TINIUS OLSEN LTD

H150KU Tensile Test Machine

Instructions For Use
Doc. Ref. 820-7001_15
Issue 03

Unit 6 Perrywood Business Park, Honeycrock Lane, Salfords, Surrey, RH1 5DZ, England, UK
Telephone:

+44 1737 765001

Facsimile:

+44 1737 764768

Website:

www.tiniusolsen.com

 Tinius Olsen Ltd

820-7001_15 Issue 3

Contents
1.
1.1.
1.2.
2.
2.1.
2.2.
3.
3.1.
3.2.
3.3.
3.4.
3.5.
3.6.
3.7.
3.8.
3.9.
3.10.
3.11.
3.12.
4.
4.1.
4.2.
4.3.
4.4.
4.5.
4.6.
4.7.
5.
6.
6.1.
6.2.
7.
7.1.
7.2.
7.3.
7.4.
7.5.
7.6.
8.
8.1.
9.
9.1.
9.2.
9.3.
10.
10.1.
10.2.
11.
12.
12.1.
12.2.
12.3.
13.
14.
14.1.

Introduction...................................................................................................................................2
Preface .......................................................................................................................................2
Overview ....................................................................................................................................2
Major Options................................................................................................................................3
Strain (Aux.) Display Option(s)...................................................................................................3
Navigator ....................................................................................................................................3
Specifications ...............................................................................................................................4
Load Frame ................................................................................................................................4
Control System...........................................................................................................................4
Force Measurement ...................................................................................................................4
Extension Measurement ............................................................................................................4
Speed Control ............................................................................................................................4
Hardware Options ......................................................................................................................5
Dimensions.................................................................................................................................5
Weight ........................................................................................................................................5
Power Supply .............................................................................................................................5
Environmental ............................................................................................................................5
CE Markings...............................................................................................................................5
Manufacturer ..............................................................................................................................5
Installation.....................................................................................................................................6
Inspection ...................................................................................................................................6
Contents .....................................................................................................................................6
Location ......................................................................................................................................7
Connection to Power Supply......................................................................................................8
Load Cell ..................................................................................................................................10
Connection to a PC ..................................................................................................................11
Connection to auxiliary equipment (optional) ...........................................................................12
Checks before powering up ......................................................................................................13
Power on......................................................................................................................................14
Turn the machine On................................................................................................................14
Check Machine Operation........................................................................................................15
Operation.....................................................................................................................................17
Handset ....................................................................................................................................17
Handset Functions ...................................................................................................................19
Special Key Functions..............................................................................................................21
Machine Protection...................................................................................................................21
Typical Settings ........................................................................................................................23
Replacing Loadcells .................................................................................................................24
Tooling.........................................................................................................................................25
Attaching to the Machine..........................................................................................................25
Conducting a test .......................................................................................................................28
Basic Operation........................................................................................................................28
Testing Using The Handset......................................................................................................28
Testing Using Optional Software..............................................................................................30
Safety ...........................................................................................................................................31
Warnings ..................................................................................................................................31
Protective Screens ...................................................................................................................32
Training........................................................................................................................................33
Maintenance ................................................................................................................................34
Electrical ...................................................................................................................................34
Calibration ................................................................................................................................34
Lubrication................................................................................................................................34
Storage ........................................................................................................................................35
Appendix .....................................................................................................................................36
Dimensions...............................................................................................................................36

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1.

Introduction
1.1. Preface
The purpose of this manual is to provide the user with sufficient information for installation,
operation, care and maintenance of this test machine and its accessories. Therefore, it is
recommended that the entire manual be read and understood before working with the machine.
Questions that arise should be directed to Tinius Olsen or its authorised representative.
A Calibration Certificate and Test Report are supplied for each Load Cell and Instrument
provided with the machine. Re-calibration of the machine and instruments should be performed
after installation and regularly at yearly intervals or as required. Tinius Olsen Ltd maintains a
Calibration and Service Department. At a nominal cost to the customer, periodic calibration and
servicing, as required, can be provided. Complete information on this service can be provided
by our Service Department or our authorized representative upon request

1.2. Overview
The Tinius Olsen H150KU Testing Machine with Strain Gauge Load Cell Weighing System is a
modern precision Tension/Compression test machine designed for the Research Laboratory
and/or Production Testing where the load requirements demand a machine with a large range of
capacities. It is also designed for fast, accurate and convenient operation in the testing of
various types of specimens.
The first line of the 602 main display on the handheld will show the Force, measured by a strain
gauge load cell and conditioner module (typically allocated to channel 1). The second line will
show the crosshead position, measured by an incremental encoder and its conditioner module
(allocated to channel 2). The third line of the display (Auxiliary) is not generally used unless an
optional LVDT or strain gage based measuring instrument and its conditioner is to be used.
Such a device may be used to measure strain (extensometer) or deflection (deflectometer) in
the specimen.
The H150KU testing machines with their versatile, easy-to-use software packages are ideal for
determining the mechanical and physical properties of materials in Tension, Compression,
Flexure and Shear. Many other physical properties may also be investigated.
The H150KU machines cater for capacities of up to 150,000N utilising a twin screw arrangement
for high capacity.
There may be aspects of material testing not covered in this operation manual in particular the
type of grips used and additional optional equipment, such as Extensometers. See the
accessory instructions provided for these options.

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2.

Major Options
2.1. Strain (Aux.) Display Option(s)
Test Lite is a software package that will allow the operator to have simple control of the machine
and setup basic test parameters to gather data from a test. This data can then be printed or
exported at the users discretion.
Please note that Test Lite does not calculate any test results. However, it will report maximum
values and dimensions can be entered for flat or round specimens and report Stress units.
Test Lite also includes the (password protected) Calibration program necessary to configure and
calibrate the machine.

2.2. Navigator
The software will control all the 602 Display settings.
The software can start the test, control the speed of the machine, stop the machine after the
test, and return the crosshead to its Start Test Position
The Software will plot the test on the computer display, perform the calculations, and the
operator can either reject or save the Test Results along with the Curve (Data Points). A
printout of the Results and Curve can be made after a test and/or recalled later. When provided
with an optional Printer, the printed curves can also be used to calculate results not reported by
the software and multiple tests can be printed on one chart. Other options with the software
include interfacing Digital Micrometers or Callipers, or other auxiliary devices.
A simplified version of Test Lite is provided with the Navigator Software for operating the
machine remotely.
The Navigator software comes in three levels:

StanPac Version where the user must pick from a set of reports that cannot be
changed.
Standard Version where the user can edit or create reports, headings, simple results,
etc.
Plus Version where the user can create their own reports, headings, simple results, etc.
In addition, the user can edit the formulas used for any customer defined results and
expanded Import capability.

NOTE
These software packages require the use of a Windows (NT/2000/XP) computer with a vacant
RS232 port. Should an RS232 port not be available, a USB port may be used in conjunction
with an adaptor.
A suitable computer and or adaptor is available from Tinius Olsen.
For customers intending to supply their own computer, please ensure that it meets the minimum
system requirements as stated in the quote for the software.
.

