TypeTEST RESULTS RE-

Maximum Load

Maximum Extension

Temperature (°C, °F)

7-1

Test Check List

TEST EQUIP-

M10-94400-1

Load Frame Type

Test Area

Specimen Grips Type

Load Cell Type

Extensometer (Strain )Printer

RecorderComputerOther Accessories, Special Fixtures, Equipment

TEST EQUIPMENT
Test Reference No.

System Operating Units

Load Cell Calibration

Crosshead Control

Crosshead Travel Stops

Area Compensation

7-2

S. I., Metric, English

Self/Non-Self ID

Auto/Manual

Speed

Gauge LengthMax. Limit (Extension)

Min. Limit (Gauge Length)

Sample No. and SettingEnergyPreset Points

Enable/ Disable

Enable/ Disable

Energy Integration Variable

Test Check List

Test Check List

Preset Points Independent Variable

Preset Point Values

Preset Point 2

Preset Point 1

Extensometer Calibration

Auto/Manual

Self/Non-Self ID

Strain Operating Mode

Percent (%) or Displacement

Strip Chart Recorder
Chart Speed

X-Y Recorder

X-Axis Drive Mode

% Range

Time/Proportional% Range Ratio

Position/ Time/ Strain

Position Full Scale (Span)

Time Full Scale (Minutes)

Autoprint

Enable/Disable

Printer Baud Rate

7-3

Test Check List

M10-94400-1

Display Panel
Load, Extension, Strain Monitoring (Track, Peak, Break)

Limits Assignments
Variable

Max Limit

Min Limit

Load
Extension
StrainBreak Detection

Cycle Action

REMARKS

7-4

Crosshead Action

Increase Load (Up/Down)

Crosshead Action

Overview•

Introduction . . . . . . . . . . . . . . . . . . . . . . . . Page 8-2•

Preventive Maintenance. . . . . . . . . . . . . . . Page 8-3•

Error Messages. . . . . . . . . . . . . . . . . . . . . . Page 8-4•

Rear Panel Indicators . . . . . . . . . . . . . . . . . Page 8-10•

Fault Indications . . . . . . . . . . . . . . . . . . . . Page 8-16

Maintenance

Chapter 8
MaintenanceThis chapter describes some maintenance procedures
you can perform to keep your testing system in goodworking order. If you encounter problems, a list of error
messages, and front and rear panel fault indications are
given to help you solve the problem.
In this chapter, you will learn:• What preventive maintenance procedures should be
performed periodically•

What to look for when things don’t work right•

What to do when you find the fault

8-1

Introduction

M10-94400-1

Introduction
GeneralThe Control Console for a Series 4400 testing system isa precision electronic device that is designed for longterm trouble-free operation with only minimum periodic
maintenance. A Resident Test Program features an automatic Self Test Routine, as described elsewhere in thismanual, which provides assurance of console reliability
each time you power up the instrument.
If the console does malfunction, this chapter describes
how to display and read error messages using the Diagnostic Monitor mode of the Resident Test Program. The
functioning of test LEDs on the rear of the console isalso described.
Included in this chapter is an interconnection drawing of
the Series 4400 console.

Special Maintenance Considerations
The control console contains a single printed circuitboard, on which are located all the features and functions of the system. Instron maintains a stock of factorytested replacement boards that can be used to replace a
defective board in your system. There are no complex,
time-consuming troubleshooting procedures, and nohighly technical replacement of defective parts. Thismeans that repairs can be effected quickly and easily,
minimizing your system downtime.
If you need help with any maintenance problem connected with your Series 4400 system, contact the factoryor your Instron regional Sales and Service Center.
8-2

Preventive MaintenancePreventive Maintenance
Periodically clean the exterior surfaces of the Control
Console with a soft, lint-free cloth. To remove grime,
dampen the cloth with water and a mild detergent. Do
not use strong cleaners or solvents on any part of theunit, and do not allow cleaning water to leak into the interior of the console.
If your Series 4400 system is operating in a dusty environment, vacuum all surfaces and air ports as required.

Maintenance

Cleaning - Control Console

8-3Error Messages

M10-94400-1

Error Messages
Overview
The Resident Test Program, described in Chapter 4, contains a Diagnostic Monitor as the main troubleshooting
mode. This monitor also allows you to display a list oferror messages relating to failures which may have occurred during the self test or cyclic test modes of the program. By using this feature of the monitor, you cancommunicate to an Instron service representative the exact nature of a failure, thus expediting repair procedures.

Displaying Error Messages
If the Self Test Routine detects a failure, the result appearson the Main Panel Display. This result remains on the display, and normal operation cannot be started. To determine
the type of failure, start the Diagnostic Monitor by pressing“S1”. The word “HELP” appears on the display, which is anacronym for the four types of commands the monitor provides: Help, Error, Look, Put. The Error command lists theerrors found for each functional section of the console during
Self Test.
Note

8-4

When “HELP” displays, if you repeat pressing[ENTER] the command type advances until “L”
and “P” alternate. If you repeat pressing [REJ], theprevious command type appears until “H” and “E”
alternate. Help, Look and Put commands arefor use by trained personnel and are beyond
the scope of this manual.

Error Messages

The “E” type commands are numbered 0 through 9, except “4” and “7”, which are not used. You must enterone of these numbers on the keypad, followed by [ENTER] to execute an “E” command. E0 lists error messages in all functional sections, E1 to E8 lists error
messages for sections 1 through 8 (except 4 and 7), respectively, and E9 prints the list of error messages.

Maintenance

When “HELP” is on the display, press [ENTER] tochange the display to “E”. This indicates that the Error
type command is in effect.

Table 8-1 lists the functional sections in the Series 4400
control console.
Table 8-1.

Sections of the Control Console

Section No.

Functional Name

Basic or Option

1
2
3
4
5
6
7
8

IEEE-488 Interface
Central Processing Unit (CPU)
Crosshead Control(Not Used)
Load Sensor Conditioner
Strain Sensor Conditioner(Not Used)
Recorder Interface

OptionBasic
Basic-BasicOption—OptionThe following examples show the use of “E” commands
after entering the Diagnostics Monitor as described previously.
EXAMPLE NO. 1:
To display errors for each Section sequentially, 1
through 8:

8-5

Error Messages

M10-94400-1(a) When the “E” command displays, press [0] [ENTER]. The display shows “E 1. - -” if no error exists
in Section 1. If an error exists, a message displaysthat relates to a failed test as shown in Table 8-2.
(b) Record any error message, then repeat pressing [ENTER] to display messages for any additional errors in
Section 1.
(c) After all error messages are shown for Section 1, theprogram automatically steps to Section 2 when youpress [ENTER]. Continue the procedure, as in Steps(a) and (b) above, for all sections through No. 8.
(d) After all error messages display for Section 8,
and you press [ENTER], the display shows “L”
for the Look command. Press [REJ] to return to
the “E” command.
(e) To escape from the Diagnostic Monitor, press “S1”to start the Cyclic Self Test. When the Self Test
number displays, press [ENTER].
EXAMPLE NO. 2:
To display errors for a particular section:(a) To select Section No. 3 error message list, for example, when the “E” command displays, press [3] [ENTER]. The display shows “E 3. - -” if no error exists
on Section 3. If an error exists, a message displaysthat relates to a failed test as shown in Table 8-2.

8-6

Error Messages

CIRCUIT
BOARD
IEEE-488

CPU

CrossheadControl

MESSAGE
E1.00
E1.01
E1.02
E1.03
E1.04
E2.01
E2.02
E2.03
E2.04
E2.10 to E2.17
E2.20 to E2.27
E2.30 to E2.37
E2.40 to E2.47
E2.50
E2.51
E2.52
E2.53
E2.54
E2.55
E2.56
E2.57
E2.71
E2.72
E2.81
E2.82
E2.83
E2.84
E3.00
E3.01
E3.02
E3.03
E3.04
E3.05
E3.06
E3.07

Error Messages
FAILED TESTI/O Port Test
Memory Initialization State Bit Test
Two Port Ram Test
Normal Mode State Bit Test
Compatibility Code Test
PROM 0 Test - Checksum
PROM 0 Test - Start Address
PROM 0 Test - Program Version
PROM 0 Test - Program Number
Same as E2.01 to E2.04 for PROM 1/PROM 2
Same as E2.01 to E2.04 for PROM 2/PROM 4
Same as E2.01 to E2.04 for PROM 3/PROM 6
Same as E2.01 to E2.04 for PROM 4/None
Option Table Test (Version 1 only)
I/O Port Test
Front Panel Interface Test - Handshake
Front Panel Interface Test - Data
Front Panel Interface Test - Compatibility
Interrupt Controller Test - Mask Register
Interrupt Controller Test - Service Register
Interrupt Controller Test - Request Register
RAM Test - Foreground (Data) Error
RAM Test Background (Address) Error
PROM F Test - Checksum
PROM F Test - Start Address
PROM Test - Compatibility
PROM Test - Program Number
I/O Port Test
Timer Interrupt Test
UP Encoder Counter/Logic Test
DOWN Encoder Counter/Logic Test
Error DAC Test - 0
Error DAC Test - Full Scale
Watchdog Timer Test
Crosshead Switch Short Test

Maintenance

Table 8-2.

