THIS SERVICE MANUAL IS ISSUED IN ADOBE

ACROBAT FORMAT FOR EASE OF VIEWING

AND DISTRIBUTING AND CAN BE VIEWED
AND PRINTED AS REQUIRED.

A LIST OF CHAPTERS IS SHOWN ON THE

LEFT HAND SIDE OF THE SCREEN. CLICKING
ON AN ARROW WILL DISPLAY THE
CONTENTS OF THE CHAPTER. TO VIEW THE
REQUIRED CHAPTER OR SECTION, CLICK ON
THE TEXT OF THE REQUIRED HEADING.

THE LIST CAN BE HIDDEN BY CLICKING THE

LEFT ICON ON THE TOOLBAR AND WILL BE
DISPLAYED BY CLICKING ON THE SECOND
TO LEFT ICON.

TO MOVE THROUGH THE MANUAL, USE THE

SCROLLBAR OR THE SINGLE ARROWS IN THE
TOOLBAR (PAGE UP AND PAGE DOWN). THE
DOUBLE ARROWS ON THE TOOLBAR MOVE
TO THE FIRST AND LAST PAGES.
THE PAGE CAN BE ZOOMED IN BY CLICKING
ON THE MAGNIFYING GLASS IN THE
TOOLBAR. THIS TOOL WILL ALSO ZOOM OUT
(e.g. WHEN VIEWING CIRCUIT DIAGRAMS) IF
THE CTRL KEY IS PRESSED WHEN CLICKING
ON THE PAGE.

THE PAGE WILL BE EXPANDED IF THE RIGHT

PAGE LAYOUT ICON IS CLICKED JUST TO THE
LEFT OF THE SEARCH BINOCULARS ICON.
THE FULL PAGE WILL BE DISPLAYED IF THE
MIDDLE PAGE ICON IS CLICKED.

SOME OF THE TEXT IN THE MANUAL IS

COLOURED:- CLICKING ON BLUE TEXT WILL
MOVE TO A LOCATION IN THE SAME
CHAPTER AND CLICKING ON RED TEXT WILL
MOVE TO A LOCATION IN A DIFFERENT
CHAPTER.

TO RETURN TO THE ORIGINAL POSITION

AFTER MOVING THROUGH A LINK, CLICK
THE RIGHT MOUSE BUTTON THEN SELECT
GO BACK.

THIS PROCEDURE WILL ALWAYS MOVE BACK

THROUGH THE SCREENS EVEN THOUGH A
LINK WAS NOT USED.
500 SERIES Material Testing Machine Mk 2

USER MANUAL

Issue 2.0
July 1997

© LLOYD INSTRUMENTS LTD. 1997

LLOYD INSTRUMENTS LTD
Forum House
Barnes Wallis Rd
Segensworth East
Fareham
Hampshire
PO15 5TT

Tel: +44 (0) 1489 574221

Fax: +44 (0) 1489 885118
Tlx: 477042 JAY JAY G

Manual Part No: 01/2791

Issue: 2.0

JULY 1997
 International Symbols

Caution! Refer to this manual before using your

500 Series Testing Machine

CAUTION

HIGH FORCES ARE OFTEN INVOLVED WITH

THE MATERIAL TESTING PROCESSES.

THE MACHINE IS POWERED BY MAINS SUPPLY

VOLTAGE

TO MAINTAIN ALL ASPECTS OF THE SPECIFICATION,

ONLY LLOYD INSTRUMENTS APPROVED ACCESSORIES
CONNECTIONS AND COMPONENTS SHOULD BE USED

ALL SPECIFIED SAFETY PROCEDURES SHOULD BE

STRICTLY ADHERED TO.

READ THIS MANUAL BEFORE USING THE 500 SERIES

TESTING MACHINE
 TABLE OF CONTENTS
Page
1.0 INTRODUCTION ........................................................... 1

1.1 SAFETY ................................................................................... 1

2.0 INSTALLATION ............................................................. 2

2.1 UNPACKING........................................................................ 2
2.2 SITING YOUR MACHINE................................................. 2
2.3 VOLTAGE SELECTION ..................................................... 2
2.4 ASSEMBLING THE SYSTEM.............................................. 3
2.5 SOFTWARE INSTALLTION............................................. 4
2.6 ON-OFF SWITCH............................................................... 4
2.7 EMERGENCY STOP............................................................ 5
2.8 LOAD CELL PLUG AND SOCKET LINK..................... 5
2.9 FITTING/INSTALLATION OF OPTIONAL
CONSOLE ............................................................................. 7

3.0 OPERATIONAL PRECAUTIONS .......................................... 8

3.1 ELECTRICAL SAFETY......................................................... 8
3.2 SAFE OPERATION/SAFETY SYMBOLS......................... 9
3.3 EMERGENCY STOP............................................................ 11
3.4 COMPRESSION TESTS ...................................................... 11
3.5 MACHINE SPLINTER SHIELDS ....................................... 11

4.0 PERFORMING A TEST.................................................. 12

4.1 LOAD CELLS...........................................................................12

4.2 GRIPS/ADAPTERS ..................................................................12
4.3 STARTING A TEST................................................................12
4.4 ERROR MESSAGES ................................................................14
4.5 LOADCELLS ............................................................................14

5.0 OPTIONAL CONSOLE .................................................. 17

5.1 CONNECTING YOUR CONSOLE ............................... 17

5.2 DATA ENTRY KEYS ........................................................... 18
5.3 MACHINE STATUS INDICATORS ................................ 19
5.4 OPERATOR CONTROLS ................................................. 20
 TABLE OF CONTENTS
Page
5.5 SETUP SEQUENCE ............................................................. 21
5.6 CONNECTING A COMPUTER WITH
THE CONSOLE FITTED.................................................... 31
5.7 PERFORMING A TEST USING THE
OPTIONAL CONSOLE ..................................................... 31

6.0 DATA ANALISYS SOFTWARE .................................... 37

7.0 CLEANING YOUR MACHINE....................................... 38

7.1 EXTERNAL FINISH AND TRIM................................................ 38

APPENDIX A: SPECIFICATION ................................................ 39

APPENDIX B: RECOMMENDED COMPUTER

SPECIFICATION.......................................................................... 41

APPENDIX C: RS232 CONNECTIONS..................................... 42

APPENDIX D: ERROR MESSAGES............................................ 43

 1.0 INTRODUCTION

Welcome to your new LLOYD INSTRUMENTS materials testing

machine. The 500 Series is one of a range of versatile testing
systems suitable for a variety of different applications. The 500
Series includes an RS232 computer interface and is supplied with
Data Analysis Software to provide machine control and data analysis.

The 500 Series is a very flexible and sophisticated instrument. It is

designed to be a modular system so it can be configured for many
varied applications and environments. The 500 Series has been
designed for computer control although an optional console is also
available if required. The use of Monitor Software allows basic
control and data analysis for simple peak load and fracture tests.
The flexibility of the machine can be further enhanced by using R
Control or Windap Software (optional) which gives access to many
more powerful features such as constant load, creep testing, load
rate control, multi-stage testing, user defined formulae and much
more.

For further information on other Lloyd Instruments software or

accessories please contact your local distributor or Lloyd
Instruments Technical Support Department on +44 (0) 1489
574221.