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3.

Specifications
3.1. Load Frame
Designation
Capacity
Style
Max Crosshead Travel
Max Specimen Diameter
Frame Stiffness
Construction

U Series
150kN (15,000kg)
Floor Mounting
1200mm
650mm
200kN/mm at normal load points
Solid steel -crossheads with sheet steel panelling
Precision Anti-Backlash Ball Screws
Ballscrew cover/protection bellows
Pre-loaded Lead Screw Thrust Races
Precision Brushless DC Servo Motor
Programmable crosshead Limit Switches
Emergency Stop Switch

3.2. Control System

602 Remote Handset

3.3. Force Measurement

Load Cell Shear Web Type
Conforms to EN10002, ASTM E4, DIN 51221, ISO 75001
Range 2% to 100% with Guaranteed Accuracy of 0.5% of applied force
Extended Range down to 1% with Guaranteed Accuracy of 1%
Rapid Change Load Cells Available:Unique ID and calibration for each load cell
Max Force Limit = 1.09x FS Load (N).
Force sampling rate typically 100 Samples/Second
(Up to approx. 350 samples/sec possible with 2 channels
and high speed computer running appropriate software)
Load cell resolution 1 part 130,000 for +/- FS
Digital Load Tear 20% whilst maintaining full load cell capacity

3.4. Extension Measurement

Extension Measurement by Precision optical encoder or optional external extensometer.
Single measurement range 0 to 1200mm
Resolution 0.0001mm
Accuracy 0.01mm/300mm

3.5. Speed Control

2 Pre-settable Speeds Under Manual Control
Fully Variable Speeds Under Test Navigator Software Control
1 Return Speed
Velocity Speed Range:Testing
0.01 mm/min to 500 mm/min
Return Speed
0.01 mm/min to 700 mm/min
Speed Velocity Programmable in 0.01 mm/min steps
Speed accuracy 0.5% of full speed
Drive system:- Brushless Servo Motor
Automatic Over/Under Speed Alarms
Motor Drive Alarms on Under/Over Voltage, Current, and Temperature

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3.6. Hardware Options

Tinius Olsen range of Contact and Non-Contact Extensometers
Tinius Olsen range of Displacement Transducers
Tinius Olsen range of Grips and Attachments
Tinius Olsen range of Guarding Options

3.7. Dimensions
Height
Width
Depth

mm
2,465
1,135
700

Inch
97
44.75
27.5

3.8. Weight
1,035 Kg
1,290 Kg Including Packaging

3.9. Power Supply

3 Phase 415+/-10% VAC

3.10. Environmental
Temperature
Humidity

Operating
0C to 38C
Storage
10% to 90% Non-Condensing Wet Bulb Method

3.11. CE Markings
EMC Directive 89/336/EEC, and conforms to the following Generic EMC specification
for Commercial and Light Industrial products.
Emissions EN 50081-1
Immunity EN 50082-1
Low Voltage Safety Directive 73/23/EEC, and conforms to the following specification.
EN 61010-1 (Safety requirements for Measurement, Control and Laboratory use)

3.12. Manufacturer
Tinius Olsen Ltd
6 Perrywood Business Park
Honeycrock Lane
Salfords
Redhill
Surrey
RH1 5DZ
England

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4.

Installation
4.1. Inspection
After unpacking, thoroughly check the machine controls for any damage.

4.2. Contents
The machines are shipped completely assembled except for the optional accessories . The
basic machines are supplied with the following items, please ensure that these are included for
the installation.
4.2.1.

H150KU Testing Machine

4.2.2.

Loadcell (Optional)
This will normally be of a shear web type 150kN, other sizes & types may be specified

4.2.3.

Loadcell Bolt (Optional)

Bolt with hexagonal head (41mm A/F) for securing the loadcell to the crosshead.

4.2.4.

Nose Piece (Optional)

Nose piece with 2 off locking collars for attaching tooling to the loadcell
Nose piece with 2 off locking collars for attaching tooling to the base plate

4.2.5.

Grip Pin (Optional)

2 off supplied Pins to suit nose pieces specified

4.2.6.

PC Connection Lead
D type 9 way socket RS232 Serial Port Lead for external computer control.

4.2.7.

Manual
Operating instruction manual and load cell calibration certificate

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4.2.8.

Other Parts
Additional parts may be supplied, which are not listed above and will depend on the
system configuration.

4.3. Location
4.3.1.

Moving the Machine

The machine will require a forklift truck or similar to move it.
When moving the machine with a forklift truck, place protective materials (rubber sheet
or cardboard) on the forks and lift the machine from the underside of the cross head

4.3.2.

Levelling
The machine is designed to be placed on a flat level floor. If this is not available, jacking
screw points are provided located at each corner. Level the machine by screwing an
M20 screw into the jacking screw holes and then insert packing material between the
feet and the floor.
If desired the machine can be bolted to the floor using any combination of the 8 off holes
located at the corners of the machine.
See Appendix for bolt dimensions and positions

4.3.3. Power Supply

The machine requires to be hard wired to a suitable 3 phase supply, this is normally:15 Amp Cont. 30A Peak
415 V +/-10% (374 456)
50/60Hz
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Other operating voltages may be used, please contact Tinius Olsen Ltd for further
details
The supply must be fitted with a power disconnect switch that is easy to operate and
reach. The machine should be positioned as close as practical to the supply to avoid
trailing leads and or conduit across the floor.

4.4. Connection to Power Supply

Electrical connections must be made by qualified personnel and it is their responsibility
for using the proper power disconnect along with the correct size and type of wire and
conduit that conforms to all applicable local electrical codes when connecting the
machine to the buildings main power.
The machine must be earthed, Under no circumstance must the machine be operated
without an earth connection

4.4.1. Electrical Disconnect

The electrical box must have a power disconnect switch that is easy to operate and
easy to reach. It must also meet IEC 60947-1 and IEC 60947-3 standards.
Recommended circuit breakers would be ones that are of the thermal magnetic type
with characteristics suitable for large inductive loads (D-type trip characteristic).
If fuses are used it is recommended that they are of the time delay type with dual
elements. These recommendations should be followed to avoid nuisance tripping.

4.4.2. Cable Size

The machine will require either a 4 core cable (3 power 1 earth) or individual cables
2
running in a trunking. The minimum wire gauge for the H150KU is 12 AWG (3.3mm ),
the earth wire must be of the same size or greater.

4.4.3. Cable Entry

A blanking plate is fitted to the side of the machine adjacent to the circuit breakers, this
plate can be drilled to suit the required gland or conduit fitting.

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4.4.4. Connections
Before the cables can be attached to the machine the gland plate, rear panel and MCB
shield must first be removed.