8-7

Error Messages

M10-94400-1

Table 8-2.
CIRCUITBOARDMESSAGE

Load Sensor Con- E5.00
E5.01
ditioner
E5.02
E5.03
E5.04
E5.05
Strain Sensor Con- E6.01
E6.02
ditioner
E6.03
E6.04
E6.05
E6.06
Recorder Interface E8.00

8-8

Error Messages (continued)
FAILED TESTI/O Port 1 Test
I/O Port 0 Test
A/D Run/Hold/Status Test
A/D 0 Volts Test
A/D 5 Volt Test
Load Section ID Test
I/O Port 1 Test
I/O Port 0 Test
A/D Run/Hold/Status Test
A/D 0 Volts Test
A/D 5 Volt Test
Strain Section ID Test
I/O Port Test (Option Test)

Error Messages(c) After all error messages display for Section 3, andyou press [ENTER] the display shows “E.3 - -” forthe end of the list. Press [ENTER] again to return to
the “E” command level.
(d) To display error messages for another section, enter
the section number as in Step (a) above, then repeat
Steps (b) and (c).

Maintenance(b) Record any error message, then repeat pressing [ENTER] to display messages for any additional errors
on Section 3.

(e) To escape from the Diagnostic Monitor, press “S1”to start the Cyclic Self Test. When the Self Test
number displays, press [ENTER].
EXAMPLE NO. 3:
To print out error messages for all sections (with yourprinter connected to the PRINTER port on the rear of
console):When the “E” command displays, press [9] [ENTER].
Table 8-2 lists error messages and the related failed test
for the “E” type commands.

8-9Rear Panel Indicators

M10-94400-1

Rear Panel Indicators
Rear Panel Indicators
GeneralThe printed circuit board used in the Series 4400 console
is divided into functional sections. These functions include Main Panel, Display Panel, Limits Panel, Load
Sensor Conditioner, and the like, and they operate moreor less independently of one another. The functional sections are monitored by LEDs and display panel indicators, and the unique combination of LEDs that are lit andthe results displayed on the front panel help to pinpoint
faults.
There are certain types of failures that may cause unusual operation of the LEDs and displays on the console
front panel. These failures could occur in the CPU or
Front Panel sections of the circuit board; the conditionof the latter is not reported by the Self Test result. If erratic operation of the front panel occurs, or normal operation is prevented due to a failure reported by the Self
Test, then the state of the rear panel indicators (LEDs)
can be used for further diagnosis.
The LEDs are visible on the on the rear of the console
though window openings in the rear cover. There arethree sets of indicators; one for the main console circuitboard, one for the Strain Sensor Conditioner board when
it is present, and one for the IEEE-488 Computer Interface board when it is present. The following sections describe the function of these indicators, and Figure 8-1
shows their location.

8-10

Rear Panel Indicators
Power Supply Condition Indicators

If the Self Test does not function, this may indicate aloss of the +5 V supply, so check its LED first.
If a ±15 V supply fails, the Self Test result will show afailure of one or more sections of the circuit board, andthe backlit status/fault indicators on the Main Panel will
not light.

MaintenanceThree LEDs indicate the condition of the three console
power supply voltages from the load frame: +5 Vd.c.,+15 Vd.c. and -15 Vd.c. Each LED is lit when its respective power supply voltage is present, and it is off if thatpower supply has failed.

If an LED is dimly lit, this indicates a drop in voltage
level from its power supply. The intensity of an LED is acoarse indicator and it will not be apparent for a small
drop in voltage level.
Green Test LEDs

Each circuit section which has its input and output undercontrol by the CPU has a green TEST LED. These
LEDs are on during the first part of the Self Test and off
during the second part. When the Self Test concludes, alit TEST LED indicates its section is good; if the LED is
not lit, the section did not pass the test. During normal
operation all green TEST LEDs are lit. However, someflickering may be seen on certain green LEDs which isdue to software telemetry. For example, the flicker of thegreen LED on the CPU section is caused by system interrupt response. Figure 8-2 shows a closeup view of thedetails of the main console indicators.

8-11

Rear Panel Indicators

M10-94400-1

STRAIN BOARD(When Installed)

IEEE-488
BOARD (When
Installed)

MAIN CONSOLE
BOARD

Figure 8-1.

Rear Panel Indicators

Red Activity LEDs

Each section with a microprocessor has a red ACTIVITY LED; these include the CPU, the IEEE-488 Interface section, and the Front Panel section. During normal
operation, the ACTIVITY LEDs flash about once persecond to indicate that the processor is running. A
steady on or off ACTIVITY LED indicates a serious failure. Continuous rapid flashing of the CPU ACTIVITY

8-12

Rear Panel Indicators

LED just after power on or system reset indicates a
RAM problem.

The latch indicators include the red CPU A RAM LED
and the red Crosshead Control FAULT LED. These
LEDs are never on except when a latch has been triggered and a system reset (main power turned off andthen on) is required.
The RAM latch protects memory in case of a power failure; the POWER status indicator on the Main Panel also
lights when this occurs.

Maintenance

Red Latch Indicator LEDs

The FAULT latch prevents the crosshead drive power
amplifier from being enabled if the watchdog timer fails;+5V POWER SUPPLYFRONT PANEL ACTIVECROSSHEAD TESTCROSSHEAD FAULTDIP SWITCHESSYSTEM UNITS SWITCH

Figure 8-2.

Closeup Detail of Console Status and Fault
Indicators
8-13

Rear Panel Indicators

M10-94400-1

the TIMER status indicator on the Main Panel also
lights when this occurs.
IEEE-488 Interface Indicators

The IEEE-488 section has additional indicators that are
exclusive for its particular functions; these are the red
ERROR, LISTENING, and TALKING LEDs.
During the Self Test Routine after system power is applied, the IEEE section undergoes a series of tests. If a
failure is encountered, a descriptive error code displayson the three LEDs and the red ACTIVITY LED, as
shown in Table 8-3. A section failure is also shown in
the Self Test report number on the Main Panel display. If
all tests pass, the red ACTIVITY LED flashes.
Table 8-3 shows the on/off state of the four LEDs if certain failures occur. The initial test checks that the four
LEDs are functioning.
Table 8-3.

LED Error Codes for IEEE-488 Section
LED NAME
DESCRIPTION

8-14

ERROR

TALKING

LISTENING

ACTIVITY

on

on

on

on

LED test

on

off

off

off

CPU RAM/Timer error
D-P Memory data error

on

off

off

on

on

off

on

off

PROM error

on

on

off

off

GPIB Driver error

on

on

on

off

D-P Memory Control error

Rear Panel Indicators

The moment after main power is applied, or a system reset occurs, the green TEST LEDs for each circuit section
light. At the end of this initial period, the self test of theprocessor on the CPU section (No. 2) begins. The green
TEST LEDs remain on and the red ACTIVITY LED on
the CPU is on. After about 2 seconds, the green LED’s
and the CPU ACTIVITY LED go out.
At the end of the Self Test Routine, when the code
comes up on the Main Panel display, the green TEST
LED for each section (except the CPU) that passes thetest light and the green LED for any section that fails thetest remains off. If the CPU section passes its self test,
its red ACTIVITY LED flashes; otherwise it will besteady on, or off. If the CPU section achieves successfulcommunication with the Front Panel section, its green
TEST lights.

Maintenance

Summary of Operating Sequence for Rear Panel Indicators

Shortly after Self Test begins, the Front Panel section
has its own self test. When this is complete, the red ACTIVITY LED for this section flashes. If the section fails
the test, the red LED remains off.
If the processor in the IEEE-488 Interface section passes
the self test, its red ACTIVITY LED flashes. The green
TEST LED for this section lights if the section passes
main self test. Thus, the ACTIVITY LED could flash
and the TEST LED could be off, indicating that the processor is running but the interface to the CPU processor is
faulty. If the IEEE section processor has a fault (ACTIVITY LED off), the CPU processor senses this and the
TEST LED remains off. The previous section describes
the action of the other LEDs for this section.

8-15

Fault Indications

M10-94400-1

Fault Indications
The fault indicators on the Main Panel light under certain conditions occurring during system operation. The
chart below lists the probable cause of these conditions
and the action to be taken.
Table 8-4.
FAULT INDICATOR
POWER(Drive disabled)
TIMER
Drive disabled)
LOAD (flashes)(Crosshead stops)

TRAVEL(Crosshead stops)
MOTOR(Drive disabled.
Indicator on steady.)

MOTOR(Drive disabled.
Indicator flashing.

Fault Indications
CAUSE

CORRECTIVE ACTION

Momentary power loss.

Cycle power off/on.

CPU malfunctions or loss of+/- 15 Vd.c. power.
Load overrange greater than
102% of cell capa- city with
AREA ≅ 1; or greater than
115% if AREA is set muchlarger than 1.
Upper or lower crosshead
travel limit reached

Cycle power off/on. Note
Self Test result.
Reduce load by UP, DOWN
or JOG keys (only proper
direction is en- abled).
Indicator flashes until a new
test is started.
Back off from limit by UP,
DOWN or JOG keys (onlyproper direction is enabled).
Wait 5 sec. If speed showsas “———-”, check frame-toconsole cabling. Do a
System reset.*

1. Motor drive enabling sequence (5 sec. duration)
2. Motor drive cannot beenabled.
3. Load frame cannot be
identified.
4. Load frame power supply
failure.
5. Crosshead second level
travel limit tripped.
6. Emergency stop switch
tripped.
7. Door interlock open.
1. Drive motor overheated.
2. Drive loop failure.
3. Drive stall.

Do a system reset.* If flashing restarts, allow motor tocool and reset*. Check for amechanical jam if fault
persists (requires service).

*To reset system, cycle power off/on or perform the key sequence [S1] [0] [ENTER] whichclears memory, or the sequence [S1] [1] [ENTER] which saves current memory.

8-16

The purpose of this appendix is to provide the basic requirements that are essential in planning a materials testing procedure. These include the applications of thetesting instrument, determining load requirements, gripping techniques, setting gauge length, choosing a testing
speed and the use of area compensation. A glossary ofterms defining the mechanical properties and tests applicable to a Series 4400 system is included as Appendix B
for your convenience.