1.1 SAFETY

Materials testing machines are very safe to use providing the

instructions presented in this manual are followed precisely.
We would like draw your attention to both the Electrical
Safety and the Safe Operation/Safety Symbols, section 3.2 on
page 4. Please refer to section 3.0 for details on safe
operation of this equipment.

500 Series Testing Machine Mk 2 1

 2.0 INSTALLATION
2.1 UNPACKING

All packing material should be carefully removed from the testing

machine and a visual inspection made to ensure that there is no
obvious transit damage. The following items should be in this
package:

Straining Frame and Power Input Cable,

Software Disk(s) (as per order), RS232 Cable,
Load Cell(s) (as per order), Operating Instructions, Rubber Mat,
2 x Grip Pins, 2 x Eye Ends, 3 x Eye End Locking Nuts, 1 x M6 Half
Nut,
1 x M6 spanner, Grips (as per order), Console (if ordered)
1 x Alignment Gauge.

If there is any damage or parts missing, please report this to your

dealer or Lloyd Instruments without delay.

2.2 SITING YOUR MACHINE

Great care should be taken in choosing the location where the frame
it is to be installed. Every effort should be made to ensure that the
machine is vertical since this may affect the accuracy of results
particularly at very low forces. The frame should be positioned such
that the front of the machine can be easily accessed, and the
emergency stop button is not obstructed in any way. Care should
be taken when lifting the machine by hand. Observe safe working
practices. The 500 Series machine weighs 25kg (55lb) without grips
fitted.

2.3 VOLTAGE SELECTION

The materials testing machine can be used with electricity

supplies in the range of 115/230V ac +/- 10% 50-60 Hz. The
power input cable is inserted in the rear of the machine.
Before inserting the power cable and switching on the
machine the voltage selection must be checked, this is shown

500 Series Testing Machine Mk 2 2

 2.0 INSTALLATION
on the mains input connector. There are two voltage selections,
230V and 115V. Ensure that the selection is correct for the voltage
range of your power supply. To change the voltage rating use a
screwdriver to open the voltage selector. The screwdriver should
then be used to move the selector from the 115V position. to the
230V position as appropriate. It is also essential to check that the
fuse rating is suitable for the supply voltage you are using. The fuses
(live and neutral) are located inside the power input connector. The
fuse ratings for 115V/230V are given in Appendix A : Machine
Specifications.

2.4 ASSEMBLING THE SYSTEM

When the 500 Series has been sited where it is to be used, the other
component parts of the system should be fitted and connected.
From the accessory kit, find the top and bottom eye ends and the
M6 spanner. Screw the eye end with one large and one small
locking nut into the load cell located in the base of the machine, the
M6 fits next to the load cell.

The eye end pin hole can be locked in a position suitable for the
grips to be used by locking the M6 nut down onto the load cell using
the spanner provided. DO NOT OVER TIGHTEN, the load cell is
a precision measuring device. When the bottom grip is fitted to the
bottom eye end with one of the pins provided, it can be firmly
locked in place to take up any slack by tightening the large locking
nut against the grip. Store the M6 spanner in a safe place for future
use.

Screw the eye end with the two large locking nuts into the under
side of the crosshead. Lock in the desired orientation with the
upper lock nut. When the top grip is fitted, lock in position with the
other nut.

Before carrying out any tests check that the upper eye end and the
load cell eye ends are in line using the Alignment

500 Series Testing Machine Mk 2 3

 2.0 INSTALLATION
Gauge supplied. If the eye ends are not in line adjust the position of
the Load Cell. This can be achieved by loosening the mounting
screws and repositioning the cell using the Alignment Gauge. Once
aligned re-tighten the fixing screws.

Place the rubber mat on the work area around the load cell. Plug
the RS232 lead into connector CN2 located at the back of the 500
Series, plug the other end of the lead into the appropriate port on
your computer. Refer to your computer manual and the Lloyd
Instruments software manual for help. Having checked the voltage
settings as per 2.3 above, insert the mains lead into the IEC plug and
then connect to your mains supply.

2.5 SOFTWARE INSTALLATION

Depending on your order, your 500 Series machine will have been
delivered with at least one set of Lloyd Instruments software. Refer
to the operating manuals supplied with the software for installation
and operating instructions. The software manual should be read in
conjunction with this manual. The software must be installed on
your computer before your 500 Series machine can be operated. If
your machine has an optional console installed (see section 2.9
Fitting and Installation of Optional Console), the 500 Series can
perform simple tests in stand alone mode without the use of
software.

2.6 ON-OFF SWITCH

The power ON/OFF switch is located in the top right hand corner
of the cover behind the column. The switch is a ‘rocker’ type with
positions O and 1. By selecting 1 power will be supplied to the
machine.

500 Series Testing Machine Mk 2 4

 2.0 INSTALLATION
2.7 EMERGENCY STOP

The Emergency Stop switch is located next to the on-off switch.

This switch is intended for emergency use only and
should not be used for turning the machine on and off in normal use.
PUSH DOWN in cases of emergency to stop the machine. TURN
CLOCKWISE to reset and release when fault condition has been
corrected.

PLEASE The indicator light in the mains ON/OFF switch

NOTE:- remains lit all the time the 500 series is connected to a
live mains supply and the mains switch is in the ON
position (even when the emergency switch has been
operated). If the emergency switch has been operated
the warning light reminds operators that the machine
is still connected to a live supply and will be re-started
as soon as the emergency stop button is reset.

2.8 LOAD CELL PLUG AND SOCKET LINK

The standard 500 Series machine is supplied with a load cell installed
in the base. If, however, your machine has been ordered with the
optional facility of installing additional load cells to the moving
crosshead, there will be a load cell plug and socket link at the rear of
your machine.

For normal operation, the lead coming from the internal load cell
should be plugged into the adjacent socket. When an external load
cell is to be used, this plug is removed from the socket and replaced
by the plug from the external load cell. Whenever the load cell is
changed, the internal memory containing the calibration information
about the load cell that was connected must be cleared, and the
calibration information of the new load cell entered.

Clearing the internal memory is achieved by turning the machine on

for a few seconds with no load cell plugged in. This procedure (also
called RAM dump) can also be used if,

500 Series Testing Machine Mk 2 5

 2.0 INSTALLATION
because of extreme electrical noise, it is feared that the calibration
information may be corrupted. When the machine is turned on for
the first time after the internal memory has been cleared and load
cell subsequently plugged in, the calibration factor for the load cell
fitted will have to be entered. The Lloyd Instruments software will
prompt you to do this with a screen dialogue box similar to the one
shown below:

Figure 1: Load Cell Information

Enter the load cell value and calibration details for the cell you wish
to use in the boxes provided then click on OK.

NOTE:- There are several types and versions of software that

can be used with your 500 Series machine which vary
slightly in the calibration information they require.
some accept the information as described above,
others require the information to be divided by 100. If
you have typed in a figure from your load cell that is
near to or 100 and the software displays the message
"PLEASE ENTER A NUMBER BETWEEN 0.25 AND
1.75" divide the load cell sensitivity/calibration
information by 100 and enter the figure derived in the
Calibration box.