Rear Panel

MCB Shield

Gland Plate

The cables must be connected as follows

L1
Tinius Olsen Ltd

L2

L3
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Earth
Page 9

When connecting the earth, ensure that the both the first nut and lock nut are fully
tightened.

4.4.5. Re Fit Panels

IMPORTANT - Before applying power to the machine, ensure all covers are re-fitted

4.5. Load Cell

The load cell is fixed to the underside of the crosshead using the bolt supplied.
NOTE - Before mounting any load cell to the crosshead, always check to ensure that the
contact surfaces are clean

Loadcell Bolt
Crosshead

RJ45 Connector
Loadcell

4.5.1.

Place the mounting bolt through crosshead and lift the loadcell into position. Screw the
bolt into the load cell. Hold load cell in position ensuring it is parallel to the crosshead
then fully tighten with a suitable spanner.
WARNING High capacity loadcells are heavy. Assistance may be required to lift the
loadcell

4.5.2.

Each loadcell is supplied with a strain module, this module must be used with the
supplied loadcell. Strain modules hold identification & calibration information and are
not interchangeable.

Tinius Olsen Ltd

Attach the strain module to the crosshead using the bracket supplied
Connect the RJ45 plug connector into load cell socket located beneath and to
the right of the moving crosshead.
Connect the round connector into the socket on the loadcell and twist to tighten.

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RJ45 Connector

Strain Module

4.6. Connection to a PC
The machine is connected to a PC using the supplied D type 9 way RS-232 Serial
cable, this connection allows the computer to communicate with the testing machines
internal electronics.
Before attempting to connect the RS-232 Serial cable, ensure that both Testing Machine
and PC computer are SWITCHED OFF.
NOTE - Only use the cable supplied with the machine
4.6.1.

The RS-232 Port is located on the right hand side of the machine towards the rear.
Simply align the 9 way D type cable socket connectors to its mating plug on the
machine, taking care not to bend any pins, whilst held in this position tighten the two
socket jack screws until the connector is fully engaged.
The picture overleaf indicates the position of machine RS-232 Port.

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RS-232 Port

4.6.2.

RJ11 Connector

The other end of the RS-232 serial cable connects to a Personal Computer RS-232
Com Port normally located at the rear of the PC Base Unit. The method is the same as
used on the machine by aligning the 9 way D-type connectors then tighten the two jack
screws.
If your computer does not have a vacant RS-232 port a USB port may be used in
conjunction with an adaptor. A suitable adaptor is available from Tinius Olsen.

4.6.3.

Connect the coiled lead between the handset and machine, the RJ11 connector is the
uppermost connector on the side of the machine near to the RS-232 Serial Port.
The handset rests on the bracket at the front of the machine.
WARNING - Do not plug the RJ11 connector of the handsets cable into any of the RJ45
connectors for the modules or you will damage the handheld device

4.7. Connection to auxiliary equipment (optional)

4.7.1.

Auxiliary equipment (extensometers etc) suitable for use with this machine are available
from Tinius Olsen.

4.7.2.

Mechanical attachment methods vary according to the type of auxiliary equipment,

these instructions will be supplied with the equipment.

4.7.3.

To connect the equipment to the control system, slide the interface module, supplied
with the equipment, into a vacant slot above the RS-232 port and plug the attached
RJ45 connector from the module into its adjacent socket.
NOTE Only use the module supplied with the auxiliary equipment as this contains
identification & calibration data.

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5.

Checks before powering up

Before powering up the machine ensure the following:

The handset is plugged in.

The power supply is attached and switched on.

Both circuit breakers are on. These are located on the rear panel near the bottom of the
machine. The breakers are on when the levers are facing upwards.
NOTE There are 2 breakers, one 3 pole (3 phase supply) and one 2 pole (internal power
supply)
See below for location of Circuit Breakers.

Circuit Breakers
(shown in on
position)

The E-stop button is released.

To check if the emergency stop switch is in its normal position rotate the top part of the
switch clockwise (direction shown by arrows on top of switch). If the switch had been
previously activated, on rotation the top will spring upwards. If no upwards movement is
felt the switch is already in its normal position

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6.

Power on
6.1. Turn the machine On
Apply power to the machine using the on/off switch on the front panel: When power is first
applied to the test machine, the remote terminal should boot up after 10 - 20 seconds.
Whenever power is first applied to the 602 System, the handset display will show the following
information.

6.1.1. Installed Version Number

Firmware version and serial number are displayed.

6.1.2. Transducer details

The display will indicate the attached conditioner modules, these will be: Force Xducer on line 1
Position Xducer on line 2
Aux Xducer (if fitted) on line 3.
If any of these modules are removed or replaced while the 602 system is displaying the
main screen, the 602 system will recognize this and read in the data from the new
module.
NOTE - Power will be removed from the motor drive during the reading process, and
return to the main screen.
If any new modules are connected while the 602 is displaying one of the Menu Screens,
the 602 will not be able to read in that module until exiting the Menu section
Typical Boot up sequence is shown below

Tinius Olsen Ltd

Handset Boot Up Screen 1

Handset Boot Up Screen 2

Handset Boot Up Screen 3

Machine Ready

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6.2. Check Machine Operation

The machine powers up in IDLE mode, the crosshead will not move unless the motor drive is
enabled, to enable or disable the motor drive the keys HI CL or LO CL are used.
NOTE - Hi Cl and Lo Cl perform the same function on this machine. Press the Hi Cl key once to
activate it, again to deactivate it. Or press the Lo Cl key once to activate, again to deactivate it.
The motor drive will be disabled when neither Hi nor Low is selected.

Return
Motor Enable
Up
Motor Enable
Stop

Down

Handset Controls

6.2.1. Enable drive

To enable the motor drive you must first select either the [Hi Cl] or [Lo Cl] keys. Hi or
Low will appear in the corner of the display Pressing the button a second time will
disable the motor drive.

6.2.2. Move Crosshead

Pressing one of the direction keys (Up or Down) after enabling the drive will
move the crosshead in the relevant direction at the first set speed, pressing the
button a second time will move the crosshead at the second set speed.
Subsequent presses will toggle between the set speeds
Pressing the stop key will stop the crosshead
Pressing the Return key will move the crosshead either up or down at the set
return speed until the position indicator returns to 0.00
IMPORTANT When using the return function ensure that there is sufficient space for
the crosshead or anything attached to it to move to the zero position without colliding
with anything placed on or attached to the machine.

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6.2.3. Travel limits

The travel limits are set by releasing the blocks mounted on the alarm rod in front of the
left hand cover and sliding them to the required position.
To confirm function of the limit switch, run the crosshead upwards then pull the alarm
rod up, the machine should stop. Next run the crosshead downwards and pull the alarm
rod down, the machine should stop

Release Upper Limit Switch, move

crosshead to new position, slide limit
switch to crosshead striker, re-tighten

Release Lower Limit Switch, move

crosshead to new position, slide limit
switch to crosshead striker, re-tighten.