Appendix A
Test Planning

Appendix A
Test Planning

The American Society for Testing and Materials(ASTM) annual book of standards contains complete
procedures regarding specimen preparation and testingfor virtually all types of materials. These standards areuniversally accepted by industry, and should be consulted for more detailed information.
European and Asian users will find that the various British, DIN, ISO, and other standards will also help in yourtest planning. In most cases, the ASTM standard has anequivalent or similar European standard.

A-1

Applications

M10-94400-1

Applications
The test capabilities of a Series 4400 instrument range
from simple tension or compression testing with a recording of specimen loading versus time, to more advanced
techniques, including modulus tests, relaxation-recovery,
and cyclic evaluations involving detailed calculations anddata analysis. This flexibility is possible due to a broad selection of options available for use with a basic system.
For example, with the recorder and printer options,graphic plots and recordings of load versus extension or
strain can be obtained. The Display Panel allows thepeak and break parameters of load, extension and strain
to be monitored and stored. The Limits Panel permits
minimum and maximum travel limits of the crosshead tobe controlled at selected load, stress, extension or strain
values. This enables cyclic evaluations of materials during relaxation and recovery. The Limits Panel can also
provide rapid return of the crosshead to gauge length after break for repetitive specimen testing.
Additionally, each Series 4400 instrument has built-inpreset points and integration capabilities for the evaluation of energy related properties, such as Tensile Energy Absorption (TEA) and elastic modulus. The wide
variety of materials testing applications for a system includes:
PLASTICS - perform tests to ASTM-D638 and ASTMD1623 to obtain tensile strength, percent elongation,
modulus of elasticity, and peak and break values of loadand strain. Perform flexural tests to ASTM-D790 for parameters such as maximum force, maximum fiber stress,
flexural strength, tangent and secant modulus, and stress at
A-2

Applications

WIRE, FOIL, SHEET METAL - determine the tensile
strength of solid wire, electrical cables, and thin sheet
metal components. Also, in compression, test for crush
resistance and insulation cut throughs. Obtain offset
yield evaluations using the optional IEEE-488 Interface
and a computer. Some ASTM tests in this category include: E8 for metals; E132 for Poisson’s ratio; E345 formetallic foil; D2633 for thermoplastic insulation; andD1351 for polyethylene insulation.
RUBBER - perform tests to ASTM-D412 to obtain peak
and break values of load and extension. Use preset
points for modulus values, and integrate the load/elongation curve to obtain energy values. Measure strain using
crosshead extension or an optional long-travel or opticalextensometer. Also, test for tear resistance to ASTMD624 and test O-rings to ASTM-D1414.

Appendix A
Test Planningspecified strain. Use specimen dimensioning and peakreadouts to enable printouts of maximum force or stressvalues. Other typical tests include: ASTM-D695 andD1621 for compression; D732 for shear strength; D1004
for tear resistance; and D1894 for friction.

TEXTILES - perform tenacity and stretch tests of fabrics, yarns and cords. Determine load at set elongation(LASE) using preset points. Apply specimen dimensioning to obtain load value relationships to units such as
grams/denier. Use a computer through the IEEE-488 interface to obtain complete statistical analyses of test results. Typical ASTM textile-related tests applicable to a
Series 4400 instrument include: D458 for man-made fibers: D2256 for yarn; D2653 for elastomeric yarns; andD2263 for grab tests of automotive fabrics.

A-3

Load Requirements

M10-94400-1

Load Requirements
The selection of a load cell is the first step in preparing
for a tension or compression test. If the approximate tensile (or compressive) strength of the specimen is known,
the choice of load cell is simplified. If the tensile
strength of the material is not known, refer to a Properties of Materials handbook to obtain a close figure.
To calculate the tensile strength in force units for a specimen, multiply its tensile strength by its cross-sectional
area. For example:
psi x in2 = lbf (pounds-force)kg/m2 x m2 = kgf (kilograms-force)
Pascals x m2 = newtons
EXAMPLE:Specimen geometry: standard ASTM tensile.
Material: Lexan
Tensile strength: 5200 psi (from a materials handbook)Specimen area: 0.502 in. wide x 0.125 in. thk = 0.063 in.
Tensile strength = 5200 psi x 0.063 in. = 328 lbf
Therefore, in this example, the 5 kN (1000 lb, 500 kg)
capacity load cell should be installed.
If an approximate value of tensile strength cannot be obtained, then always use the highest capacity load cell initially and perform a preliminary test at a slow speed todetermine the load range required.
A-4

Selection Of Grips

Selection Of Grips

Examples of gripping techniques are shown in Table A1. In many cases you will have to experiment with several gripping techniques to eliminate or minimize
slippage in the grips. For grips with interchangeable
faces, such as screw-action and pneumatic-action types,
the serrated, flat and rubber-coated faces can be tried todetermine the best method.

Appendix A
Test Planning

The selection of grips depends upon the material, geometry and strength of the test specimen; but the tensile
strength of the test specimen should be a primary consideration. If, for example, a material has a tensile strengthof 500 lbf, then pneumatic grips should not be used, as
these grips are designed for loads not exceeding 200 lbf.
Always determine the capacity of the grips being usedprior to a test and do not overload test fixtures.

A-5

Selection Of Grips

M10-94400-1

Table A-1.

A-6

Gripping Techniques

SPECIMEN
MATERIAL

SPECIMENGEOMETRY

MAX. BREAK
LOAD (LB)

TYPES OF GRIPSAND FACES

Paper

25 mm (1 in.)
wide

100

Screw-action or
Pneumatic (25 x 50 mm
flat faces)

Plastic Films

25 mm (1 in.)
wide

100

Same as above.
Also, line contact faces
can be used.

Rigid Plastics

25 mm wide x12.5 mm thick(1 in. wide x.5 in. thick)1000

Wedge-action or
screw-action withserrated faces.

Wire and
Sheet Metal.50 to 1.5 mm
diameter(.002 to .060 in.)200

Screw-action or
pneumatic-action with
25 mm x 50 mm flat orserrated faces.

Cord and Yarn

.50 to 4.8 mm
diameter

350

Pneumatic cord andyarn grips.

Fabrics

25 mm or 100
mm wide strip(1 in. or 4 in.)1000

Screw-action or
pneumatic-hydraulicwith flat faces.

Elastomers

mm to 6 mm
wide (.125 to.250 in.)150

ElastomericEstablishing Gauge Length

Establishing Gauge Length

Establishing gauge length is one of the most important
decisions to be made when performing tension tests.
Gauge length is used as a basis for calculating percent
elongation and in determining specimen strain rate;
hence, it can seriously affect the test results.
Sometimes the choice of gauge length is dictated by theavailable length of the material, although commonlyused gauge lengths for paper, plastic film, wire, cord andyarns are from 4 to 10 inches (100 to 250 mm). In general: establish the longest possible gauge length, consistent with the capacity of the testing instrument, in order
to increase the sensitivity and accuracy of the elongation
measurement.

Appendix A
Test Planning

The gauge length used for a tensile test refers to theoriginal length of the specimen or the initial distance between the grips. Whereas for a compression test, it refers
to the original height of the specimen, assuming the anvil and compression table are both initially in contact
with the specimen.

A-7

Selection Of Testing Speed

M10-94400-1

Selection Of Testing Speed
The selection of a testing (or crosshead) speed depends
upon the material being tested and the type of test. Materials that are very stiff, such as metals and rigid plastics,
should be tested at a slow speed. The other extreme ishighly extensible materials, such as elastomers, which
are tested at a fast speed, generally 20 inches per minute(500 mm/min). For materials in between these two extremes, an intermediate speed should be used. Table A-2
lists a range of speeds used to test various materials.
Table A-2.

A-8

Typical Testing Speed Ranges for Various
Materials
MATERIAL

SPEED
in/min (mm/min)

Metals.02-1.0 (.5-20)

Wire.2-2.0 (5-50)

Rigid Plastics.2-2.0 (5-50)

Plastic Films.5-20 (10-500)

Tire Cord

12 (300)

Yarn and Fabrics

12 (300)

Elastomers

10-20 (200-500)

Strain Rate

Strain Rate
For certain materials, the specimen strain rate is specified rather than a testing speed. But once the gauge
length (G.L.) has been established, the testing speed canbe calculated from the strain rate.
Testing Speed = Strain Rate x G.L.
EXAMPLE:

Gauge length: 10 in. (250 mm)
Strain rate (from designated test procedure):
0.5 in/in/min (0.5 mm/mm/min)Testing speed = 0.5 in/in/min x 10 in. (250 mm)= 5.0 in/min (125 mm/min)

Appendix A
Test Planning

Specimen: Plastic film

Therefore, in this example, perform the tensile test on
the film at 5.0 in/min (125 mm/min).

A-9

Area Compensation

M10-94400-1

Area Compensation
Description
The use of area compensation when testing specimens ofdifferent cross-sectional area allows the load signal to becalibrated in terms of stress, or similar units relating
force and specimen size. Stress is defined as the load ona specimen divided by the original cross-sectional areaof the specimen. Other applications relating force andspecimen size where area compensation could be used,
include the testing of yarn or fiber to determine tenacity
in grams per denier.
In a Series 4400 system, area compensation values areentered as a base number (mantissa) and an exponent using two key sequences, as described in Chapter 5. Increasing the mantissa values from between 1.000 to
9.999 proportionally decreases the sensitivity of the load
weighing system. For example, increasing the value
from 1.000 to 2.000 decreases load sensitivity by 1/2, sothat twice as much loading on the test specimen will be
required for full scale stress response. The load-stress relationship is expressed by the formula:
L = S x A or S = L/A
where (in English units, for example)
L = Load in pounds
S = Stress in psi
A = Cross-sectional area (in2)
When an area compensation value is entered that corresponds to the cross-sectional area of a specimen, theload channel gain is divided by the mantissa; that is, by
A-10

Area Compensation

Determining Stress Range
The stress range indicated by full scale on a recorderchart may be determined from the following equation
Full Scale Stress = A.C. x

L.R.
A

Appendix A
Test Planninga number normalized between 1.000 and 9.999. As a result, the digital load signal to the LOAD display and theanalog load signal to a recorder are both normalizedwith respect to stress. This allows calibration of the recorder scale in terms of stress (normalized), with the fullscale value easily changed by selecting a % RANGE on
the Recorder Panel. When the normalized area value foreach additional specimen is entered, the recorder scaleremains calibrated. Thus, each specimen can easily becompared as all plots are on the same stress scale.

where:
A.C. =

Area Compensation value the normalized base number (mantissa)of the specimen cross-sectional area.