500 Series Testing Machine Mk 2 6

 2.0 INSTALLATION
If the machine is being used in stand alone mode with the optional
console, the console will prompt you to enter the new information
after the first turn on (see section 5.0 Optional Console).

To maintain EMC compatibility, calibration and readability by the

internal electronics ONLY LLOYD INSTRUMENTS APPROVED
CELLS SHOULD BE USED.

If the optional extra load cell facility is required on a machine which

was originally ordered without it, this can be supplied and fitted as a
kit at any time. The instructions for fitting the extra load cell kit are
supplied with the kit. The kit contains all the looms, connectors to
make the conversion.

2.9 FITTING/INSTALLATION OF OPTIONAL CONSOLE

The standard 500 Series machine is not supplied with a console.

The system is designed to operate with Lloyd Instruments software
and compatible PC. (see Computer Specification) However, the
machine may be used in stand alone mode if the optional console is
fitted.

If the optional console is ordered at the same time as the straining

frame, the straining frame will have the additional socket already
fitted and the console can be connected at any time. If the console
has been ordered after delivery of the 500 Series, a fitting kit of
looms and socket will have to be installed. Please read section 5.0
Optional Console.

500 Series Testing Machine Mk 2 7

 3.0 OPERATIONAL
PRECAUTIONS
3.1 ELECTRICAL SAFETY

1. The 500 Series materials testing machines have been designed to

meet the requirements of BS EN 61010-1 : 1993 Safety
requirements for electrical equipment for measurement, control
and laboratory use.

2. This instruction manual contains some information and warnings

which have to be followed by the user to ensure safe operation
and to maintain the machine in a safe condition.

3. The machine is for indoor use. only It may occasionally be

subjected to temperatures between +5 degrees C and -10
degrees without degradation of its safety.

4. Before switching on the machine make sure that it is set to the

voltage of the mains supply.

5. This machine complies with electrical safety grade Class 1 which

means that it is an earthed apparatus and requires the mains plug
to contain a protective earth terminal. The mains plug shall only
be inserted in a socket outlet provided with a protective earth
contact. The protective action must not be negated by the use
of an extension cord without a protective conductor.

6. The machine must be disconnected from all the voltage sources

before it is opened for any adjustments, replacement,
maintenance or repair.

7. Capacitors inside the machine may still be charged even if the

machine has been disconnected from all voltage sources.

500 Series Testing Machine Mk 2 8

 3.0 OPERATIONAL
PRECAUTIONS
8. Any adjustment, maintenance and repair of the opened machine
under voltage shall be avoided as far as possible and, if inevitable,
shall be carried out only by a skilled person who is aware of the
hazard involved.

9. Make sure that only fuses with the required rated current and of
the specified types are used for replacement. The use of
makeshift fuses and the short-circuiting of fuse holders is
prohibited.

3.2 SAFE OPERATION / SAFETY SYMBOLS

The crosshead is marked with a caution symbol to warn users

about the moving crosshead. Lloyd Instruments materials
testing systems are inherently safe if used properly.

Operators must be aware that

1. High physical forces are involved.

2. Samples under test may shatter.

3. Electrical power supplies are involved.

The following must, therefore, always be brought to the

attention of any operator before they are allowed to use the
machine.

CAUTION! 1. Hands, fingers and other parts of the body must at all
times be kept well away from the moving crosshead. and
the lower parts of any grips, fixtures etc. Operators
should be particularly careful when moving the crosshead
to insert test samples to ensure that no part of the hand
could be accidentally compressed as the crosshead and
grips are jogged into position.

2. Never drive the machine from a computer when anyone

else is working near the straining frame.
500 Series Testing Machine Mk 2 9
 3.0 OPERATIONAL
PRECAUTIONS
3. If there is any danger that liquids may be spilt during tests,
operators must use a drip tray (which is available from Lloyd
Instruments) to guard against the possibility of any spillage
entering the machine and giving rise to electrical or other
hazards.

4. Extra care should be taken when operating in compression mode

where specimens may burst, shatter or fly out from between the
platens. Operators should STAND CLEAR during testing.
Splinter shields are available.

5. All operators must receive adequate training in basic operation

before being allowed to use the machine. Additional copies of
this manual are available from Lloyd Instruments. Lloyd
Instruments also offer on site training, please contact Customer
Services for further information.

6. Operators must ensure that the emergency stop button is never

obstructed. DO NOT use the emergency stop button in normal
operation as it is intended purely for emergencies.

7. Operators must ensure that the 500 Series is regularly serviced /

calibrated by Lloyd Instruments or one of their accredited service
dealers.

8. Never attempt any form of repair without disconnecting the

mains electrical supply.

9. Never attempt to test any samples with a type of grip or other

accessories which are not designed for that particular test or to
use grips or the machine for tests in excess of the stated load
limits. A comprehensive range of alternative grips, together with
an applications advisory service, is available from Lloyd
Instruments and its accredited dealers.

500 Series Testing Machine Mk 2 10

 3.0 OPERATIONAL
PRECAUTIONS
3.3 EMERGENCY STOP

If, for any reason, the machine needs to be stopped without delay or
isolated from the mains, an emergency stop mushroom is provided by
the on/off switch at the right hand corner of the top cover behind the
column. This switch will isolate the machine from the electricity
supply. It can be released by turning a quarter of a turn clockwise.
The machine will then restart if the on/off switch is already on.

3.4 COMPRESSION TESTS

When undertaking compression tests it is imperative that the large

locking nut on the bottom eye end is not screwed down so that it is,
or may, come into contact with the flat working area of the 500
Series machine. Failure to do this will stop the fitted load cell
working during compression tests. Overload to the main frame and
grips could occur. If there is any risk that the locking nut may move
down because of vibration etc on repetitive testing, remove it
completely and store it in a safe place.

3.5 MACHINE SPLINTER SHIELDS

Transparent splinter shields are available as an option to enclose the

test sample if there is any danger of samples shattering as a result of
the test. While not mandatory for many applications and countries,
Lloyd Instruments strongly recommended that users consider fitting
this optional item.

500 Series Testing Machine Mk 2 11

 4.0 PERFORMING A TEST
4.1 LOAD CELLS

If external load cells are being used, the correct load cell should be
fitted to the moving crosshead for the application being undertaken.
Great care should be taken of these as they are precision
measurement devices and can be damaged if used incorrectly.

4.2 GRIPS/ADAPTERS

It is important that the grips are fitted along the central straining axis
of the machine and that no side load is applied to the load cells
(internal or external) as this will affect the accuracy of the load
readings The grips should be connected to the load cell and anchor
pin, using only the pins provided and care should be taken not to
exceed the load rating of the grips. It is important to ensure that the
grips used are suitable for the material under test. Any slippage of
the material in the grips will affect both load and extension readings.
Please also refer to the instructions provided with the grips/adapter.

4.3 STARTING A TEST

If you are new to Lloyd Instruments test instruments and software

we recommend that at this stage you refer to the on-line help
provided by the software. This can either be viewed and read
directly from your monitor or printed out and kept with the
operating manual for future reference. Refer to your software
operating manual and start your software. The on-line help should
be read in conjunction with the software operating manuals. See Fig.
2 next page.