IMPORTANT if the machine fails to stop when the limit alarm is tested DO NOT use
the machine until the problem has been remedied.
NOTE If the crosshead is allowed to contact the alarm block, the machine will stop, in
this case in order to restart the machine, release and move the block away from the
crosshead. If it is not possible to move the block away from the crosshead then the
interlock override function must be used. (See 7.4.5)

6.2.4. Emergency Stop

Pressing the emergency stop button (located on the front panel) will immediately stop
the machine and disable the drive.
The button will remain down after being released, to reset the switch, rotate the top part
of the switch clockwise (direction shown by arrows on top of switch), on rotation the top
will spring upwards. If no upwards movement is felt the switch is already in its normal
position.
IMPORTANT if the machine fails to stop when the emergency stop switch is tested
DO NOT use the machine until the problem has been remedied.

6.2.5. Load cell

Press the ZERO FORCE key to zero the force displayed on the handset
With the crosshead stationary, pull down and push up the underside of the load cell and
check the force display on the handset.
When the loadcell is pulled down, the load should be positive
When the loadcell is pushed up, the load should be negative.
IMPORTANT to prevent damage to the loadcell when using low capacity loadcells do
not use excessive force.

6.2.6. Overload alarm

A load limit alarm is flagged when the machine or load cell capacity is exceeded either
in tension or compression. The value of the alarm depends upon the load cell fitted and
is approximately 9% greater than load cell capacity. E.g. If a 100KN load cell is fitted
the alarm would be triggered at 109kN in tension or compression. This system should
not be relied on to protect the machine or operator, as the machines ability to stop prior
to damage is greatly reduced at high crosshead speeds.
The alarm is indicated by the flashing load and position indication on the handset. The
alarm can be cleared by backing the crosshead off in the opposite direction to reduce
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the applied force using the interlock override function (See 7.4.5). If the alarm persists
it is possible that the load cell has been damaged.
The user is able to set a lower load limit if desired

7.

Operation
7.1. Handset
The handset will always show Force on the top line of the main display. This reading comes
from a strain gage load cell and its conditioner module (typically channel 1). The second line
indicates crosshead position. It comes from an incremental encoder and its conditioner module
(channel 2). The third line may be blank or it may display the reading from an Auxiliary device
like an extensometer or deflectomer. Tinius Olsen supplies LVDT and strain gage based strain
devices which, in conjunction with the appropriate module, may be selected

The bottom two lines will display Status information. The second to last line will show SBD
on the left if the Sample Break is ON, HI or LOW in the middle to show which Clutch Range
is selected, and PK= on the right if Peak Hold (for Force) is on. The last line will show the
current mode of operation on the left, this will be IDLE when the system is first booted or when
leaving a Menu screen, READY once the [Test/Clear] key is pressed, TEST while a test is
running, HOLD when the [Stop ] key is pressed, and an Error message when an error is
detected. The right side of the last line will show the speed setting or current speed during a
test. If the 602 is not running a test then pressing Up or Down will show on the last line.
NOTE The user should first press the [STOP] key before pressing [TEST/CLEAR] to ensure
that the crosshead does not drift whilst in the Ready mode.
Before testing, select the drive by pressing either Hi or Low Clutch and then press Stop (Hold).
Then press Test/Clear (status shows Ready) and then press either Up or Down to start the
crosshead moving and begin the Test. The Peak Hold and Sample Break (if selected) will only
work in the Test mode
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 Tinius Olsen Ltd

820-7001_15 Issue 3

1.
2.
3.
4.

1.
2.
3.
4.
5.
6.

This will refresh the 602 display. This is only needed for older handsets

3. Configuration

4. Protected*

5. Refresh

*-

1.
2.
3.
4.
5.

2. Display

The Stop

key is used as an [Enter] key when on a Menu Screen.

A general Passcode (602602) is needed to enter the Protected Menu Selections.

Interlock This will bring up a Screen on a Mechanical Machine to override the Crosshead Limit Switches.
Lock/Unlock This will lock and unlock the 602 Machine Control & Configuration Menus.
Bootloader This is used when flashing a program into the 602 CPU. Power must be removed to get off this screen.
DAC Test This screen will allow the operator to select certain DAC output levels for testing the DAC Signal.
Filter This will display the Bandwidth & Delta settings for the three 602 Display Channels Force, Position & Aux.
Additional Sets the Hold Rate & Sampling Rate. The 602 will re-boot after exiting.

Force The operator can select which force transducer to direct to the main Force Display.
Position The operator can select which position transducer to direct to the Position Display.
Auxiliary The operator can select which module to direct to the Auxiliary Display.
CPU This will bring up the Title Screen with the 602 Version.

Units The Force, Position, Auxiliary Channel & Speed Units can be changed.
Peakhold The 602 Force Peak Hold Function can be turned ON or OFF.
Backlight The 602 Display Backlight can be turned ON, OFF or set to a 10 minute timed delay.
Contrast The contrast of the 602 Display can be adjusted from 1 16.
Language The operator will be able to choose the language for the Menu Screens.

1.
2.
3.
4.
5.

1. Machine Control

Speeds The two Test Speed Settings. Return Speed & Proportional Gains can be displayed and edited.
Position Control The HOME Position, Threshold and the HOLD Gains can be displayed and edited.
Limits The FORCE, POSITION & DAC Limits can be displayed and edited.
Sample Break Detect The Sample Break Detector is set to Stop/Return on Break or is turned OFF.
Sample Break Set The Force Start Load (%fs) & Dropoff (%pk) are set for the Sample Break Detector.

602 Display Main Menu Selections

7.1.1. Handset Menu

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7.2. Handset Functions

7.2.1. Zero Channel Keys

These function keys are used to zero the three display channels between tests while on
the Live Screen.
Pressing the [Zero Force] key will zero the force reading on the first line. This should
be done before inserting the specimen in the grips or holders.
Pressing the [Zero Pos.] key will zero the position reading on the second line. This
should be zeroed when the crosshead is at the Start Test position. This zero position
is where the crosshead will go to when the [Return


] key is pressed.
Pressing the [Zero Aux.] key will zero the reading on the auxiliary line. When using an
extensometer, it should be zeroed after clamping it on the specimen just prior to starting
a test.
Pressing one of these keys for any given channel causes the display value for that
channel to be automatically zeroed. If the transducer is mechanically so far off zero that
it cannot be electrically zeroed, the display will not change. The transducer should then
be checked and/or adjusted, and the "zero" key pressed again. Strain Gauge
Conditioner Modules will zero up to 20%, LVDT Conditioner Modules will zero up to
50%, and Encoder Modules will zero any value. The zero keys WILL WORK during a
test but SHOULD NOT BE USED unless intended.