L.R. =

Load Range - in pounds (g or kg, N orkN). Load range is determined by theload cell in use and the % RANGE
selected on the Recorder Panel.

A=

Cross-sectional Area (actual) of
specimen

EXAMPLE:
Assume a specimen has an Area = 0.075 in ; that a 100lb capacity load cell is installed; and a 10% RANGE has
A-11

Area Compensation

M10-94400-1

been selected on the Recorder Panel. Determine the fullscale stress reading as follows:
Set the mantissa of the area compensation to 7.50, thatis, normalize the base number of the specimen area to avalue between 1.000 and 9.999. A 100-lb capacity loadcell with the % RANGE set at 10% has a full scale load
range of 10 lb. Substituting these values into the equation for Full Scale Stress:
7.50 x 10 lb
0.0750 in2= 1000 psi

If the % RANGE were changed to 20 (L.R. = 20) in theabove example, the Full Scale Stress would be 2000 psi.
This would overload the load cell (refer to Section
A.7.3).

Limitations Due To Load Cell Capacity
The maximum allowable stress within the capacity of aload cell is determined by:
Maximum Allowable Stress =L.C.
Awhere: L.C. = Load Cell maximum capacity and A =cross-sectional area of specimen.
For example, for a 100-lb load cell, and an Area = 0.075
in2, the maximum allowable stress would be 1333 psi.
Thus, to determine the highest % RANGE to use thatwill not exceed the maximum allowable stress (Smax),
use the equation:

A-12

Area Compensation%RANGE =Smax x A
x 100
A.C. x L.C.

This would be equal to 13% for the example of a 100-lb
capacity load cell and a specimen area = 0.075 in2.
Hence, 10% is the highest % RANGE that could be used
for calibrating a recorder to Full Scale Stress.
Do not use a full stress range that exceeds the
maximum allowable stress..

In some cases it may not be possible, and only part of
the recorder scale can be used without overloading thecell. Under this condition, it is better to use a higher capacity cell.

Appendix A
Test Planning

Note

A-13

Chart Magnification

M10-94400-1

Chart Magnification
When using a strip-chart recorder with a time base, thechart or X-axis speed should be selected to give a convenient record length for a test. A record of 5 to 15
inches (125 to 375 mm) is sufficient, but it can be as
long as desired.
By the use of chart magnification, the chart time axis
can indicate the displacement of the crosshead in either areduced or magnified manner.
The chart magnification ratio (M) is the ratio of the chart
time axis speed to crosshead speed, that is:
Magnification Ratio (M) =Chart Time Axis Speed
Crosshead Speed

The following example illustrates the selection of chart
time axis and crosshead speeds, and then the Magnification Ratio required.
EXAMPLE:
Material:

Nylon% extension/minute:

100%

Ultimate extension:

50% (approximate)

Gauge length:

250 mmCrosshead speed:= Gauge length x % ext./min.
= 250 mm x 100%/min.
= 250 mm/min.

A-14

Chart Magnification

A 250-mm chart record is desired for the expected test
duration of 1/2 -minute (time expected to reach ultimate
extension). Therefore, the chart time axis should travel
500 mm in 1 minute, and a chart speed of 500 mm/min
is required. Then:
M=

500 mm⁄min= 2
250 min⁄min

11== Crosshead Displacement (mm)M
2
To determine the percentage of total strain directly fromthe chart:% Strain =Appendix A
Test Planning

Each millimeter of chart, along the time-drive axis, will
indicate:

Chart displacement x 100
M x Gauge length

A-15

Chart Magnification

A-16

M10-94400-1

Appendix B
Glossary

Understanding these tests and their applications is basic
to performing them. The terms listed in this glossary arechosen because of their relation to the types of tests
within the capability of a Series 4400 testing instrument.

Bend Test.

Appendix B
Glossary

The following glossary of terms related to mechanicaltests of materials will assist you in the application ofyour testing system. As materials are commonly specified by their properties, defining a property and measuring it is generally done by a mechanical testingprocedure. The procedures cited here refer to American
Society for Testing and Materials (ASTM) standards andtest methods. Most of these standards have an equivalent
DIN or ISO standard.

Method for measuring ductility of certain materials.
There are no standardized terms for reporting bend test
results for broad classes of materials; rather, terms associated with bend tests apply to specific forms or types ofmaterials. For example, materials specifications sometimes require that a specimen be bent to a specified inside diameter (ASTM A-360, steel products). A bend
test for ductility of welds is given in ASTM E-190. Results of tests of fiberboard are reported by a descriptionof the failure or photographs (ASTM D-1037).

B-1

Glossary

M10-94400-1

Bending Strength.
Alternate term for flexural strength. It is most commonly used to describe flexure properties of cast ironand wood products.

Bond Strength.
Stress (tensile load divided by area of bond) required torupture a bond formed by an adhesive between two metal blocks. (ASTM D-952).

Breaking Load.
Load which causes fracture in a tension, compression,
flexure or torsion test. In tension tests of textiles andyarns, breaking load also is called breaking strength. In
tensile tests of thin sheet materials or materials in formof small diameter wire it is difficult to distinguish between breaking load and the maximum load developed,
so the latter is considered the breaking load.

Breaking Strength.
Tensile load or force required to rupture textiles (e.g., fibers, yarn) or leather. It is analogous to breaking load ina tension test. Ordinarily, breaking strength is reported
as lb. or lb/in of width for sheet specimens.

Bulk Modulus of Elasticity.
Ratio of stress to change in volume of a material subjected to axial loading. Related to Modulus of Elasticity(E) and Poisson’s Ratio (r) by the following equation:
K=

B-2

Er
3(1−2r)Glossary

Cleavage Strength.
Tensile load (lb/in of width) required to cause separationof a 1-in. long metal-to-metal adhesive bond under theconditions set in ASTM D-1062.

Climbing Drum Peel Test.
Method for determining peel resistance of adhesive bond
between a relatively flexible and a rigid material.
(ASTM D-1781).

Coefficient of Elasticity.
An alternate term for modulus of elasticity.

Cohesive Strength.

Complex Modulus.
Measure of dynamic mechanical properties of a material, taking into account energy dissipated as heat during
deformation and recovery. It is equal to the sum of static
modulus of a material and its loss modulus. In the caseof shear loading, it is called dynamic modulus.

Appendix B
Glossary

Theoretical stress that causes fracture in tension test if
material exhibits no plastic deformation.

Compressibility.
Extent to which a material is compressed in test for compressibility and recovery of gasket materials (ASTM F36). It is usually reported with recovery.

Compressibility and Recovery Test.
Method for measuring behavior of gasket materials under short time compressive loading at room temperature.
B-3

Glossary

M10-94400-1

ASTM F-36 outlines a standard procedure. This test is
not designed to indicate long term (creep) behavior andshould not be confused with the plastometer test.

Compression-Deflection Test.
Nondestructive method for determining relationship between compressive load and deflection under load forvulcanized rubber. (ASTM D-575).

Compression Fatigue.
Ability of rubber to sustain repeated fluctuating compressive loads. (ASTM D-623).

Compression Set.
The extent to which rubber is permanently deformed bya prolonged compressive load (ASTM D-395). Thisshould not be confused with low temperature compression set.

Compression Test.
Method for determining behavior of materials undercrushing loads. Specimen is compressed, and deformation at various loads is recorded. Compressive stress andstrain are calculated and plotted as a stress-strain diagram which is used to determine elastic limit, proportional limit, yield point, yield strength and (for somematerials) compressive strength. Standard compression
tests are given in ASTM C-773 (high strength ceramics),
ASTM E-9 (metals), ASTM E-209 (metals at elevatedtemperatures) and ASTM D-695 (plastics).

B-4

GlossaryCompressive Deformation.
Extent to which a material deforms under a crushingload.

Compressive Strength.
Maximum stress a material can sustain under crush loading. The compressive strength of a material that fails by
shattering fracture can be defined within fairly narrow
limits as an independent property. However, the compressive strength of materials that do not shatter in compression must be defined as the amount of stressrequired to distort the material an arbitrary amount.
Compressive strength is calculated by dividing the maximum load by the original cross-sectional area of a specimen in a compression test.

Stress which causes a material to exhibit a specified deformation. Usually determined from the stress-strain diagram obtained in a compression test. See also yieldstrength.

Appendix B
GlossaryCompressive Yield Strength.

Creep.
Deformation that occurs over a period of time when amaterial is subjected to constant stress at constant temperature. In metals, creep usually occurs only at elevatedtemperatures. Creep at room temperature is more common in plastic materials and is called cold flow or deformation under load.
Data obtained in a creep test usually is presented as aplot of creep vs time with stress and temperature constant. Slope of the curve is creep rate and end point of
B-5

M10-94400-1

CREEP

Glossary

Minimum Creep Rate

TIME

the curve is time for rupture. As indicated in the accompanying diagram, the creep of a material can be divided
into three stages. First stage, or primary creep, starts at a
rapid rate and slows with time. Second stage (secondary) creep has a relatively uniform rate. Third stage(tertiary) creep has an accelerating creep rate and terminates by failure of material at time for rupture. See alsostress-relaxation.