500 Series Testing Machine Mk 2 12

 4.0 PERFORMING A TEST

Figure 2: A Typical Lloyd Instruments Start Up Screen

Once you have become familiar with the basic operation of the
software and system, the crosshead can be moved to a suitable
position for the grips to be fitted and your sample loaded. Move the
crosshead to a suitable position by clicking on the fast up button on
the software console with your left mouse button.

Fast UP button

Figure 3: Software console

If the software console is not visible in the software start up screen,

hold down Alt and press Tab on your keyboard until it appears. If it
does not appear, it has not been started. Alt /

500 Series Testing Machine Mk 2 13

 4.0 PERFORMING A TEST
Tab back to Program Manager and start the Console by double
clicking on the icon. Click on Setup and then Test Conditions and
install the test setup parameters that you require. Press <F1> or
click on Help for any clarification you need.

Once the test setup parameters have been set you can perform a
test but you may wish to annotate the reports that will be produced.
See your software operating manual or on-line help for this function
and others. To start a test either click on Test or the Test button in
the tool bar.

Test Button
Figure 4: Tool Bar Test Buttons

4.4 ERROR MESSAGES

If an error condition exists the error will be shown on the Windows

/ Lloyd Instruments software screen or on the LCD as ERROR + a
number if a console is fitted. This error must be cleared before a
test can be performed. See Appendix D : Error Messages for an
interpretation of the error numbers.

4.5 LOAD CELLS

All machine operators should be aware that Lloyd Instruments load

cells are precision force measuring instruments which should be
treated with the utmost care to avoid accidental damage. The
optional low force cells that

500 Series Testing Machine Mk 2 14

 4.0 PERFORMING A TEST
4.5 LOAD CELLS cont,

can be used with the 500 Series are easily damaged if abused or used
without sufficient care. Refer to the fitting and operating
instructions supplied with optional add on low force load
cells.

Please take the following precautions:

• Do not subject load cells to physical shock.

• When an external load cell is removed from the machine, place it

immediately in its padded case and store in a dry place.

• To install a load cell, refer and adhere to the fitting instructions

supplied.

• When fitting grips to the load cells, never force the grip onto the
load cell eye ends. Avoid bumping the eye ends with the grips.

• In both tension and compression tests, centre the specimen in

line with the axis of the load cell and other eye end to avoid side
thrust.

• In compression tests, if special lower fixtures are used, ensure

that they are fixed in position so that they cannot be accidentally
moved so as to block the normal downward movement of the
upper fixture, e.g. where a tongue on the upper fixture must fit
into a slot in the lower fixture.

• Avoid overloading beyond the rated capacity of the load cell

being used. Prior to testing ensure, if possible, that the
maximum force anticipated will not exceed the capacity of the
cell installed. If maximum capacity is approached during a test,
run the machine at slow speed

500 Series Testing Machine Mk 2 15

 4.0 PERFORMING A TEST
4.5 LOAD CELLS cont.

in local mode and reverse the crosshead if capacity is exceeded.

Note: All Lloyd Instruments load cell systems incorporate

overload protection devices which will stop the
machine if capacity is exceeded in either tension or
compression. However, at higher speeds, momentum
may carry the crosshead far enough after shut-off to
damage the cell. Cells damaged in this way are not
covered by the warranty.

To meet the requirements of BS EN 10002, ASTM and DIN, the

load measuring system on your machine should be calibrated at least
annually by a qualified service organisation.

500 Series Testing Machine Mk 2 16

 5.0 OPTIONAL CONSOLE
An optional control console is available which allows the 500 Series
to be configured as a stand alone machine. The console has a very
legible LCD and provides simple control via a membrane key panel.
When running the machine with the console the output is displayed
on the LCD as well as being transmitted across the RS232 for
connection to Lloyd Instruments software if required.

5.1 CONNECTING YOUR CONSOLE

There are two slightly different procedures for connecting a console.

Which procedure is used depends on whether or not the console
was 1) ordered at the same time as the main frame or 2) ordered
after the original machine has been delivered. The procedures are
as follows:

1) Your console was ordered at the same time as the main frame

The console plugs into CN5 on the right hand side of the
straining frame base. This is a 37 way D socket. Plug the
console connecting lead into this socket and when the machine is
turned on the LCD will show:

LLOYD INSTRUMENTS LTD

Materials Testing Machine

followed by

500 Series Machine

2) Your console was ordered after you have taken delivery of the
main frame. ENSURE THAT THE MACHINE IS
DISCONNECTED FROM THE MAINS SUPPLY

Turn the 500 Series machine on its side and remove bottom
cover plate which is secured by 7 countersunk screws.

500 Series Testing Machine Mk 2 17

 5.0 OPTIONAL CONSOLE
Remove the small side socket hole cover plate. Take care not to
drop any of the small nuts and washers "in the works"!

Find the loom 09/0590 and fit the 37 way "D" socket in place
through the side of the machine and secure it in place. Fit the 40
way socket to CN3, the 40 way connector on the main long
PCB.

Replace the machine base cover plate

Proceed as in 1) above.

5.2 DATA ENTRY KEYS

<A> (Accept option A) This key is used to accept the answer

to a question during the setup. It is used in conjunction with the
<B> and <C> keys.

<B> (Accept option B) The <B> key is used in conjunction

with the <A> key if two options are presented. In the READY
mode it can be used to return to the end of the setup mode. The
setup parameter displayed will be the last option before the READY
mode was entered. The JOG UP key can then be used to move
backwards through the setup parameters.

<C> (Change) The <C> key is used to change a previously

selected option or value.

<R> (Reset) Pressing the <R> key will return you to the
beginning of the setup mode. For example, if you would like to
change any of the setup parameters, press the <R> key and step
through the setup sequence until meter is reached. It can also be
used to return to computer control if ‘local’ has been selected from
the software main menu.

500 Series Testing Machine Mk 2 18

 5.0 OPTIONAL CONSOLE
Numeric Key Pad

The numeric key pad is used to enter values of load/extension,

speed etc during the test setup sequence.

kN, N, mm,
mm/min, kgf, lbf,
in, in/min. These keys are used after entering a numeric value.
They are used select the required units for force, extension and
speed. If an inappropriate units selection is made a ‘?’ will appear on
the LCD and the user should enter the correct units.

5.3 MACHINE STATUS INDICATORS

The optional console has a panel of lights which show the current
status of the machine. These are as follows:

RUNNING This indicator will be illuminated when

the test is actually in progress and the crosshead
is moving.

MANUAL This indicator will be illuminated when

the machine is in Local Mode

REMOTE This indicator is illuminated when the

testing machine is under the control of a remote
computer.

READY This indicator is illuminated when all of

the test parameters have been entered correctly
and the testing machine is ready to perform a
test.

MOTOR This indicator will be illuminated if motor

has power supplied to it. If this indicator is not
lit this will signify a motor fault.

500 Series Testing Machine Mk 2 19

 5.0 OPTIONAL CONSOLE
5.4 OPERATOR CONTROLS

The operator controls are found in the lower portion of the control
module. These are used to control the operation of the machine
while in Local Mode:

GO The <GO> button is used to start a test. The test setup

sequence must have been completed before the <GO> button is
operative, i.e. the machine must be in the ready state.