7.2.2. Menu Key

Pressing the [Menu] key will bring up the 602 Main Menu Screen. From this menu, the
operator can press a number key for one of the choices or press the [Menu] key to exit
the menu mode. Refer to the 602 Instructions provided after this booklet for the Menus
and their functions

7.2.3. Drive Enable

or

Pressing the [HI CL] or [LO CL] will ready the motor drive, once an instruction to move
has been given the drive will enable and remain enabled until the button is pressed a
second time. These are also the [4] & [7] keys when using the Menu Screens

7.2.4. Return Crosshead Key

Pressing the [Return


] key will activate the return function of the 602 system. If the
crosshead is beyond the threshold value, the crosshead will attempt to return at the
Speed set on the Speeds Menu 1-1. As the crosshead is returning, the lower left hand
corner of the 602 remote will show RETURN. As the crosshead approaches the
threshold value, the 602 will switch to a HOLD Segment as set up on the Position
Control Menu 1-2. The bottom status line will show the system in a HOLD Mode while
at the home position. This key can be pressed at anytime; if a test is being conducted, it
will end the test. This is also the [8] key when using the Menu Screens

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7.2.5. Max Key

The [Max.] key will display the maximum value obtained for each display Channel
during the last test performed until the [Test/Clear] key is pressed for the next test.
Pressing the [Test/Clear] key after a test will reset the current maximum values. If
higher values are obtained after the test has been ended by the operator pressing the
[Stop
 ] key or by the Sample Break Detector, they will not register as maximum values.
The [Max.] key can pressed during a test but will continue to update while pressed.
This is also the [9] key when using the Menu Screens.

7.2.6. Test / Clear Key

Pressing the [Test/Clear] key resets the stored maximum values from the last test,
resets the Sample Break Detector (if enabled), resets any overload errors and places
the display into a "READY" Mode for the next test as shown on the bottom status line.
Do not press this key until the maximum values are recorded for the prior test, as
it will clear those values

7.2.7. Upper Directional Key

Pressing the raise [
] once will start to run the crosshead up at the Speed 1 setting on
the Speeds Menu 1-1. Pressing this same key again will advance the machine to the
Speed 2 setting on the Speeds Menu 1-1. This key will not do anything unless the drive
is enabled and the 602 display is in the IDLE or HOLD Mode

7.2.8. Lower Directional Key

Pressing the lower [
] once will start to run the crosshead down at the Speed 1 setting
on the Speeds Menu 1-1. Pressing this same key again will advance the machine to the
Speed 2 setting on the Speeds Menu 1-1. This key will not do anything unless the drive
is enabled and the 602 display is in the IDLE or HOLD Mode.

7.2.9. Stop (Hold) Directional Key

On the Live Screen, the [Stop
 ] key will stop the crosshead by immediately executing a
Position Hold (as shown on the bottom Status Line) on the current position. Depending
on the speed that the crosshead is running, the crosshead will stop and return a little to
the position value at the time the [Stop
 ] key was pressed. This key will also end a
test, if in the TEST Mode. In the Menu Mode, its the [Enter] key to accept an entry

7.2.10. Speed Increase Adjust Key

When running a speed (Speed1 or Speed2) pressing the [Speed  ] key once will
cause the current speed setting to be incremented and momentarily show the change in
the setting. Pressing and holding this key will continue to increase the selected speed in
greater increments. After showing the setting change, the bottom line of the 602 display
will return to the current rate display. This is also the [0] key when on one of the Menu
Screens.

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7.2.11. Speed Decrease Adjust Key

When running a speed (Speed1 or Speed2) pressing the [Speed  ] key once will
cause the current speed setting to be decremented and momentarily show the change
in the setting. Pressing and holding this key will continue to decrease the selected
speed in greater increments. After showing the setting change, the bottom line of the
602 display will return to the current rate display. This is also the decimal [.] key when
on one of the Menu Screens.

7.2.12. Non-Function Keys

These six keys have no function except when on a Menu Screen for entering the
number on the key or the minus (-) sign for entering negative values.

7.3. Special Key Functions.

7.3.1. Force Calibration Check Number
Pressing the [Menu] key, the [Zero Force] key and the [Menu] key in sequence will
activate or deactivate the Cal-Check for that pressure transducer or load cell directed to
the Force Channel. The Cal-Check number will be shown on the first 602 channel and
the left side of the bottom status line will show Cal-Check. Repeat the key sequence
again to deactivate the cal-check. The force display line must first be properly zeroed
before reading the cal-check number. This only works with Strain Gauge Conditioner
Modules. This value is recorded at Calibration and noted on the Report and/or sticker.
This value should not change by more than 1% for any given Load Cell. It is an
indication that the system's electronics are operating properly but is not a substitution for
verification of the system's accuracy to approved standards.
NOTE - The Cal Check number changes if the initial conditions change. The best way to
use this function is to let the load cell warm up, remove any weight such as grips, zero
the Force, then activate the Cal-Check and record this number

7.4. Machine Protection

7.4.1. Zero Motion Detect
Should the machine detect no change in position when the crosshead should be moving
after a certain amount of time then the drive will be disabled and the error Pos will be
displayed on the handset. This protects the machine should the encoder be
disconnected or faulty. Pressing [Test/Clear] will clear this condition.

7.4.2. Travel Limits

Damage to the load cell, tooling etc. caused by overtravel of the crosshead can be
prevented by the operator properly setting the Adjustable Limit Switch Blocks located on
the long rod on the left hand side of the machine.
When one of the Position Limit Switches is activated, the 602 display will flash and the
proper error message UprLmt or LwrLmt will be shown in the lower left hand
corner. This will also disable the motor drive.
To clear this alarm, the operator can manually move the adjustable block on the limit
switch rod if possible and then run the machine away from the limit switch collar. If the
collar cannot be moved anymore, there is an Interlock Override feature on the 602 that
will allow the operator to force the crosshead to move regardless of the Limit Switch.
(See 7.4.5)
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CAUTION:
When using the Interlock Override be sure that the Crosshead is moved in the
OPPOSITE direction AWAY from the activated Limit Switch Collar. DO NOT MOVE
the Crosshead in the same direction as it will go through the limit switch and will
damage the Limit Switch Arrangement. Overtravel may also damage the loadcell
and tooling.
Should this occur please contact Tinius Olsen for advice before continuing to use
the machine.

7.4.3. Loadcell Overload

The maximum force limit is 1.09 x FS capacity (N). The Positive and Negative Limits
must be set for their respective limits. The user may enter smaller limits if desired.
Should the loadcell be subjected to excessive load, the lower left hand corner of the
remote will show Ovrld, the display will flash and the drive will be disabled.
If the load can be removed or reduced then pressing the [Test/Clear] button will re-set
the display.
If it not possible to remove the load, the crosshead can be backed off using the override
feature. (See 7.4.5)
CAUTION:
When using the Interlock Override be sure that the Crosshead is moved in the
OPPOSITE direction AWAY from the applied load. DO NOT MOVE the Crosshead
in the same direction as damage will be caused to the loadcell

7.4.4. Position Limit

The position limit is set using the Menu [1] [3], this limit is normally set to +/-1199mm.
Should the limit be exceeded, the lower left hand corner of the remote will show Pos,
the channel displays will flash and the drive will be disabled.
The machine crosshead can be moved back into a valid position by simply re-zeroing
the position or using the override feature (See 7.4.5)

7.4.5. Operation of Interlock Override

To get to the Interlock Override press: The [Menu] key
The [4] key for the Protected Mode
Type the Passcode (602602)
The [1] key for Interlock Override
The following menu will display.
Interlock Override
Use up and down arrow
Keys to move crosshead.
Press Menu key to exit.