Creep Limit.
Alternate term for creep strength.

Creep Rate.
Time rate of deformation of a material subject to stressat a constant temperature. It is the slope of the creep vstime diagram obtained in a creep test. Units usually are
in/in/hr or % of elongation/hr. Minimum creep rate is theslope of the portion of the creep vs time diagram corresponding to secondary creep.

B-6

Glossary

Creep Recovery.
Rate of decrease in deformation that occurs when load isremoved after prolonged application in a creep test. Constant temperature is maintained to eliminate effects ofthermal expansion, and measurements are taken fromtime load is zero to eliminate elastic effects.

Creep Rupture Strength.
Stress required to cause fracture in a creep test within a
specified time. An alternate term is stress rupture strength.

Maximum stress required to cause a specified amount of
creep in a specified time. Also used to describe maximum stress that can be generated in a material at constant temperature under which creep rate decreases withtime. An alternate term is creep limit.

Creep Test.
Method for determining creep or stress relaxation behavior. To determine creep properties, material is subjected
to prolonged constant tension or compression loading atconstant temperature. Deformation is recorded at specified time intervals and a creep vs time diagram is plotted. Slope of the curve at any point is creep rate. If
failure occurs, it terminates the test and time for rupture
is recorded. If the specimen does not fracture within test
period, creep recovery may be measured. To determine
stress relaxation of material, specimen is deformed agiven amount and decrease in stress over prolonged period of exposure at constant temperature is recorded.
Standard creep testing procedures are detailed in ASTM

Appendix B
Glossary

Creep Strength.

B-7

Glossary

M10-94400-1

E-139, ASTM D-2990 and D-299 (plastics) and ASTM
D-2294 (adhesives).

Crush Resistance.
Load required to produce fracture in a glass sphere subjected to crush loading. (ASTM D-1213).

Crushing Load.
Maximum compressive force applied during a compression or crushing test. For materials that do not shatter,crushing load is defined as the force required to produce
a specified type of failure.

Crushing Strength.
Compressive load required to cause a crack to form in asintered metal powder bearing (ASTM B-438 and B439). Cold crushing strength of refractory bricks andshapes is the gross compressive stress required to cause
fracture. (ASTM C-133).

Deformation Energy.

STRESS

Energy required to deform a material a specified
amount. It is the area under the stress-strain diagram up
to a specified strain.

Deformation Energy
at Yield Stress(0.2% Offset)

0.2 %

B-8

STRAIN

Glossary

Deformation Under Load.
Measure of the ability of rigid plastics to withstand permanent deformation and the ability of nonrigid plastics
to return to original shape after deformation. Standard
test methods for determining both types of deformation
under load are given in ASTM D-621. For rigid plastics,
deformation (which can be flow or flow and shrinkage)is reported as % change in height of specimen after 24hours under a specified load. For nonrigid plastics, results are reported as % change in height after 3 hours under load and recovery in the 1-1/2 hour period following
removal of the load. Recovery is % increase in heightcalculated on basis of original height.

Measure of the node-to-node bond strength of honeycomb core materials. It is equal to the tensile load applied to a honeycomb panel at fracture divided by its
width times its thickness (ASTM C-363).

Dry Strength.

Appendix B
Glossary

Delamination Strength.

Strength of an adhesive joint determined immediately after drying or after a period of conditioning in a specified
atmosphere. (ASTM D-2475).

Ductility.
Extent to which a material can sustain plastic deformation without rupture. Elongation and reduction of area
are common indices of ductility.

Dynamic Creep.
Creep that occurs under fluctuating load or temperature.

B-9

Glossary

M10-94400-1

EASL
Elongation at a specified load.

Eccentricity of Loading.
Distance between the actual line of action of compressiveor tensile loads and the line of action that would produce a
uniform stress over the cross section of the specimen.

Edge Tearing Strength.
Measure of the resistance of paper to tearing whenfolded over a V-notch beam and loaded in a tensile testing machine. Results are reported in lb or kg. (See Tear
Resistance.)

Elastic Hysteresis.
Difference between strain energy required to generate agiven stress in a material and elastic energy at thatstress. It is the energy dissipated as heat in a material in
one cycle of dynamic testing. Elastic hysteresis divided
by elastic deformation energy is equal to damping capacity.

Elastic

STRESS

Hysteresis

STRAIN

B-10

Glossary

Elastic Limit.
Greatest stress that can be applied to a material withoutcausing permanent deformation. For metals and othermaterials that have a significant straight line portion in
their stress/strain diagram, elastic limit is approximately
equal to proportional limit. For materials that do not exhibit a significant proportional limit, elastic limit is an arbitrary approximation (the apparent elastic limit).

Arbitrary approximation of the elastic limit of materials
that do not have a significant straight line portion on a
stress/strain diagram. It is equal to the stress at which
the rate of strain is 50% greater than at zero stress. It is
the stress at the point of tangency between the stressstrain curve and the line having a slope, with respect tothe stress axis, 50% greater than the slope of the curve at
the origin.

Appendix B
Glossary

Elastic Limit, Apparent.

Apparent
Elastic
Limit
a/2

STRESSaSTRAIN

B-11

Glossary

M10-94400-1

Elasticity.
Ability of a material to return to its original shape whenload causing deformation is removed.

Elongation.
Measure of the ductility of a material determined in atension test. It is the increase in gage length (measured
after rupture) divided by original gage length. Higher
elongation indicates higher ductility. Elongation cannot
be used to predict behavior of materials subjected to sudden or repeated loading.

Embrittlement.
Reduction in ductility due to physical or chemicalchanges.

Endurance.
Alternate term for fatigue limit.

Engineering Stress.
Load applied to a specimen in a tension or compression
test divided by the cross-sectional area of the specimen.
The change in cross-sectional area that occurs with increases and decreases in applied load, is disregarded incomputing engineering stress. It is also called conventional stress.

Extensometer.
Instrument for measuring changes in linear dimensions.
Also called a strain gauge. Frequently based on strain
gauge technology.

B-12

Glossary

Fatigue.
Permanent structural change that occurs in a material
subjected to fluctuating stress and strain. However, inthe case of glass, fatigue is determined by long-term
static testing and is analogous to stress rupture in othermaterials. In general, fatigue failure can occur withstress levels below the elastic limit.

Fatigue Life.
Number of cycles of fluctuating stress and strain of a
specified nature that a material will sustain before failure occurs. Fatigue life is a function of the magnitude of
the fluctuating stress, geometry of the specimen and test
conditions. An S-N diagram is a plot of the fatigue life
at various levels of fluctuating stress.

Maximum fluctuating stress a material can endure for an
infinite number of cycles. It is usually determined froman S-N diagram and is equal to the stress corresponding
to the asymptote of the locus of points corresponding to
the fatigue life of a number of fatigue test specimens.
An alternate term is endurance limit.

Appendix B
Glossary

Fatigue Limit.

STRESS (S)Fatigue Limit

CYCLES (N)

B-13

Glossary

M10-94400-1

Fatigue Notch Factor.
Ratio of fatigue strength of a specimen with no stressconcentration to fatigue strength of a specimen with anotch or other stress raisers. Fatigue notch factor is usually lower than the theoretical stress concentration factor
because of stress relief due to plastic deformation. An
alternate term is strength reduction ratio.

Fatigue Ratio.
Ratio of fatigue strength or fatigue limit to tensile
strength. For many materials, fatigue ratio may be used
to estimate fatigue properties from data obtained in tension tests.

Fatigue Strength.
Magnitude of fluctuating stress required to cause failure
in a fatigue test specimen after a specified number of cycles of loading. Usually determined directly from the SN diagram.

Fatigue Strength Reduction Factor.
An alternate term for fatigue notch factor.

Fatigue Test.
A method for determining the behavior of materials under fluctuating loads. A specified mean load (which may
be zero) and an alternating load are applied to a specimen and the number of cycles required to produce failure (fatigue life) is recorded. Generally, the test isrepeated with identical specimens and various fluctuating loads. Loads may be applied axially, in torsion, or in
flexure. Depending on amplitude of the mean and cyclic

B-14

Glossaryload, net stress in the specimen may be in one direction
through the loading cycle, or may reverse direction.
Data from fatigue testing often are presented in an S-Ndiagram which is a plot of the number of cycles required
to cause failure in a specimen against the amplitude of
the cyclical stress developed. The cyclical stress represented may be stress amplitude, maximum stress or minimum stress. Each curve in the diagram represents a
constant mean stress.
Most fatigue tests are conducted in flexure, rotating
beam, or vibratory type machines. Fatigue testing is generally discussed in “Manual on Fatigue Testing,” ASTM
STP 91-A. ASTM D-671 details a standard procedurefor fatigue testing of plastics in flexure.

Stress through a point in a part in which stress distribution is not uniform. For example, the stress in a beam under bending load varies from compression to tension
across the beam. It is more meaningful in determining
the properties of the beam material to consider the maximum stress generated in the outer fibers of the beam.
Similarly, stress in a beam under twist loading is a maximum in the material furthest from the axis of twist.

Appendix B
Glossary

Fiber Stress.

Flex Resistance.
Ability of foam rubber to sustain repeated compressive
loads without damage to cell structure. (ASTM D-1055).

Flexural Modulus of Elasticity.
Alternate term for modulus in bending.

B-15

Glossary

M10-94400-1

Flexural Strength.
Maximum fiber stress developed in a specimen just before it cracks or breaks in a flexure test. Flexural yieldstrength is reported instead of flexural strength for materials that do not crack in the flexure test. An alternate
term is modulus of rupture.