STOP The <STOP> button is used to end a test if the machine

does not automatically stop the test or the user needs to abort the
test.

JOG (Up/Down) These two keys allow the crosshead to be

moved slowly into position when loading and removing samples.
They are only operative before a test and the crosshead will run at a
user pre-set jog speed which is one of the setup options. They only
operate when they are being pressed, i.e. momentary action. During
the setup mode the jog UP key can be used to reverse through the
setup parameters.

FAST (Up/Down) The FAST switches are only operative in the

ready state. They allow the crosshead to be moved at maximum
speed to any desired position. They are useful when moving the
crosshead large distances in a short time. They are only operative
when they are being pressed, i.e. they have momentary action. It is
important to realise that this will result in the crosshead moving at
its highest speed and therefore it is essential to ensure there are no
obstructions. This should only be used for moving large distances
and not for final adjustment when the grips are close together.

ZERO ℜ This button is used to zero the load and extension displays.
This is normally at the start of a test but can be used at any time in
the ready state. If Auto Zero was selected in

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 5.0 OPTIONAL CONSOLE
the setup routine the system will automatically be zeroed when
<GO> is pressed to start the test.

RETURN The return button is operative both during a test and

in the Ready mode when used under Local control. When pressed
the crosshead will return to the position when the zero button was
last pressed. The crosshead will move at maximum speed until the
final destination is close and will then slow into its final position.

5.5 SETUP SEQUENCE

SIGN-ON MESSAGE When switching the power on three

messages will be displayed as follows:

2. Company name.

3. Software version number. This message gives the version

number and this should be used in all correspondence regarding
the operation of your materials testing machine.

OPERATOR ACCESS CODE

The operator access code gives an option to restrict the use of your
materials testing system. This option will only be given when a RAM
dump occurs (see RAM dump, page 25). The LCD will display the
message shown below:

TO ESTABLISH OPEN ACCESS OPERATE A

If A is pressed at this point the console will move on to the next

option. However, if restricted access is required the user should
press B or C and the following message will appear.

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 5.0 OPTIONAL CONSOLE
SETUP NEW ACCESS CODE

The user can then enter a four number sequence of their choice and
should finish by pressing the A key. The LCD will then ask the
operator to confirm the access code with the following message:

TRY OUT NEW ACCESS CODE

The user must now repeat the four figure number followed by A to
accept to continue. If the wrong number is input then an error
message WRONG ACCESS CODE is given and this is repeated until
the correct number is used. Once this option has been selected,
every time the machine is switched on it will ask for the appropriate
access code before moving to the next option. The only way to
remove this number is to perform a RAM dump. This facility is
designed to stop unauthorised or unqualified personnel from using
this equipment.

LOAD CELL

After the initial message screen the display will show the last load
cell value fitted to the machine. The user may accept this value or
change to another cell if required. CARE SHOULD BE TAKEN
THAT THIS VALUE IS CORRECT AS THIS WILL AFFECT LOAD
READINGS.

CELL SENSITIVITY

Each load cell has its own individual calibration sensitivity figure. This
figure can be found on the load cell label, the sensitivity is measured
in %. IF THE LOAD CELL IS CHANGED THEN THE SENSITIVITY
MUST BE CHANGED FOR CORRECT CALIBRATION OF THE
SYSTEM.

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 5.0 OPTIONAL CONSOLE
LOCAL/REMOTE OPERATION The testing machine will give
the prompt:

REMOTE B LOCAL A

If <A> is pressed then local control is achieved, i.e. operation via

the console, and the machine will proceed to the next phase. If
<B> is pressed the remote operation is selected, i.e. computer
control, the console will then try to establish communications across
the RS232 interface for thirty seconds, after which time if
communication is not achieved it will revert back to local control
automatically.

SET LOAD RANGE

This option is used to set the full scale load required and the prompt
is as shown:

LOAD RANGE 0 - 500N ACCEPT A/CHANGE C

The accept and change option shown at the end of this line
alternates every four seconds. To accept the suggested load range
press the <A> key. To change the load range press the <C> key.
Having pressed the <C> key, you are required to enter a numeric
value which represents the maximum load required. Once the value
has been input then a units key (N, kN, Kgf, lbf must be pressed and
this new value of load may be accepted by pressing <A>. Until the
<A> key has been pressed the value entered can be removed by
pressing the <C> key and a new value entered.

Note: It is not possible to accept a value greater than the

value of the load cell fitted or the maximum capacity of
the testing machine. The value that you enter will be
rounded off to the nearest 1% of the load cell value.
The minimum value that can be entered is 2% of the
load cell value.

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 5.0 OPTIONAL CONSOLE
The load reading is Single Range and Fixed Resolution. The purpose
of this option is to stop the machine exceeding the chosen load limit.
If the load limit is reached during a test, an error message will be
displayed and the test will be terminated.

SET EXTENSION RANGE

This option is to set the full scale extension required and the prompt
is:

EXTENSION RANGE 450MM ACCEPT A/CHANGE C

The accept and change option shown at the end of the display
alternates every four seconds. The resolution of the extension
reading for a chart recorder is adjusted by this option automatically
to give the maximum resolution possible for the test. If the
extension limit is reached during a test an error message will be
displayed and the test will be terminated. To accept the currently
selected range press the <A> key. To change the extension range
press the <C> key. If the <C> key is pressed the maximum
extension will be cleared from the display and a numeric value
representing the new maximum extension range should be entered.
This number must be followed by an appropriate units key (mm or
in). This value may now be accepted by pressing the <A> key.
Until the <A> key is pressed the value entered may be cleared at
any time by pressing the <C> key. The maximum allowed
extension is 450 mm.

SET TEST SPEED

This option is used to set the required test speed and the prompt is
as shown:

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 5.0 OPTIONAL CONSOLE
CROSSHEAD SPEED 10MM/MIN
ACCEPT A CHANGE C

The accept and change option shown at the end of the display
alternates every four seconds. If the <A> key is pressed the
currently selected speed will be the new test speed. To change the
test speed, press the <C> key. The currently selected speed will
be cleared from the display and the new speed value can be entered.
The new speed value must be a number followed by pressing the
appropriate units key (mm/min or in/min). The speed value can be
changed at any time by pressing the <C> key and finally accepted
by pressing the <A> key.

DISPLAY TEST OPTIONS

This option gives the operator the choice of looking at further test
parameters or accepting all parameters and moving onto Ready
Mode. The prompt given is:

DISPLAY OPTIONS B ACCEPT OPTIONS A

If <A> is pressed the machine will move to the Ready Mode ready
to perform a test. However, if <B> is selected it will move onto
the next phase of the setup.

TEST TYPE

This option prompts for the type of test required. The options
available are tension, the crosshead will move in an upward
direction, or compression, the crosshead will move in a downward
direction. The options may be selected by pressing the <A> or
<B> keys as appropriate.

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 5.0 OPTIONAL CONSOLE
CYCLE ON CYCLE OFF

This option allows the machine to be used in the cycle mode. Using
<A> or <B> will select cycle on or off depending on previous
settings.