Use Caution when

moving Crosshead.

Once the crosshead has moved enough to clear the fault position press the [Menu] key
to exit back to the live screen. It may be necessary to press [Test/Clear] to clear out the
old fault status.
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7.5. Typical Settings

When set at the factory, the handset will typically display the following settings. Settings
highlighted should not be altered under normal circumstances and may be locked on the
handset (see Error! Reference source not found. [Menu # 4 2])

7.5.1. Speed [Menu # 1 1]

Speed 1
Speed 2
Return Speed
Gain 1
Gain 2
Gain Return

0.01 500 mm/min

0.01 500 mm/min
0.01 750mm/min *
0.5
0.5
0.25

(*) Max speed will depend upon supply voltage.

7.5.2. Position Control [Menu # 1 2]

Home
Threshold
Hold P Gain
Hold I Gain

0
2
0.25
0

7.5.3. Limits [Menu # 1 3]

+ Force
+150000N *
- Force
-150000N *
+ Position
+1199.9mm
- Position
-1199.9mm
+ DAC
+99.98
- DAC
-99.98
(*) Force limit will depend upon loadcell fitted.

7.5.4. Units [Menu # 2 1]

Force
Position
Speed

N
mm
mm/min

7.5.5. Hold / Sample Rate [Menu# 4 1 6]

Tinius Olsen Ltd

Hold Rate
Sample Rate

1000
100

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7.6. Replacing Loadcells

7.6.1. Fitting
To change Load Cells, the primary load cell must be removed and the new Load Cell
mounted (See 4.5.1) With each load cell there must a cable with a Strain Gauge
Conditioner Module. Mount the module onto the crosshead and plug the 8-pin RJ45
jack into the receptacle on the side. The 602 will read in the new module and the
Configuration Screen for that module will be shown and then return to the live screen.
DO NOT PLUG ANY NEW MODULES DURING A TEST BECAUSE THE 602 WILL
STOP THE DRIVE DURING THE READ IN PROCESS.

7.6.2. Selecting Device

Once the read in process is done, the operator must direct the new Load cell to the
Force Display (top line) by pressing [Menu], the [3] key on the Main Menu for
Configuration, the [1] key on the Select Channel Menu for Force, and then [1] on the
Xducer Menu for Select Transducer. The 602 will show a list of any connected Force
Modules by description. Press the number for the description of the new Load cell to be
used. If the desired cell is not listed, check that it is connected correctly. The 602 will
exit back to the live screen. Press the [Zero Force] key to zero the load cell, then
manually push up on the base of the loadcell and check that the Force Display shows
an appropriate response. If optional software is being used, this can be done by the
software settings and the operator doesnt have to use the 602 menus.
NOTE - Only modules that are intended to be used should be plugged in to the RJ45
connectors. That is because any device with the RJ45 connectors plugged in is
considered active by the 602. Too many connected devices reduces the bandwidth of
the system, particularly at higher sample rates. It is recommended that the total number
of connected devices be limited to 3 or 4

7.6.3. Setting Force Limits

Note that for the Force Limits to apply, the load cell must be directed to the first (Force)
line on the 602. When a lower capacity load is read into the 602, the Force Limit
Settings will be rewritten 1.09 x FS capacity (N), but when adding a higher capacity load
cell the operator MUST enter the higher limits manually or have them entered in the
software settings and let it load them in.

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8.

Tooling
Tinius Olsen manufacture a wide range of sample tooling, please contact Tinius Olsen or local
authorised distributors to discuss your requirements.

8.1. Attaching to the Machine

8.1.1.

A large proportion of tooling uses the same method of attachment to secure the tooling
to the machine / load cell.
In general this comprises:Nose Piece
Locking Collar (X 2)
Grip pin
The diagram below indicates attachment parts.

8.1.2.

Nose pieces have a threaded section to screw into the loadcell / machine and a parallel
section to fit inside the tooling. The parallel section includes a hole for a grip pin to be
inserted to attaching to the tooling.
The size of the nose piece is determined by the maximum load to be applied as follows:Load (kN)

Nose Piece Dia

Grip Pin Dia

0 - 20
20 50
50 100
100
150
200 - 300

5/8 inch (15.875mm)

3/4 inch (19.05mm)
30mm
40mm
50mm
60mm

5/16 inch (7.9375mm)

3/8 inch (9.525mm)
1/2 inch (12.7mm)
16mm
20mm
24mm

The attachment fixing threads range from M6 to M42, depending on the capacity of load
cell used. The tooling attachment for the fixed crosshead is M36 and standard loadcell
is M33, an adaptor is available to reduce this if required.
8.1.3.

Before attempting to install the tooling attachments check the following :a)
Size of fixing thread in load cell
b)
Size of female noise piece used on tooling
c)
Size of grip pin

8.1.4.

To install the tooling attachment to the load cell, first ensure both locking collars are
centralised on the tooling attachment. Align the fixing thread to the load cell and rotate
in a clockwise direction to engage. Once engaged rotate a further 6 to 8 times. This is
to ensure the correct amount of thread has been inserted. Ensure the tooling
attachment hole is facing forward. Now rotate the fixing locking collar clockwise until it
makes contact with load cell. Do not tighten the attachment locking collar at this stage.
Repeat the above procedure for the fixed crosshead, this will require a M33 fixing thread
tooling attachment.
The diagrams below indicate tooling attachments for load cell and fixed crosshead.

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8.1.5.

Installing Tooling
Depending on the type of tooling to be installed, this procedure may require additional
help (tooling may be heavy). Ensure the distance between the load cell and the fixed
crosshead is sufficient for installation of tooling, the distance may require to be
increased using the direction control keys.

8.1.6.

Align tooling female nose piece with load cell attachment male nose piece, slide the two
together until daylight can be seen through both grip pin hole in tooling and attachment.
Insert the grip pin from the front, make small adjustments to the tooling position to
enable the grip pin to slide in freely. Repeat the above procedure for the fixed
crosshead tooling.
The diagram below indicates the HW20 Wedge Grip fitted to the load cell.

NOTE - The HW20 Wedge Grip is shown as an example, the same principals apply to
all tooling using this type of attachment.
8.1.7.

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Tooling Alignment
Tooling alignment is extremely important to obtain realistic measurements.
Misalignment distorts the test sample leading to irregular loading and in extreme cases
generates large errors in extension measurement. Alignment problems can be greatly
reduced by the method used to tighten the attachment and tooling locking collars.

