Testometric

CX Service Manual
 CX SERVICE MANUAL

CX TROUBLESHOOTING....................................................................................................................................................................................2
CX Motor enable/disabled by crosshead switch............................................................................................................................................3
CX System Board ..................................................................................................................................................................................................5
Advanced Service Notes......................................................................................................................................................................................8
CX Tester Machine Set-up from front screen...................................................................................................................................................8
Configuration .......................................................................................................................................................................................................9
CX Settings............................................................................................................................................................................................................9
Extensometer Set-up ..........................................................................................................................................................................................10
Reset Absolute.....................................................................................................................................................................................................11
ADVANCED TROUBLESHOOTING.................................................................................................................................................................12
1. Motor drive disabled.....................................................................................................................................................................................12
2. System check ...................................................................................................................................................................................................13
3. Load cell Tare selection ...............................................................................................................................................................................14
Operator Notes ...................................................................................................................................................................................................15

1
CX Troubleshooting

Applying Power:-

The status led on the CX front panel is normally ON after switch on. If the Status led is not illuminated
after power is applied to the CX then check the following:

i) Fuse in power connector

ii) Check Voltage selector (120/240) is in correct position.
iii) Confirm correct supply voltage

If Status led is ON then check the following:

Note: It is advisable to troubleshoot any problems from within the CX Panel mode (default mode on
switch on).

If screen is active the following troubleshooting can be performed and is categorised below:-

i) Crosshead cannot be driven

ii) Force reading static
iii) Force reading incorrect
iv) No extension readings
v) No communications with computer

i) Crosshead cannot be driven

Check speed switch is not set to 000.00 mm/min (00.000 in/min)

Check that Emergency Stop is not operated

Confirm absolute limit inputs have not been exceeded.

Check that the load cell is not in OVERLOAD condition. Display would normally indicate OVERLOAD.
Return of the crosshead should be possible with this condition.

Check there is no Cell Impact condition. Note that this condition can occur if a high negative load has not
been zeroed, by depressing the Tare button, prior to running the crosshead DOWN in tensile mode. It is
important to note that the TARE button should NOT be used to remove any positive load reading after the
specimen has been fixed in the grips. The operator should always confirm that the load reading is near zero
before specimens are fixed, so that any pre-loading of the specimen when the grips are tightened is
accounted for during the test.

Check the load cell is connected.(If the load cell is left unplugged the load system can temporarily drift into
an CELL OVERLOAD condition.)

Check Sample Break Detection (SBD) figure and confirm that the setting is not oversensitive for the type
of material being tested.

2
CX Motor enable/disabled by crosshead switch

To prevent motor failure, a micro switch is fixed to the top of the machine frame to disable the motor drive when
activated. The crosshead will activate this switch when approx. 50mm from the top of the frame. The switch is
visible when the magnetic ball screw covers are detached from the frame.

If the switch is operated and the motor disabled the motor can be enabled and the crosshead moved by moving a
link on the CX system board.

Crosshead
limit switch

CX System board location (front cover removed)

3
Location of Motor enable link on CX System board

Motor enable link

To move the crosshead DOWN ONLY move the link to enable the motor drive.

• Press the DOWN button

• When clear of the micro switch relocate the link.

See Fig 1 below.

4
CX System Board

Important: When crosshead has moved down a few millimetres, move the link back to the park
position or the motor disable safety feature will not operate.

Board area

CX Board

M. Ena ble

To en ab le m otor d riv e

M o ve lin k to po sition 1 & 2 .

R eturn to p ark p os itio n (2 & 3)

a fter c ros sh ea d lim it s witc h
h as rele as ed. Motor
Drive
1 1
Motor 1
2 2 Enable 2
E. ST OP
3 3 M oto r 3

En ab le P ark En able SW

p os itio n p os ition E. Sto p

Check that top crosshead limit switch has not been operated. Enable motor via Motor Enable link. Refer
1. Motor drive disabled.

Check status of Motor drive card in rear of control console. Red led status is fault condition.

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ii) Force reading static

Check load cell lead is connected correctly.

Check correct load cell is displayed on screen

Check load cell and load cell lead for damage.

Loss of load cell data due to memory corruption. This condition can be checked by an incorrect Force
Calibration check figure.

Re-initialise system by switching off power - wait for 3 seconds - switch power on.

iii) Force reading incorrect

Confirm correct load cell lead and load cell are connected.

If the force reading is confirmed to be incorrect and an error is suspected in the load system, a Cal. check
should be carried out by selecting the icon on the CX Panel.
The force figure displayed should be approximately 50% of the load cell range:

e.g. Load cell fitted 100kgf- Cal check figure 50.00 kgf +/-0.5%

Note: This is a system check only and does not affect the calibration of the force system.

If the Cal check figure confirms there is a problem then further checks need to be made as follows:

If force reading is incorrect by a factor of 10 or greater, check decimal point position and carry out re-
format if necessary.

If force reading is locked on zero then stored memory may be corrupted.

If force system is in an OVERLOAD condition, confirm there is no damage to the load cell.

If there is a suspicion of memory corruption then a system re-format may be necessary. Refer to CX
Tester Machine Set-up.

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iv)Incorrect extension readings

Check the Absolute reading is correct. Re-zeroing the Absolute reference may be necessary. Refer
Resetting Absolute position in CX User Manual.