NUMBER OF CYCLES

This allows the user to select the number of cycles to be carried out
during test. Use numerical key pad to input number of counts then
<A> to accept. At the end of a test, if no break is detected, the
final display will be (if the number of cycles specified was 50) CYCLE
50 EXTENSION 0MM. If during a test a break is detected, then
the final display will be (if the break occurred at the 23rd cycle)
CYCLE 23 EXTENSION 10MM.

CYCLE ON LOAD OR EXTENSION

This allows the user to specify whether the machine will cycle
between two load limits or two extension limits. Depending on the
option selected, the user will be prompted to enter maximum and
minimum values between which it will cycle.

DISPLAY LOAD OR EXTENSION

During a cycle test the display will show the current cycle number
and either the load or extension value depending on the setting of
this option.

LOAD UNITS

This option allows the user to select whether load or stress is

displayed. If stress is selected, the load value will be displayed in
MPa or PSI, depending on whether the sample area is

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 5.0 OPTIONAL CONSOLE
entered in mm² or inches ² Before entering the Ready Mode, the
sample area must also be entered to enable the calculation of stress to
be made. This must be entered in mm² or inches². To enter the
sample area in mm², type in the value required and press the mm key.
For inches² press the inches key. When in the Ready Mode the
sample area can be changed by pressing either the mm or inches key.
When pressed, the display will prompt the user to accept the previous
value or to type in a new sample area. When the entered value is
accepted, the system returns to the Ready Mode and the display is
updated to show stress readings calculated using the new sample
area.

EXTENSION UNITS

This option allows the operator to select the required extension

units that are to be displayed. If you have previously entered the
maximum extension range in metric units (mm) you will be
prompted for the extension to be displayed in mm or % strain.
Alternatively, if you previously entered the maximum extension
range in imperial units (in) you will be prompted for the extension to
be displayed in inches or % strain. If the % strain option is taken a
further message will be given to select the gauge length in either mm
or in. The extension displayed will then be a percentage of gauge
length.

PRELOAD

This option gives the user the choice of whether a preload should be
applied or not. If a preload is applied, the user will be prompted to
enter a preload value. During the test, when the load value reaches
the preload value set, the extension reading is zeroed. The user may
specify that the load reading is also zeroed.

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 5.0 OPTIONAL CONSOLE
UPPER MOVEMENT LIMITS

It is possible to enter either a tension or compression movement

limit depending on the type of test set. When this limit is reached
during a test, the test will be terminated in the same way as if the
stop key had been operated or if a sample break had been detected.
The crosshead will remain stationary or return to zero if the
automatic return is selected. The value entered cannot be greater
than the extension range selected. The main purpose of this option
is to allow the user to do an automatic return before the sample
breaks.

AUTO RETURN

(SEE ALSO BREAK DETECTOR) This option allows the crosshead

to return to its original position automatically after sample break or
on termination of the test. If rigid specimens are being tested in
tension it is suggested that Auto Return should NOT be used as the
ends of the broken specimen will possibly crunch together. We
recommend that when the crosshead stops, remove the upper half
of the specimen and then press <Return> manually.

AUTO ZERO

This option allows the user to automatically zero load and extension
when the test is started, i.e. when <GO> is pressed. If conducting
large batches of samples it is recommended that this option is set to
Manual Zero. The reason for this is that on any mechanical system
there will always be a finite error on return. With auto zero
selected, every time <GO> is pressed the error will be zeroed and
this error will gradually compound and may be significant if testing
batches in excess of one hundred samples. With Manual Zero
selected the error will never be worse than the resolution of the
machine return to zero accuracy, normally

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 5.0 OPTIONAL CONSOLE
better than 10 microns on LLOYD INSTRUMENTS 500 Series Mk 2
machines.

BREAK DETECTOR

This option allows the Internal Break Detector to be switched on or

off. If the break detector is switched on, the crosshead will stop
moving when the load measuring system detects a sample break, i.e.
a sudden drop in load. The sensitivity of the break detector can be
set in two ways, Automatic or Manual - press <A> or <B> to select
your required option.

1. Automatic. If automatic is selected the break detector will start

when the load reaches 7% of the load range and a break will be
detected when the load drops to 3% of the load range or when
the software detects 3 consecutive drops of 7% of the maximum
load value detected. If 3 consecutive drops are detected, the
break point is taken as the start of the first 7% drop. The load is
sampled every 100 msec. If the load never exceeds 7% of load
range, a break will never be detected. This means care must be
taken to chose a sensible value for the load range.

2. Manual. Manual is selected you will be prompted to enter a

value for the break sensitivity as follows:

%Break of Peak (3 - 97%) 30% ACCEPT A

The break sensitivity is defined as the percentage of peak load.

The peak value of load is continually updated throughout the test
and the break will be detected when the actual load value drops
below this percentage of peak load. For example, if the load
range was 100N but the peak load of the test was 50N, with a %
break of peak set to 90% the test would terminate at a load of
45N, i.e. a drop in load of 10%.

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 5.0 OPTIONAL CONSOLE
PRINTER

(T5130L OPTIONAL). The control module will automatically

detect the presence of the optional printer. If a printer is fitted the
testing machine will prompt you for the printing of test results or no
printing. If the printing of test results is selected you will be further
prompted for the printing of extension at peak and at break. You
will then be prompted to select either a batch ticket or a ticket at
the end of each test. Before proceeding to Ready Mode you will be
prompted to enter the date, batch number and a reference number
which will be printed on the test ticket. The printer is connected to
the RS232 socket. No printer message will be displayed if printer is
not connected.

HOLD PEAK

The load and extension displays will normally follow the actual values
whether they increase or decrease. It is possible to remember the
peak during a test by selecting this option. If you choose to hold the
peak you will be further prompted to hold either the extension at
maximum load or the extension at sample break. You will also be
prompted to hold either maximum load or load at break. The
maximum or break load and extension readings will be held after a
successful test until a key is pressed. The machine will then return
to the ready mode for the start of a new test.

JOG SPEED SELECT

This option prompts the user to select a speed for the Jog/Inching
buttons. This will be used when setting up a sample or loading grips
and the speed required will vary depending on the type of sample
under test. The jog speed can be set in integer values between 2
and 100 mm/min.

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 5.0 OPTIONAL CONSOLE
CHANGING OPTIONS

The above test sequences can now be repeated by pressing the

<R> key if you are unhappy with any of your choices. In order to
simplify the setting of test options the accept key will be tagged to
the last selected option, e.g. if the machine was set to external
extensometer, and the last time you went through the setup
sequence you selected the internal extensometer the next time
through the setup sequence the internal extensometer will be
selected using the <A> key. This makes it very easy to step
through the setup sequence by only pressing the <A> key until you
reach the option that you would like to change. This feature can
also be used to quickly step through if you want to check which
options you have selected. To reverse through the options list
whilst still displaying another setup option, press the JOG UP key.
This is useful if you accidentally passed the option you were looking
for when pressing the <A> key. From the Ready
mode, pressing <B> will jump to the last setup option entered.
Pressing the JOG UP key will then reverse through the previously
entered options list.

5.6 CONNECTING A COMPUTER WITH THE CONSOLE

FITTED

A computer can be connected to the 500 Series at any time. If

remote operation is set on the optional console the control will then
be handed over to the computer as appropriate. .Please refer to
section 4.3, your software manual or on-line help for further details
of software operation. The information that follows is to be used in
conjunction with the optional console.