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8.1.8.

Ensure the fixed crosshead tooling is parallel to the crosshead. Whilst held in this
position lightly tighten both attachment and tooling locking collars. Repeat this
procedure for the tooling attached to the load cell. Check alignment in all three axis. If
alignment is out , loosen the tooling locking collars, reposition tooling and retighten
collars. Repeat this procedure until the tooling is aligned. Fully tighten the fixed
crosshead locking collars with the breaker bar supplied. Care must be taken when
tightening locking collars attached to a load cell as lower capacity load cells can be
damaged from excess torque. To minimise risk of damage ensure the sensitive area of
the load cell is supported when tightening these locking collars. The same care must be
taken when removing tooling from the load cells.

8.1.9.

As a general rule load cell capacities from 25 to 100N only require locking collars finger
tight. Load cells from 200N to 2kN should be lightly tightened with breaker bar. Load
cells from 5kN to 10kN can be fully tightened with breaker bar, and above 10kN the
breaker bar limits torque that can be applied. Note Load cells below 25N can be
damaged by handling alone. When installing low capacity load cells, extreme care must
be taken.

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9.

Conducting a test
9.1. Basic Operation
These are some typical precautions to be observed when operating a Tinius Olsen H150KU
Testing Machine. The Load Cell Weighing System of the H150KU is considered a very "HARD"
type of weighing system. The force-measuring element (Load Cell) will only deflect
approximately 0.1mm at the full rated capacity. This "HARD" weighing system permits
extremely sensitive and accurate load indication. The following information is included to
caution the operator as to unintentional misuse and resulting damage to the load cell.

9.1.1. Overloads
The Load Indicating System of this test machine is provided with protective Overload
Limit Switch Circuitry that removes power from the drive motor whenever the load
exceeds full scale. The purpose of this feature is to prevent damage that can be caused
by exceeding the capacity of the weighing system or the tooling being used for the test.
However, the overload protection is only effective when the machine is being operated
within the response capabilities of the load indicator. Obviously, the overload protection
cannot prevent overloading and the resulting damage if a rigid specimen is impacted at
a high rate of speed.

9.1.2. Clearance
Care must be taken whenever running the crosshead up or down, that the Load Cell and
any attached tooling or specimens do not contact any part of the machine or any tooling,
specimens, etc

9.1.3. Mounting of Specimens

Care must be taken to insure that the specimen is always cantered in the grips, etc.,
when testing in tension or centred between the compression platens when testing in
compression. Off centre loading can result in an erroneous load reading and possible
damage to the load cell or tooling.

9.1.4. Use of Low Capacity Loadcells

The load cells are designed for some overloading, but if the load exceeds 150% of the
rated capacity this can result in zero shift, span changes and possible damage or
breakage. EXTREME CARE should be taken when using low capacity load cells that
they are not dropped or overloaded when mounting tooling. Overloading a load cell will
usually result in the inability to zero the load cell or an offscale reading. As load cell
damage can be difficult to see visually and where load cells may be damaged, the
extent and responsibility is to be determined solely by the manufacturer.

9.2. Testing Using The Handset

The following assumes that the machine is set up, all grips are fitted and all handset settings
have been made. See this manual for further details.
CAUTION:
DURING A TEST, ALWAYS CHECK THE CLEARANCES IN THE AREA AROUND
THE CROSSHEAD. IF INSUFFICIENT, STOP THE TEST BEFORE THE TRAVEL OF
THE CROSSHEAD CAN CAUSE DAMAGE.

9.2.1. Preparing the Machine

With the proper grips or holders installed, run the crosshead to the desired starting
position and press the [Zero Pos] key to zero the Position Channel at this position.
The Force Channel can also be zeroed now by pressing the [Zero Force] key.

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9.2.2. Mount Specimen

Secure the specimen properly in the grips or holders. When securing a specimen there
might be some amount of preload applied to the specimen. The operator can start the
test with a small preload on the specimen, or they can run the crosshead slowly in the
proper direction until zero force is displayed. DO NOT USE THE FORCE CHANNEL
ZERO TO ELIMINATE PRELOAD ON A SPECIMEN.

9.2.3. Mount Aux Instruments (if applicable)

If Strain data is to be recorded, mount the Strain Instrument following the instructions
provided for the instrument, the Strain System and/or Computer being used.

Mount the module into the rack at the rear of the machine and plug the adjacent
8-pin RJ45 jack. The 602 will read in the new module and the Configuration
Screen for that module will be shown and then return to the live screen. DO
NOT PLUG ANY NEW MODULES DURING A TEST BECAUSE THE 602
WILL STOP THE DRIVE DURING THE READ IN PROCESS
Once the read in process is done, the operator must direct the new instrument
to the Aux Display (third line) by pressing [Menu], the [3] key on the Main Menu
for Configuration, the [3] key on the Select Channel Menu for Aux, and then
[1] on the Xducer Menu for Select Transducer. The 602 will show a list of any
connected Aux Modules by description. Press the number for the description
of the new instrument to be used. If the desired cell is not listed, check that it is
connected correctly. The 602 will exit back to the live screen.
NOTE - Only modules that are intended to be used should be plugged in to the
RJ45 connectors. That is because any device with the RJ45 connectors
plugged in is considered active by the 602. Too many connected devices
reduces the bandwidth of the system, particularly at higher sample rates. It is
recommended that the total number of connected devices be limited to 3 or 4

9.2.4. Install Protective Devices (if applicable)

If necessary, install protective devices around the test specimen or test machine to
prevent injury to the operator or personnel in the area. (See 10.2)

9.2.5. Set Speeds

The machine uses the programmable Speeds on the Speeds Menu # 1-1 or optional
Software to set the speed(s) of the test. Set a crosshead speed or rate that meets the
applicable test specification; in some cases, it may be necessary to calculate the loading
speed from known or given data. In the absence of a testing specification, a good rule
to follow is to select a loading speed (rate) slow enough that the force display can be
accurately read at any time.
NOTE - typically Speed 1 is set for a slow speed (e.g. pre-yield speed) and Speed 2 is
set for a faster speed (e.g. post-yield speed or jog speed).

9.2.6. Start Test

Tinius Olsen Ltd

Ensure that the drive is enabled by pressing [Hi] or [Low]

Press [STOP] to keep the 602 in Hold mode
Before starting the test, the [Test/Clear] key must be pressed, placing the 602
into a "READY" Mode. If the 602 remote is not in the READY Mode before
starting a test, the Peak Hold and Maximum Values will not be retained, and the
Sample Break Detector is not active.
Press either the lower directional key (compression test) or upper directional key
(tension test) once to start running a test at the programmed Speed #1 and the
602 display should show TEST in the bottom left corner of the display. If
needed, press the directional key a second time to go to Speed #2. The
operator can see the actual crosshead rate in the bottom right corner of the 602
display.