If an Extensometer is fitted:

Check device is connected to the correct input/output socket on the rear panel of the machine.

Check device has been correctly selected during Test Definition

Ensure extensometer is fully closed onto setting stops before commencing a test.

Ensure extensometer and/or transducer (if fitted) are set to operate at the desired gauge length before
commencing a test.

Ensure that the grips are not slipping on the sample, thereby reducing the overall extension reading. If
slippage is suspected it should be possible to adjust the position of the knife edges so that they are fully
closed and clamp the sample throughout the test.

If the extensometer is loosing counts and slippage is not suspected contact Service personnel.

v) No communications with computer (PC)

Check the interface lead is correctly inserted.

Check that the correct COM port on the PC has been set up correctly.

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Advanced Service Notes

The CX System Board has a number of links that allow for system diagnostics and enabling/disabling
certain control system features.

The following refer to the CX system board which is accessed after removing the CX Front panel.

The CX has an internal 2x16 line display to assist in system diagnostics. This can be enabled by moving the
Display Enable link from the park position (default) to enable. See 2. System check.

Normal display:

Line 1 L1= +=0123.4

L1 +001.0N
N 000 000 ‘L1’ signifies Load cell 1 is connected.

A = + 0234.456 mm
Line 2 ‘A’ is the Absolute position reading

‘000’ are system status flags.

CX Tester Machine Set-up from front screen

Whilst viewing the CX Panel; press the ‘Key’ icon on CX Panel to access the machine settings options.

Selecting View allows the operator to note the current settings of the testing machine.

The factory settings “Configuration”, “Factory” and “Reset Absolute” are password protected to
reduce the possibility of accidental modification of factory settings.

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Configuration

Password : TESTOM

CX Settings

Use the scroll bar to move through the load cell selection.
Press the left mouse button to select the desired cell
Modify load cell sensitivity figure.
Important notice: Changing this figure will alter the load calibration and should therefore only be
modified by approved calibration personnel.

K Factor figures (mm/kN) will be provided. K Factor values are used during testing to modify the
extension or deflection results and compensate for deflection within the machine’s mechanical system when
being taken up to load. Typical values are 0.1mm/kN but actual values will depend on the type of tests
being performed, grips and fixtures used, capacity of load cell etc.

9
Extensometer Set-up

Above are default values for ME type.

Machine Set-up

Machine : M500 or M350 Type

Efactor : Figure is based on machine type and converts pulse information from the motor encoder to
crosshead extension readings.

Machine Type Efactor

350/5kN 2087
350/10kN 1390
500/25kN 0894
500/50kN 0894

Max. Travel Limit : Machine based absolute limit for maximum allowed crosshead travel.
Min. Travel Limit : Machine based absolute limit for minimum allowed crosshead travel.

Important: Incorrectly entered limits can be dangerous. Always check that travel limits are
correct after modifying.

10
Reset Absolute

In order to adjust the absolute crosshead position you must first of all enter the correct password. The password to
allow alteration of the absolute position is 0121.

The new absolute position should be entered in the empty box shown below.

Pressing the “Set” button will transfer this position into the CX memory.

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Advanced Troubleshooting

1. Motor drive disabled

Operation of the Emergency Stop or crosshead limit switch will be displayed on the console screen.
Operation of the crosshead limit switch at the top of the frame will disable the motor drive.
To move the crosshead DOWN ONLY move the link to enable the motor drive. See Fig 1 below.
Important: When crosshead has move down a few millimetres move link to the park position

Fig.1 Location of Motor Enable Link

CX System Board

Board area

CX Board

M. Ena ble

To en ab le m otor d riv e

M o ve lin k to po sition 1 & 2 .

R eturn to p ark p os itio n (2 & 3)

a fter c ros sh ea d lim it s witc h
h as rele as ed. Motor
Drive
1 1
Motor 1
2 2 Enable 2
E. ST OP
3 3 M oto r 3

En ab le P ark En able SW

p os itio n p os ition E. Sto p

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2. System check

To aid in system diagnostics the internal display can be enabled. Note: Enabling the internal display will
reduce system performance by approximately 10%.

CX System Board

Fig 2: Location of Internal display enable link

Board area

CX Board

Display P1 2 B36 DH

Enabled

Display
Disabled

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3. Load cell Tare selection

The load cell pre-tare figure can be displayed by depowering the CX for a few seconds. Switch on CX
and the pre- tare value will be displayed. Do not depower or reset the PC during this operation!
Tare adjustment:
This selection for Cells 1-4 allows for connection to two Tare potentiometers Tare1 & Tare2.
The Tare potentiometers are located on the P. Mod plug-in board.
Selection in Fig 3. below connects Tare 1 potentiometer to Cell 1.

If Tare 1 is already selected use Tare 2

Cell 2 connected to Tare 2 will be position 2 on the selection pins.

Adjust pre-tare load figure to be approx. 0 and must be < 10% of load cell capacity.

Important:

Always adjust pre-tare figure with correct grips attached to load cell.
CX System Board

Fig 3: Load Cell Tare selection

14
 Board area

Tare pot. 1 & 2

CX Board

+ +
E
P
R Lo ad
O +
M Ce ll
Cell P M o d ul e
1 2 3 4
Cal Ta re
1 2 3 4 12

+
+
+
+
+ +
K ey pa d +
Tare
Ta re
1 2 1 2 S el ecti o n Ta re

TX

RX

Operator Notes

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