5.7 PERFORMING A TEST USING THE OPTIONAL

CONSOLE

5.7.1 Entering the Ready Mode

The user can enter the Ready Mode in one of two ways:

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 5.0 OPTIONAL CONSOLE
1. Ready Mode is automatically selected if the four basic machine
parameters have been entered and Accept Options is selected.
The four basic machine parameters are:

• Local/Remote Operation

• Load Range

• Extension Range

• Test Speed

2. The Ready Mode will also be automatically selected when all set
up options have been viewed. The control console contains a
battery backed up memory so that the previous test options will
always be remembered even if the machine has been switched
off. The user can simply accept the previous options if the
machine is being used for the same test or modify the options to
set a new test. The console display will always show the last
selected option on the right side of the display, i.e. option A,
where two options are given and, therefore, the user can simply
proceed with the original parameters by continually pressing the
key until the Ready Mode is reached.

5.7.2 READY MODE

Once the user has entered the Ready Mode the Ready Mode status
indicator will illuminate indicating that the machine is ready to
perform a test. In this mode the LCD display will alternate between
three messages which are as follows:

LOAD 0.00 EXTENSION 50.0mm

OPERATE [GO] FOR TENSION TEST
OPERATE [R] TO CHANGE THE TEST CONDITIONS

500 Series Testing Machine Mk 2 32

 5.0 OPTIONAL CONSOLE
Each of these messages will be displayed in rotation at four second
intervals. Pressing any key on the console will always return the LCD
to the load and extension display.

5.7.3 SETTING THE CROSSHEAD

The main purpose of the Ready Mode is to allow the user to prepare
the materials testing system to perform a test. In this mode, and
only in this mode, the bottom part of the console becomes active.

JOG UP - JOG DOWN

These keys allow the user to move the crosshead at its pre-set
speed and are used to set the sample into position. Great care
should be used in this operation to ensure the grips are not ‘driven’
together and that any obstacles are removed. These keys are only
active whilst being pressed and the crosshead will stop as soon as
the key is released (i.e. momentary action).

FAST UP - FAST DOWN

These keys allow the crosshead to be moved at the FULL SPEED of

the machine to allow large movements quickly. Great care should
be used in this operation to ensure there are no obstacles in the path
of the crosshead / grips / load cell etc as damage can be incurred
with improper use. These keys are only active whilst being pressed
and the crosshead will stop as soon as the key is released (i.e.
momentary action).

Note: When using the Down Jog keys in the Ready Mode
there will be a force limit of 50N. This is a safety
feature to reduce the risk of damage to the load cells if
they are accidentally driven together.

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 5.0 OPTIONAL CONSOLE
ZERO ℜ

The <Zero> key will zero both load and extension values while the
crosshead is stationary. This will determine the point at which the
crosshead will return on completion of a test (if Auto Return has
been selected) or when the Return key is pressed.

RETURN

This key will cause the crosshead to return to its zero position.
Care should be taken to ensure that all obstacles have been
removed (such as broken samples etc) as the crosshead will return
at full speed until it approaches the final position.

START TEST [GO]

This key will start a test according to the setup of the parameters
selected.

STOP [STOP]

This key will stop the crosshead if it is moving and can be used at any
time either in Ready Mode or during a test.

5.7.4 SAMPLE PREPARATION

The Ready Mode is used to prepare the sample for a test. The
accessories being used will be dependent on the type of test being
conducted.

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 5.0 OPTIONAL CONSOLE
5.7.5 LOAD CELLS

The correct load cells should be fitted in the machine for the
application being undertaken. Great care should be taken of these
as they are precision measurement devices and can be damaged if
used incorrectly. Use the Alignment Gauge supplied to align the top
and bottom eye ends.

5.7.6 GRIPS / ADAPTERS

It is important that grips are fitted along the central straining axis of
the machine and that no side loads are applied to the load cells as this
will affect the accuracy of the load readings. The grips should be
connected to the load cell and the anchor pin using only the pins
provided and care should be taken not to exceed the load rating of
the grips. It is important to ensure that the grips used are suitable for
the material under test. Any slippage of the material in the grips will
affect both load and extension readings.

5.7.7 STARTING A TEST

Once the sample has been positioned and the necessary accessories
have been installed, the ZERO button may be pressed (if required)
to zero the load and extension readings (this is not necessary if Auto
Zero was selected during test options). The test may now be
started by pressing the GO button. The crosshead will move
according to the set-up and the load and the extension values will be
displayed on the LCD during the test. If the hold peak option has
been selected the display will show the maximum load reached
during a test. THE TEST MAY BE STOPPED AT ANY TIME
BY PRESSING THE <STOP> key.

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 5.0 OPTIONAL CONSOLE
5.7.8 CLEARING THE BATTERY MEMORY

(RAM DUMP) This memory is used to store machine setup

parameters and options when the power has been switched off.
The parameters for the last test done prior to shut off will,
therefore, be re-displayed when the machine is turned on. One of
the options stored in the battery is the operator access code. A new
access code can only be entered when the memory is empty. The
battery memory can be cleared by removing the connector to the
load cell before switching on. When the machine is now powered
up it will check to see if the load cell is connected, and if not, the
battery memory will be cleared. Mains interference can cause this
memory to be corrupted. Should unusual functions occur the
memory should be cleared.

500 Series Testing Machine Mk 2 36

 6.0 DATA ANALYSIS SOFTWARE
Lloyd Instruments Data Analysis Packages (DAP) software acquires,
records, analyses, stores and prints test data instantaneously without
operator skill or manual effort. Data analysis software greatly
simplifies the process of analysing test results. It removes the
guesswork from graph interpretation and performs calculations such
as psi, area under the graph, offset yield etc in seconds. Software
provides you with a very powerful tool for analysing data produced
by your testing machine. The Lloyd instruments Data Analysis
Packages (DAPs) run on most IBM PC compatible computers. The
range of software varies from very simple to use versions to very
sophisticated and flexible packages suitable for use by research
establishments, universities etc. Lloyd Instruments standard library
of DAPs covers a very wide range of testing standards. They are
suitable for testing food texture, plastics, metals, fabrics, tear and
peel, stress relaxation and many more. In addition to the standard
library, we have an ever growing library of special packages. If one
of our standard packages is not suitable for you, please contact our
Sales Department who will be able to discuss a suitable package for
your needs.

500 Series Testing Machine Mk 2 37

 7.0 CLEANING YOUR MACHINE
7.1 EXTERNAL FINISH AND TRIM

The finish and appearance of your machine can be maintained by

regular cleaning with a damp cloth containing a small amount of mild
detergent. The machine must be turned OFF and disconnected
from the mains supply whilst cleaning is taking place. Strong
proprietary cleaners and petroleum based or other solvents should
not be used.

CAUTION: Take care to use only a damp cloth. NO moisture

must ever be allowed to enter the machine. Wipe the
machine dry before connecting to the mains supply and
restarting.

THERE ARE NO USER SERVICEABLE PARTS WITHIN THE

MACHINE

Any servicing and adjustments should be entrusted to Lloyd

Instruments Service Engineers or their appointed agents.