Flexure Test.
Method for measuring behavior of materials subjected tosimple beam loading. It is also called a transverse beam
test with some materials. Specimen is supported on two
knife edges as a simple beam and load is applied at its
midpoint. Maximum fiber stress and maximum strain
are calculated for increments of load. Results are plottedin a stress-strain diagram, and maximum fiber stress at
failure is flexural strength. Flexural yield strength is reported for materials that do not crack. Standard test procedures are given in ASTM D-790 (plastics) and ASTM
C-674 (fired whiteware). ASTM D-797 (elastomers),
ASTM A-438 (cast iron) and ASTM D-86 (glass).

Flow Stress.
Stress required to cause plastic deformation.

Fracture Stress.
True stress generated in a material at fracture.

Fracture Test.
Visual test wherein a specimen is fractured and examined for grain size, case depth, etc.

B-16

Glossary

Hardness.
Measure of a material’s resistance to localized plastic deformation. Most hardness tests involve indentation, but
hardness may be reported as resistance to scratching(file test), or rebound of a projectile bounced off the material (scleroscope hardness). Some common measuresof indentation hardness are Brinell Hardness Number,Rockwell Hardness Number, ASTM Hardness Number,
Diamond Pyramid Impact Test Hardness Number,
Durometer Hardness, Knoop Hardness, and Pfund Hardness. A table relating various types of hardness values ofmetals is given in ASTM E-140. Hardness often is agood indication of tensile and wear properties of a material.

Stress is directly proportional to strain. Hooke’s law assumes perfectly elastic behavior. It does not take into account plastic or dynamic loss properties.

Kink Test.

Appendix B
Glossary

Hooke’s Law.

Method for determining ductility of metal wire. A shortsection of wire is looped and drawn in tension to produce a kink. Relative ductility is indicated by the occurrence or non-occurrence of failure and extent to whichkink may be opened up without failure.

Knot Strength.
Tenacity of a fiber in which an overhand knot is tied.
Knot strength is a measure of a fiber’s sensitivity to compressive and shear stresses.

B-17

Glossary

M10-94400-1

LASE.
Load At Specified Elongation.

Load-Deflection Diagram.
Plot of load vs corresponding deflection.

Maximum Fiber Stress.
Maximum tensile or compressive stress in a homogeneous flexure or torsion test specimen. For a specimen
loaded as a simple beam at its midpoint, maximum fiber
stress occurs at mid-span and may be calculated by theformula (for rectangular specimens):
S=

3PL
2bd2

where S is maximum fiber stress; P, load; L, span; b,width of the beam; and d, depth of the beam. For a circular cross section member loaded in torsion, maximum fiber stress may be calculated by the following formula:
S=

Tr
J

where T is twisting moment; r, original outer radius andJ, polar moment of inertia of original cross section.

Mean Stress.
Algebraic difference between maximum and minimum
stress in one cycle of fluctuating loading, as in a fatigue
test. Tensile stress is considered positive and compressive stress negative.

B-18

Glossary

Minimum Bend Radius.
Minimum radius to which a sheet or wire can be bent toa specified angle without failure.

Modulus.
Alternate term for modulus of elasticity, often used inconnection with rubber.

Modulus in Bending.
Ratio of maximum fiber stress to maximum strain,
within elastic limit of stress-strain diagram obtained in
flexure test. Alternate term is flexural modulus of elasticity.

Rate of change of strain as a function of stress. The
slope of the straight line portion of a stress-strain diagram. Tangent modulus of elasticity is the slope of thestress-strain diagram at any point. Secant modulus ofelasticity is stress divided by strain at any given value ofstress or strain. It also is called stress-strain ratio. Tangent and secant modulus of elasticity are equal, up to the
proportional limit of a material.

s1

Appendix B
Glossary

Modulus of Elasticity.

s1

Tangent modulus

Secant modulus
of elasticity= s1/e1

STRESSSTRESS

of elasticity= sl/ae1

ae1
STRAINa

STRAIN

B-19

Glossary

M10-94400-1

Depending on the type of loading represented by thestress-strain diagram, modulus of elasticity may be reported as: compressive modulus of elasticity (or modulus of elasticity in compression); flexural modulus ofelasticity (or modulus of elasticity in flexure); shear
modulus of elasticity (or modulus of elasticity in shear);tensile modulus of elasticity (or modulus of elasticity intension); or torsional modulus of elasticity (or modulus
of elasticity in torsion). Modulus of elasticity may be determined by dynamic testing, where it can be derived
from complex modulus.
Modulus used alone generally refers to tensile modulus
of elasticity. Shear modulus is almost always equal totorsional modulus and both are called modulus of rigidity. Moduli of elasticity in tension and compression areapproximately equal and are known as Young’s modulus. Modulus of rigidity is related to Young’s modulus
by the equation:
E = 2G(1+r)
where E is Young’s modulus (psi), G is modulus of rigidity (psi) and r is Poisson’s ratio. Modulus of elasticity
also is called elastic modulus and coefficient of elasticity.

Modulus of Rigidity.
Rate of change of strain as a function of stress in a specimen subjected to shear or torsion loading. It is the modulus of elasticity determined in a torsion test. Alternate
terms are modulus of elasticity in torsion and modulus
of elasticity in shear.
Apparent modulus of rigidity is a measure of the stiffness of plastics measured in a torsion test (ASTM DB-20

Glossary1043). It is “apparent” because the specimen may be deflected past its proportional limit and the value calculated may not represent the true modulus of elasticity
within the elastic limit of the material.

Modulus of Rupture.
Ultimate strength determined in a flexure or torsion test.
In a flexure test, modulus of rupture in bending is the
maximum fiber stress at failure. In a torsion test, modulus of rupture in torsion is the maximum shear stress inthe extreme fiber of a circular member at failure. Alternate terms are flexural strength and torsional strength.

Modulus of Strain Hardening.
Alternate term for rate of strain hardening.

The work done on a unit volume of material as a simple
tensile force is gradually increased from zero to thevalue causing rupture is defined as the Modulus ofToughness. This may be calculated as the entire area under the stress-strain curve from the origin to rupture.
Toughness of a material is its ability to absorb energy inthe plastic range of the material.

Appendix B
Glossary

Modulus of Toughness.

Necking.
Localized reduction of cross-sectional area of a specimen under tensile load. It is disregarded in calculating
engineering stress but is taken into account in determining true stress.

B-21

Glossary

M10-94400-1

Nominal Stress.
Stress calculated on the basis of the net cross section ofa specimen without taking into account the effect of geometric discontinuities such as holes, grooves, fillets, etc.

Offset Yield Strength.
Arbitrary approximation of elastic limit. It is the stressthat corresponds to the point of intersection of a stressstrain diagram and a line parallel to the straight line portion of the diagram. Offset refers to the distance between
the origin of the stress-strain diagram, and the point ofintersection of the parallel line and the 0 stress axis. Offset is expressed in terms of strain (often 0.2%).

Operating Stress.
Stress imposed on a part in service.

Overstressing.
Application of high fluctuating loads at the beginning ofa fatigue test and lower loads toward the end. It is ameans for speeding up a fatigue test.

Peel Resistance.
Torque required to separate an adhesive and adherend in
the climbing drum peel test (ASTM D-1781). It is ameasure of bond strength.

Peel Strength.
Measure of the strength of an adhesive bond. It is the average load per unit width of bond line required to partbonded materials where the angle of separation is 180
degrees and separation rate is 6 in/min (ASTM D-903).
B-22

Glossary

Plastic Deformation.
Deformation that remains after the load causing it is removed. It is the permanent part of the deformation beyond the elastic limit of a material. It also is called
plastic strain and plastic flow.

Plasticity.
Tendency of a material to remain deformed, after reduction of the deforming stress, to a value equal to or lessthan its yield strength.

Plasticity Number.

Poisson’s Ratio.
Ratio of lateral strain to axial strain in an axial loaded
specimen. It is the constant that relates modulus of rigidity to Young’s modulus in the equation:

Appendix B
Glossary

Index of the compressibility of rubber at elevated temperatures. Equal to 100 times the height of a standard
specimen, after a 3 to 10 minute compression by a 5 kg
load (ASTM D-926).

E = 2G(r+1)
where E is Young’s modulus; G, modulus of rigidity;
and r, Poisson’s ratio. The formula is valid only within
the elastic limit of a material. A method for determining
Poisson’s ratio is given in ASTM E-132.

Proof Stress.
Stress that will cause a specified permanent deformation.

B-23

Glossary

M10-94400-1

Proportional Limit.
Highest stress at which stress is directly proportional tostrain. It is the highest stress at which the curve in a
stress-strain diagram is a straight line. Proportional limit
is equal to elastic limit for many metals.

Rate of Strain Hardening.
Rate of change of true stress as a function of true strain

STRESS

Proportional Limit

STRAINin a material undergoing plastic deformation. An alternate term is modulus of strain hardening.

Recovery.
Index of a material’s ability to recover from deformationin the compressibility and recovery test (ASTM F-36),
the deformation under load test (ASTM D-621) and theplastometer test (ASTM D-926). In the compressibility
and recovery test, it usually is reported with compressibility and given as %. It is calculated by dividing the difference between recovered thickness and thickness
under load, by the difference between original thickness
B-24

Glossaryand thickness under load. In the deformation under load
test, it indicates the extent to which a nonrigid plastic recovers from prolonged compressive deformation at anelevated temperature. It is given as %, and is calculatedby dividing the difference between height recovered 11/2 hours after load is removed and height after threehours of loading, by the change in height under load. In
the plastometer test, it indicates the extent to which anelastomer recovers from compressive loading at an elevated temperature. It is equal to plasticity number minus
recovered height.

Recovery Test.
Method for measuring compressibility and recovery ofgasket and seal materials (ASTM F-36).