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9.2.7. End Test

The test can be ended and the crosshead returned to its start test position automatically
by the Sample Break Detector if there is a detectable drop-off in force. If there is no
drop-off or failure during a test, the operator must end the test manually using the
[Stop
 ] key. The 602 display will then go to HOLD Mode and hold that crosshead
position. When you are ready to return the crosshead to its starting position press the
[Return


] key. For tensile testing, the Sample Break Detector is normally set to trigger
at a large amount of "drop off in load" such as 75% to ensure that the specimen has
broken completely.
NOTE - A small Start Load % of Full Scale (typically 1-10 % FS) is required to prevent
false triggering of the Sample Break Detect

9.2.8. Record Results

Record the test data required the Peak Force will be shown on the right side of the
second to last line on the 602 or the maximum values for three Display Channels can be
recalled by pressing the [Max.] key. Remove the tested specimen, then press the
[Test/Clear] key on the 602 remote to clear the maximum values being held, reset the
602 Display and Sample Break Detector, if enabled, for the next test.
NOTE - Do not press the [Test/Clear] key until the results from the prior test are
recorded, because once the [Test/Clear] key is pressed the prior results are cleared.

9.2.9. Next Test

The machine should always be left in its Start Test (Home) Position until the next test is
ready to be started. If the 602 display in the READY mode simply press the
directional key to start the next test. The user must press [Test/Clear] to clear the old
results and re-arm the 602 for the next Test

9.3. Testing Using Optional Software

For machines provided with optional Tinius Olsen Test Software, the computer will send all the
needed information to the 602 Display to run the test remotely. In addition, all the controls on
the 602 are available on the Top Tool Bar in the Software. Setup the test the same as
described in section 9.2, but start the test in the software instead using the directional key.
Once the test has started, the program monitors the test and advances the segments according
to the program and the Machine Control Settings being used for that test. After the test is over,
and the results are saved, etc., the program will prompt the operator to choose whether to have
the 602 automatically return the crosshead or to return it manually by using the [Return


] key.
WARNING - the user must take care if using the handheld in conjunction with the computer
because of possibility of conflict. When using a computer, it is best to configure the system and
run the machine entirely from the computer to avoid potential conflicts

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10. Safety
10.1. Warnings

Tinius Olsen Ltd

Under NO circumstances must the machine/tooling be used if damaged.

Under NO circumstances should the machine/tooling be modified without consent
from Tinius Olsen.
When left unattended always disable the drive by pressing the E-Stop or taking it
out of Hi/Low clutch mode. Do not rely on the simply pressing [STOP] as the
drive is still active
Installation of the machine must be carried out as described in section 4 of this
manual.
Only trained operators should use the machine. (Including operation of software)
Operator must wear appropriate clothing. (No loose clothing)
Eye protection must be worn at all times when operating the machine.
Operator must not place any part of their body within the test area when the
machine is moving.
Mains Supply isolator must not be obstructed and be within easy reach.
Machine Emergency Stop switch must not be obstructed.
The machine should never be left unattended in a loaded condition.
Service/Repair of the machine must be carried out by trained personal

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10.2. Protective Screens

10.2.1. Standard machines are not supplied with protective screens. Depending on the type of
material being tested a protective screen may be required. Please contact Tinius Olsen
if you require screens for your application.
10.2.2. Prior to conducting any testing, the operator must assess the type of sample failure
likely to occur. This assessment will enable the correct protective screen to be selected.
As a general rule, if there is any possibility of fragments being ejected from the machine
when a sample fails then a protective screen should be fitted.
Where high loads and large extensions are required to break a sample failure often
becomes more violent, in this case interlocked screens should be fitted.
In case of doubt or for more advice on protective screens please contact Tinius Olsen
or your local authorised distributor to discuss your requirements.

Illustration shows a fully enclosed guarding solution.

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11. Training
Tinius Olsen or local authorised distributors with qualified factory trained engineers can give
operator training at the time of machine installation. Training covers both machine hardware
and computer software. Training can be further extended to give a more in-depth knowledge of
system on request.
Contact Tinius Olsen or local authorised distributors to discuss your requirements.
For details of your nearest distributor, please check our website at www.tiniusolsen.com.
Tinius Olsen Ltd
6 Perrywood Business Park
Honeycrock Lane
Salfords
Redhill
Surrey
RH1 5DZ
England

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12. Maintenance
The mechanics within the machine are designed for a minimum amount of maintenance.
Typically the replacement and re-adjustment of the drive belts should be performed by qualified
service personnel and should not be attempted by the customer unless instructed on how to do
the required service.

12.1. Electrical
12.1.1. Supply
The H150KU machine operates from a 3ph phase 415V +/- 10% 50/60 Hz 15Amp
Continuous, 30A peak.
12.1.2. Electronics
All the electronics in the machine are solid state and do not require any maintenance.
12.1.3. Circuit Breakers
To protect the machine two circuit breakers have been incorporated at the rear of the
machine. In the event of either circuit breaker repeatedly tripping please contact Tinius
Olsen or one of our authorised distributors.

12.2. Calibration
12.2.1. The internal force and extension range calibration adjustments on this machine are set
to factory specifications and should not be changed in the field. Each load cell has its
own calibrated conditioner module. All the load cells supplied will already be calibrated
and a calibration certificate provided.
12.2.2. It is also recommended that routine calibration of the load cell(s) in Tension and/or
Compression be performed by qualified personnel since improper use or adjustment of
the load cell could result in calibration errors or possibly damage to the machine.
12.2.3. Re-calibration of the machine and auxiliary equipment should be performed regularly at
yearly intervals or as required. Tinius Olsen maintains a Calibration and Service
Department within the UK or through local authorised distributors with qualified factory
trained technicians.
For details of your nearest distributor, please check our website at www.tiniusolsen.com.

12.3. Lubrication
12.3.1. Bearings
Bearings are pre-packed with grease on assembly and should not require additional
lubrication.
12.3.2. Guide columns
The columns (adjacent to the ballscrews) use DU dry self lubricating bearings. If
required the shaft can be lubricated using most lubricating oils that do not chemically
attack the PTFE/Lead overlay or the porous bronze interlayer.

12.3.3. Ballscrews
The ballscrew nuts require a lithium soap based grease Number 2. They will require
approximately 2cc of grease per 12,000-15,000m of travel.

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13. Storage
Long Term Storage
If the machine is not to be used for some time ensure that it is unloaded and the mains power is
disconnected. To help to keep the machine clean cover with a protective cover. If the machine
is to be stored outside its normal working environment repack into its original packing case as
supplied. The storage environment should be clean and dry and out of direct sun light with an
ambient temperature range of -10C to 45C. Under certain conditions condensation can form
within the packing and cause parts within the machine to rust. To reduce this problem place at
least one desiccator within the packing case.

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14. Appendix
14.1.

Tinius Olsen Ltd

Dimensions

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