500 Series Testing Machine Mk 2 38

 APPENDIX A : SPECIFICATION

TECHNICAL SPECIFICATION: 500 SERIES MACHINE Mk2

Force Accuracy Exceeds the requirements of BS1610: Part 1:
1992 and BS EN10002-2: 1992 Class 1.0,,
ASTM E4,, DIN 51221
Maximum load - compression or 500N
tension
Load Cell Range, 500N Cell Fitted 10 - 500 N
Standard Load Cell Ranges 500N plus additional special options
Load Resolution Maximum resolution 0.01% of load cell rating
Range Between Eye Ends 40 - 490mm, (60 - 510 between pin. centre
lines.)
Range Setting Without Grips 1-450mm
Speed Range 0.1-1020mm/min
Speed Accuracy (running, steady Better than 0.2%
state)
Computer Interface RS232 25 way D connector
Console Optional
Cycling Cycling between load and extension limits
available when the machine is used in Local
mode (with the optional console). When
used in conjunction with some data analysis
programs a wide variety of cycling tests are
available.
Accessories (optional) A range of grips to meet national and
international and industrial standards is
available.
Service and Support Qualified calibration and service engineers
provide a prompt and efficient service
world-wide.
Supply Voltage 115/230Vac +10%, 50-60Hz
Power Consumption 65 VA (max)
Fuses 1A (T)
Temperature Operating: 5ºC to 35ºC (40 ºF to 90 ºF)
Storage: -20 ºC to 55 ºC (-4 ºF to 130 ºF)
Atmospheric Normal industrial and laboratory conditions
Dimensions Width: 250mm
Depth: 470mm
Height: 871mm
Weight Unpacked: 25kg (with standard accessories )
Packed: 40kg (approx. with standard packing)

500 Series Testing Machine Mk 2 39

 APPENDIX A : SPECIFICATION
Mounting All systems are bench mounted
Input and Output Connections CN1 - IEC Plug Mains In
CN2 - 25 way D socket RS232 interface
CN3 - Internal Load Cell Plug (optional)
CN4 - Load Cell Socket Internal / External
(optional)
CN5 - Optional Console Connector 37 way
D socket (optional)

Lloyd Instruments Ltd has an on-going programme of design and development which
may alter product specification. Therefore Lloyd Instruments Ltd. reserve the right
to change the specification at any time without notice.

No part of this manual may be reproduced or transmitted in any form without prior
permission of Lloyd Instruments Ltd.

500 Series Testing Machine Mk 2 40

 APPENDIX B : RECOMMENDED
COMPUTER SPECIFICATION
• PC Compatible - Pentium Processor

• Single 3.50" floppy disk drive

• CD ROM

• RS232 port configured as COM1 to COM4, 16550 type UART

• 16Mb RAM

• Windows 95 or NT4 installed.

NOTE: Depending on the software selected, a lower

specification may be suitable, please consult Lloyd
Instruments Software Support Dept.

Lloyd Instruments Ltd cannot accept any responsibility for problems

caused due to incompatible computer systems. If the computer is
purchased from Lloyd Instruments the computer will have all
relevant software installed and will be system tested to ensure
correct operation.

500 Series Testing Machine Mk 2 41

 APPENDIX C : RS232
CONNECTIONS

09/0311
RS232 9 way LR Series 25 way
‘D’ (female) ‘D’ (male)

500 Series Testing Machine Mk 2 42

 APPENDIX D : ERROR MESSAGES

ERROR 1 Upper crosshead limit stop. Go DOWN only. This signifies that the
upper software limit has been reached. Note if it is not possible to
drive down,, the crosshead may have reached the hardware stop
which implies that the slidewire is not set correctly.

ERROR 2 Tension overload stop. Go DOWN only. This means that the full 10
volts has been reached by the load cell. If this occurs on clearing the
RAM it implies that the load cell is damaged.
ERROR 3 Tension invalid stop. Go DOWN only. This means that the load cell
amplifier is reading eight volts which is equivalent to 100% load and
is designed to prevent damage of the load cell.

ERROR 5 Lower crosshead limit stop. Go UP only. This is the software crash
stop and is designed to prevent damage to the grips. It should
always be set so the grips cannot come into contact. If this occurs
when out of limit it will be due to either a faulty console or noise on
the extension readings.
ERROR 6 Compression overload stop. Go UP only. This works on the same
principles as Error 2,, although in compression.
ERROR 7 Compression invalid stop. Go UP only. The same as Error 3 but in
compression.
ERROR 8 Wrong access code. This will occur only when not operating in open
access. It means that the pass code has not been input correctly and
can be removed by clearing the battery backup RAM.
ERROR 9 Load cell supports tension only. This occurs when using small load
cells (less than 5N) and is designed to prevent compression
overloads on small cells.
ERROR 10 Watchdog timeout. This means the internal timer has timed out
which signifies the software has lost control for more than 200ms.
Possible causes are:(i) RS232 hangs up,, excess commands; (ii) Short
power failure; (iii) Power supply rises too slowly; iv) Software
failure.
ERROR 11 Load range exceeded. This error only occurs in the test state and
stops the test when the user input load range has been reached.
ERROR 12 Extension range exceeded. This error only occurs in the test state
and stops the test when the user input extension value has been
reached.
ERROR 13 Guard not closed. This informs the user that the plastic guard doors
are not closed. If doors are not fitted check micro switch.
ERROR 14 Drive fault. Switch off power. This signifies that a motor fault signal
has been detected. The software will beep continuously and the
machine must be reset.

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 APPENDIX D : ERROR MESSAGES
ERROR 15 Printer fault. This indicates a fault in the printer address. It is usually
due to a fault in the printer buffer chip and if no printer is fitted this
chip may be removed. (Refer to Service Manual).
ERROR 16 RS232 Tx buffer overflow. Indicates that the console has filled its
output buffer. This implies that the PC is not clearing the buffer fast
enough (ensure that you are using a computer with a 286/386 CPU).
ERROR 17 RS232 Rx buffer overflow. Indicates that the internal buffer is full
and implies that the machine is not acting on incoming command fast
enough. Not common due to high clock speed.
ERROR 18 Keyboard buffer overflow. This error implies keyboard buffer full.
This is almost impossible under normal conditions and probably
would only be caused by a bad or intermittent connection.
ERROR 19 Unknown interrupt. Only occurs if the interrupt address given is
invalid.
ERROR 20 RS232 Rx parity*. Will occur if the sending computer is using the
wrong parity. The RS232 port in the sending computer is initialised
by the R Control software.
ERROR 21 RS232 Rx overrun. This occurs when the embedded software does
not see a stop bit after the first eight data bits. Can be caused by an
incorrect baud rate.
ERROR 22 RS232 Rx parity/overrun. Combination of Errors 20 and 21.
ERROR 23 RS232 Rx framing *
ERROR 24 RS232 Rx parity/framing *
ERROR 25 RS232 Rx overrun/framing *
ERROR 26 RS232 Rx parity/overrun/framing *
ERROR 27 Unauthorised link to PC
ERROR 28 Compression safety switch
ERROR 29 Crosshead on limit switch.

This error is only likely to occur if you are using software which has
not been written by LLOYD INSTRUMENTS.

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