Measure of the ductility of metals obtained in a tension
test. It is the difference between original cross-sectional
area of a specimen and the area of its smallest cross-section after testing. It is usually expressed as % decrease inoriginal cross-section. The smallest cross-section can bemeasured at or after fracture. For metals, it usually ismeasured after fracture and for plastics and elastomers,
it is measured at fracture.

Appendix B
Glossary

Reduction of Area.

Relative Modulus.
Ratio of the modulus of a rubber at a given temperature
to its modulus at 73° F. It is determined in the Gehman
torsional test.

B-25

Glossary

M10-94400-1

Relaxation.
Rate of reduction of stress in a material due to creep.
An alternate term is stress relaxation.

Residual Elongation.
Measure of ductility of plastics. It is the elongation of aplastic specimen measured 1 minute after rupture in atension test.

Rupture Resistance.
Indication of ability of rubber to withstand tensile loading. It is the load required to rupture a rubber specimen
under conditions set out in ASTM D-530.

Rupture Strength.
Nominal stress developed in a material at rupture. It is
not necessarily equal to ultimate strength. And, sincenecking is not taken into account in determining rupture
strength, it seldom indicates true stress at rupture.

S-N Diagram.
Plot of stress (S) against the number of cycles (N) required to cause failure of similar specimens in a fatigue
test. Data for each curve on an S-N diagram are obtainedby determining fatigue life of a number of specimens
subjected to various amounts of fluctuating stress. The
stress axis can represent stress amplitude, maximum
stress or minimum stress. A log scale is almost always
used for the N scale and sometimes for the S scale.

B-26

Glossary

Secant Modulus of Elasticity.
Ratio of stress to strain at any point on curve in a stressstrain diagram. It is the slope of a line from the origin toany point on a stress-strain curve.

Shear Modulus of Elasticity.
Tangent or secant modulus of elasticity of a material subjected to shear loading. Alternate terms are modulus ofrigidity and modulus of elasticity in shear. Also, shear
modulus of elasticity usually is equal to torsional modulus of elasticity. A method for determining shear modulus of elasticity of structural materials by means of atwisting test is given in ASTM E-143. A method for determining shear modulus of structural adhesives is given
in ASTM E-229.

Maximum shear stress that can be sustained by a material before rupture. It is the ultimate strength of a material subjected to shear loading. It can be determined in a
torsion test where it is equal to torsional strength. The
shear strength of a plastic is the maximum load required
to shear a specimen in such a manner that the resulting
pieces are completely clear of each other. It is reported
in psi based on the area of the sheared edge (ASTM D732). The shear strength of a structural adhesive is the
maximum shear stress in the adhesive prior to failure under torsional loading (ASTM E-229). Methods for determining shear strength of timber are given in ASTM
D-143 and ASTM D-198.

Appendix B
Glossary

Shear Strength.

B-27

Glossary

M10-94400-1

Splitting Resistance.
Measure of the ability of felt to withstand tearing. It is
the load required to rupture a slit felt specimen by gripping lips of the cut in jaws and pulling them apart(ASTM D-461). An alternate term is tear resistance.

Springback.
Degree to which a material returns to its original shapeafter deformation. In plastics and elastomers, it is also
called recovery.

Stiffness.
Measure of resistance of plastics to bending. It includes
both plastic and elastic behavior, so it is an apparent
value of elastic modulus rather than a true value (ASTM
D-747).

Strain.
Change per unit length in a linear dimension of a part or
specimen, usually expressed in % Strain, as used withmost mechanical tests, is based on original length of thespecimen.
True or natural strain is based on instantaneous length, andis equal to:
ln ⋅

l
,
lo

where l is the instantaneous length and l0 is the original
length of the specimen. Shear strain is the change in angle between two lines originally at right angles.

B-28

Glossary

Strain Energy.
Measure of energy absorption characteristics of a material under load up to fracture. It is equal to the area under the stress-strain curve, and is a measure of thetoughness of a material.

Strain Hardening Exponent.
Measure of increase in hardness and strength caused byplastic deformation. It is related to true stress and truestrain by the equation:σ = σ0δη
where σ is true stress, σ0 is true stress at unit strain, δ istrue strain and η is strain hardening exponent.

Temperature at which internal stress in glass is substantially relieved in about 1 hour. (ASTM C-336).

Strain Rate.

Appendix B
Glossary

Strain Point.

Time rate of elongation.

Strain Relaxation.
Alternate term for creep of rubber.

Strength Reduction Ratio.
Alternate term for fatigue notch factor.

Stress.
Load on a specimen divided by the area through which it
acts. As used with most mechanical tests, stress is based
B-29

Glossary

M10-94400-1

on original cross-sectional area without taking into account changes in area due to applied load. This sometimes is called conventional or engineering stress. Truestress is equal to the load divided by the instantaneouscross-sectional area through which it acts.

Stress Amplitude.
One-half the range of fluctuating stress developed in a
specimen in a fatigue test. Stress amplitude often is used
to construct an S-N diagram.

Stress Concentration Factor.
Ratio of the greatest stress in the area of a notch or otherstress raiser to the corresponding nominal stress. It is atheoretical indication of the effect of stress concentrators
on mechanical behavior. Stress concentration factor usually is higher than the empirical fatigue notch factor orstrength reduction ratio, because it does not take into account stress relief due to local plastic deformation.

Stress Ratio.
Ratio of minimum stress to maximum stress in one cycleof loading in a fatigue test. Tensile stresses are considered positive and compressive stresses negative.

Stress Relaxation.
Decrease in stress in a material subjected to prolonged
constant strain at a constant temperature. Stress relaxation behavior is determined in a creep test. Data often ispresented in the form of a stress vs time plot. Stress relaxation rate is the slope of the curve at any point.

B-30

Glossary

STRESS RELAXATIONSTRESS

Original Stress

TIME

TIME

Stress Rupture Strength.
Alternate term for creep strength.

Stress-Strain Diagram.

Appendix B
Glossary

Graph of stress as a function of strain. It can be constructedfrom data obtained in any mechanical test where load is applied to a material, and continuous measurements of stressand strain are made simultaneously. It is constructed forcompression, tension and torsion tests.

RuptureSTRESSSTRESS

RuptureSTRAINSTRAIN

B-31

Glossary

M10-94400-1

Stress-Strain Ratio.
Stress divided by strain at any load or deflection. Below
the elastic limit of a material, it is equal to tangent modulus of elasticity. An alternate term is the secant modulus
of elasticity.

Stripping Strength.
Alternate term for peel strength.

Tangent Modulus of Elasticity.
The instantaneous rate of change of stress as a functionof strain. It is the slope at any point on a stress-strain diagram.

Tear Length.
Measure of the drawability of sheet metal. Two small
parallel slots are cut in the edge of the sheet to form atab which is gripped and torn from the sheet. The variation in length of tabs torn in different directions is an indication of crystal orientation in the sheet (tabs torn inthe direction of orientation are longer). The degree oforientation is an indication of difficulty to be expected in
drawing the sheet to uniform shapes.

Tear Resistance.
Measure of the ability of sheet or film materials to resist
tearing. For paper, it is the force required to tear a single
ply of paper after the tear has been started.
Three standard methods are available for determining
tear resistance of plastic films: ASTM D-1004 details amethod for determining tear resistance at low rates ofloading; a test in ASTM D-1922 measures the force reB-32

Glossaryquired to propagate a pre-cut slit across a sheet specimen; and ASTM D-1038 gives a method for determining tear propagation resistance that is recommended forspecification acceptance testing only.
Tear resistance of rubber is the force required to tear a 1inch thick specimen under the conditions outlined in
ASTM D-624. Tear resistance of textiles is the force required to propagate a single-rip tongue-type tear (starting from a cut) by means of a falling pendulum
apparatus (ASTM D-1424).

Tearing Strength.

Tenacity.
Force required to break a yarn or filament, expressed ingrams per denier. It is equal to breaking strength divided
by denier.

Appendix B
Glossary

Tensile force required to rupture a pre-slit woven fabricspecimen under the conditions outlined in ASTM D2261 and ASTM D-2262. Edge tearing strength of paper
is the force required to tear a specimen folded over a Vnotch and loaded in a tensile test machine.

Tensile Modulus of Elasticity.
Tangent or secant modulus of elasticity of a material subjected to tensile loading. Alternate terms are Young’s
modulus and modulus of elasticity in tension. It can bemeasured in a tension test or in a dynamic test where it
is related to resonant frequency on a cylindrical rod by
the equation:

B-33

Glossary

M10-94400-1E=

4π2l2 ρ f2
k2 j4

where E is modulus of elasticity; l, length of the rod; ρ,density; f, resonant frequency; k, radius of gyration of
the rod about an axis normal to the rod axis and plane of
motion (d/4 for cylindrical rods); and j, a constant dependent on the mode of vibration. Tensile modulus ofelasticity is approximately equal to compressive modulus of elasticity within the proportional limit.

Tensile Strength.
Ultimate strength of a material subjected to tensile loading. It is the maximum stress developed in a material ina tension test.

Tension Impact Test.
Method for determining energy required to fracture a
specimen under shock tensile loading (ASTM D-1822).

Tension Set.
Extent to which vulcanized rubber is permanently deformed after being stretched a specified amount for ashort time. It is expressed as a % of the original length
or distance between gage marks (ASTM D-412).

Tension Test.
Method for determining behavior of materials under axial stretch loading. Data from test are used to determine
elastic limit, elongation, modulus of elasticity, proportional limit, reduction in area, tensile strength, yield
point, yield strength and other tensile properties. Tension
tests at elevated temperatures provide creep data.
B-34

Glossary

Procedures for tension tests of metals are given in
ASTM E-8. Methods for tension tests of plastics are outlined in ASTM D-638, ASTM D-2289 (high strain
rates), and ASTM D-882 (thin sheets). ASTM D-2343
outlines a method for tension testing of glass fibers;
ASTM D-897, adhesives; ASTM D-412, vulcanized rubber.

Time for Rupture.
Time required to rupture specimen under constant stressand temperature in a creep test.

Method for determining behavior of materials subjected
to twisting loads. Data from a torsion test is used to construct a stress-strain diagram and to determine elastic
limit torsional modulus of elasticity, modulus of rupture
in torsion, and torsional strength. Shear properties areoften determined in a torsion test. (ASTM E-143).

Torsional Deformation.

Appendix B
Glossary

Torsion Test.

Angular displacement of specimen caused by a specified
torque in torsion test. It is equal to the angular twist (radians) divided by the gauge length (in.).

Torsional Modulus of Elasticity.
Modulus of elasticity of material subjected to twist loading. It is approximately equal to shear modulus and also
is called modulus of rigidity.

B-35

Glossary

M10-94400-1

Torsional Strain.
Strain corresponding to a specified torque in the torsion
test. It is equal to torsional deformation multiplied by
the radius of the specimen.

Torsional Strength.
Measure of the ability of a material to withstand a twisting load. It is the ultimate strength of a material subjected to torsional loading, and is the maximum
torsional stress that a material sustains before rupture.
Alternate terms are modulus of rupture and shear
strength.

Torsional Stress.
Shear stress developed in a material subjected to a specified torque in torsion test. It is calculated by the equation:
S=

Tr
J

where T is torque, r is the distance from the axis of twist
to the outer-most fiber of the specimen, and J is the polar moment of inertia.

True Strain.
Instantaneous % of change in length of specimen in mechanical test. It is equal to the natural logarithm of the ratio of length at any instant to original length.

B-36

Glossary

True Stress.
Applied load divided by actual area of the cross section
through which load operates. It takes into account thechange in cross section that occurs with changing load.

Ultimate Elongation.
Alternate term for elongation of material at rupture under tensile loading.

Ultimate Strength.
Highest engineering stress developed in material before
rupture. Normally, changes in area due to changing load
and necking are disregarded in determining ultimate
strength.
Ultimate

RuptureSTRESSStrength

Appendix B
Glossary

Strength

Wet Strength.
Breaking strength of paper saturated with water. Also,
the strength of an adhesive bond after immersion inwater.

B-37

Glossary

M10-94400-1

Yield Point.
Stress at which strain increases without accompanying
increase in stress. Only a few materials (notably steel)have a yield point, and generally only under tension loading.

Yield Point Elongation.
Strain at yield point of a material. It is an indication ofductility.

Yield Strength.
Indication of maximum stress that can be developed in amaterial without causing plastic deformation. It is thestress at which a material exhibits a specified permanent
deformation and is a practical approximation of elastic
limit. Offset yield strength is determined from a stressstrain diagram. It is the stress corresponding to the intersection of the stress-strain curve, and a line parallel to its
straight line portion offset by a specified strain. Offset
for metals is usually specified as 0.2%, i.e., the intersection of the offset line and the 0-stress axis is at 0.2%
strain. Offset for plastics is usually 2%.

Yield Strength Elongation.
Strain corresponding to yield strength of material. It is
an indication of ductility.

Yield Value.
Stress in an adhesive joint at which a marked increase in
deformation occurs without an increase in load.

B-38

Glossary

Young’s Modulus.

Appendix B
Glossary

Alternate term for modulus of elasticity in tension orcompression.

B-39

IndexAbout This Manual, 1-3
AC/DC Conditioner, 6-30
Air Kit Option, 6-44
Automatic Release Operation,
6-49
Automatic Start Operation, 6-48
Continuous Pretension Testing,
6-50
Description, 6-44
Excess Tension Operation, 6-48
Grip Control Function Operation, 6-47
Manual Operation, 6-46
Operation, 6-45
Pretension Operation, 6-47
Set Excess Tension Level, 6-50
Set Pretension Level, 6-49
Time Delays, 6-50
Area Compensation
Calculating, A-10
Description, 5-38
Entering Values, 5-38
AREA Key, 4-5
AT G.L. Indicator, 4-4
BBalance
As part of Calibration, 5-15
Balance Errors, 5-16

BREAK Key, 4-13
Built-in Options, 6-2
C
Cabling for Optional Equipment,
3-9
Calibration
See Load Calibration
See Strain Calibration
Central Processing Unit
Description, 1-14
Control Console
Components, 1-7
Console Mounting, 3-3
Description, 1-4
Installing Cables , 3-7
Internal Functions, 1-14
Opening the Console, 3-11
Crosshead Action Keys, 4-14
Crosshead Control Function
Description, 1-14
Crosshead Jog Control, 5-37
Crosshead Speed, 5-35
Crosshead Travel Limits, 5-34
Cycle Counter, 6-39
Cycle Count Display, 6-39
Cycle Count Limit, 6-39
Cycle Count Printout, 6-40
Cyclic Test Routine
Overview, 4-21

Index

A

Index-1

D

L

D
Data Storage, 4-16
DC Conditioner, 6-30
Display Panel
Description, 1-10, 5-26
Operation, 5-26
E
EEEE Display, 4-12
Energy Option
Description, 6-37
Operation, 6-37
Error Messages
Displaying, 8-4
Overview, 8-4
Extensometers
Calibration, 5-20
Description, 5-20
Operating Notes, 5-25
External Accessories, 6-2

G
G.L. RESET Key, 4-4Gauge Length, 5-28
Establishing, A-7
Setting, 5-28
Gauge Length Reset, 5-28
Grips
Gripping Techniques, A-5
Selection, A-5
H
HELP Display, 4-22
I
IEEE-488 Interface
Description, 1-15
Installation
General Considerations, 3-2
Installing Cables, 3-7
JF
Jog Control, 5-37
Fault Indicators, 8-16
Firmware Version, 4-31
Front Panel
Description, 1-8
Function of Controls
Display Panel, 4-12
Limits Panel, 4-14
Main Panel, 4-3
Preliminary Considerations, 4-2

Index-2

L
Limits
Crosshea Action Keys, 4-14
Electronic, 5-30
Setting, 5-31
Limits Panel
Description, 1-10
Operating Notes, 5-30

M

R

M
Main Panel
Description, 1-8
Maintenance
Cleaning, 8-3
General, 8-2
Preventive Maintenance, 8-3
MAX/MIN Keys, 4-14
Mounting the Console, 3-3
N
Non-Volatile Memory
Description, 4-16
Functions and Variables, 4-16

O
Opening the Console, 3-11
Operating Units, 4-32
Operation
Operating Considerations, 5-2
P
PEAK BREAK Key, 4-13
PEAK Key, 4-13
Pip Control, 6-41
Pip Blanking Delay, 6-42
Pip Filter, 6-41
Pip Height, 6-41
Pip Counter, 6-39
Power On Sequence, 5-4
Preset Points
Description, 6-34
Load and Energy Printout, 6-36
Operation, 6-35
Pretest Procedures, 5-3
Printer
Baud Rate, 6-24
Description, 6-24
Installation, 6-24
Operation, 6-25
Printout Format, 6-25
Printout Units, 6-26
Product Support, 1-3

Index

Load Calibration
Calibration and Balance Errors,
5-16Electrical - Self Identifying
Load Cells, 5-9Load Weighing System Balance,
5-15
Manual - Non-Self Identifying
Load Cells, 5-13
Manual - Self Identifying Load
Cells, 5-10
Overview, 5-8
Load Cells
Selection, A-4
Load Sensor Conditioner
Description, 1-14
LOSS Display
See System ResetR
Rear Panel
Description, 3-5

Index-3

S

U

Rear Panel Indicators
General, 8-10
Green Test LEDs, 8-11
IEEE-488 Interface Indicators,
8-14
Operating Sequence, 8-15
Red Activity LEDs, 8-12
Red Latch Indicator LEDs, 8-13
Recorders
Overview, 1-12
Reset, 4-16
RESET PEAKS Key, 4-13
Resident Test Program, 4-20
Running a Test, 5-45
S
Self Test Routine
Detailed Description, 4-23
Overview, 4-20
User Interaction, 5-5
Series 4400 Testing System
General Characteristics, 1-4
Introduction, 1-2
Specifications, 2-3
SL Display, 4-10
Specifications, 2-3
Specimen Installation, 5-42
SPEED Key, 4-5
Strain Calibration
Electrical - Self Identifying
Extensometers, 5-22
Manual - All Extensometers,
5-22

Index-4

Overview, 5-18
Strain Gauge Extensometers, 5-20
Strain Rate
Calculation, A-9
See also SPEED Key
Strain Sensor Conditioner
Description, 1-15
Strip Chart Recorder
Chart Speed, 6-3
Description, 6-3
Installation, 6-7
Operation, 6-8
Paper Supplies, 6-3
System Introduction, 1-2
System Operating Units, 4-32
System Reset, 4-16, 5-7
T
Testing
Applications, A-2
Planning, A-1
Testing Area
Setting, 5-43
Testing Speed, A-8
TRACK Key, 4-12
U
Units, 4-32
Area Units, 4-35
Energy Units, 4-35
For Non-Self Identifying Load
Cells, 4-34

V

X

V
Version Number, 4-31
Volatile Memory, 4-16
W
Warm Restart, 4-8
Warm-up
Load Cell Warm-up, 5-8

System Warm-up, 5-4
Turn System On: Warm-up, 5-4,
5-8
X
X-Y Recorder
Description, 6-12
Installation, 6-6, 6-15
Operation, 6-16
Paper Supplies, 6-12

Index

For Self-Identifying Load Cells
and Frames, 4-33

Index-5

X

Index-6

X