FIE/UNITEK

OPERATING INSTRUCTIONS
FOR

FOUR COLUMN UNIVERSAL TESTING MACHINE

MODEL : UNITEK-94100

MACHINE SR.NO. 1/2021-415

MANUFACTURED BY

FUEL INSTRUMENTS AND ENGINEERS PVT. LTD.

PLOT NO. – 68 TO 89, PARVATI CO-OP INDUSTRIAL ESTATE,
YADRAV – 416145, TAL: SHIROL, DIST: KOLHAPUR,
MAHARASHTRA STATE (INDIA)
PHONE: +91-2322-252137 FAX: +91-2322-252397
EMAIL: [email protected]
Website: www.fietest.com & www.fuelinstrument.com

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INDEX
Sr. No. Description Page No.

1. Applicability & Range of application 3

2. Specifications 4

3. Description of the machine 5

3.1 Loading Unit 5

3.2 Driving Unit 6

4. Installation 6

5. Preparing machine ready 6

6. Method of testing 7

7. Attendance & Maintenance 7

7.1 Lubrication 7

7.2 Cleaning 7

7.3 Checking the accuracy of the machine 7

8. Warranty of Machine 8

9. General assembly drawing 9

10 Electrical wiring diagrams 10 to 11

11 Universal 2020 Panel Operation Manual 12 to 25

12 Back plate 26

13 Load and Extensometer Calibration 27 to 34

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FOUR COLUMN UNIVERSAL TESTING MACHINE

MODEL : UNITEK-94100

(1) APPLICABILITY AND RANGE OF APPLICATION :

FIE Electronic Tensile Testing Machines, designed for wide variety of testing, such as

Tension, Compression, Bending of different Materials are having rigid construction. Due to

use of modern electronics in the mechanical machines, the machine features, higher

productivity and it offers many facilities useful in the testing of various materials such as

leather, rubber, plastic, asbestos, paper, plywood, fabric yarn, cables, conductors, wires,

“SHOCK ABSORBERS” can be tested in conformity with I.S. and B.S.

Operation of the Machine is by mechanical transmission of the load from test specimen to

LOAD CELL where it is converted into electronic signal and processed for Digital load

indication. The Drive for the machine is obtained through chain and sprocket which are driven

by A.C. SERVO motor. The variable traverse speed can be obtained by entering suitable

speed value as mm / min in Electronic panel which changes motor speed directly. The

displacement is measured through universal rotary encoder and displayed on the Electronic

panel.

Load verification of the testing machine meets requirements of IS. 1828-2000.

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(2) SPECIFICATIONS :

COMPUTERISED UNIVERSAL TESTING MACHINES

MODEL UNITS UNITEK UNITEK UNITEK UNITEK UNITEK

9401/05 9410 9450 94100/250 94100/500
Max. Capacity kN 1/5 10 50 100 100

Load Range 0-1 / 0-5 0 – 10 0 – 50 0 – 100 0 – 100

Load Resolution :

range: 0-100% of F.S. 1/50000 of nominal Load cell connected.

Load Measuring accuracy: 1% from 2% to100% of nominal load of Load cell used.

Max. Cross head stroke MM 1000 1000 1000 1000 1000

without grips and load cell

Clearance between columns MM 450 450 450 450 450

Cross head displacement MM 0.01 0.01 0.01 0.01 0.01

measurement:

Cross head speed range MM/Min 0.5 - 500 0.5 - 500 0.5 - 500 0.5 - 250 0.5 - 500

Power supply 230V AC 1 Ph. 50Hz 440V AC 3 Ph. 50Hz

SPECIAL OPTIONS

* Electronic Extensometer Model EE-2 for proof Load

* Load full scale of 50000 counts

Note :

* Due to constant R & D, specifications and features are subject to change without notice.

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(3) DESCRIPTION OF THE MACHINE :

1) Loading unit.

2) Driving unit.

3) Electronic Control Panel.

3.1 Loading Unit

The loading unit consists of a frame consisting of bottom plate (1), middle cross-head (2) &

top plate(3). (Please ref. Schematic diagram) The bottom plate is firmly fixed on a frame (8)

made of channels & angles. All the three plates are tied up between 4 columns. Two Ball

screws (5) and two cylindrical shafts (7) are fixed at top & bottom plates by screws are

supported between two sets of bearings (Ball bearings & thrust bearings) at both ends.

Bellows are provided to protect the ball screws and columns from dust and dirt. Middle cross

head while moving with nut (6) on the ball screw, slides along columns. The tensile &

compression tests are carried out in between middle cross head & bottom plate.

Up and down motion of the middle cross head is given by servo motor through gear box. This

assembly is fitted below the bottom plate. Two ball screws are connected to the gear box by

using chain and sprockets. One hex screw is provided below the bottom plate for chain

tightening.

One electronic encoder is fitted below the bottom plate which is used to measure the

displacement of the middle cross head.

The Load cell is fitted on the Load cell plate which is fixed on the bottom plate of the machine.

Load cell is used to sense the load. While testing the samples different types of grips should

be fitted on the Load cell.

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Limit switch assembly is fitted at the bottom side on the right hand channel. Limit switch

actuator is fitted on the middle cross head. It is used to restrict the up & down motion of the

middle cross head to a selected limits.

3.2 Driving Unit

A A.C. Servomotor (10) drives the gear box, rotates and gear box output shaft drives a chain

which in turn ball screws. The gearbox & motor is mounted on a plate, which in turn is fixed to

the bottom plate. Being a variable speed motor the middle cross head can be moved up and

down at the required speed.

A rotary encoder is in-built in the servomotor to measure the middle cross head movement

and in turn the elongation, displacement in the specimen.

(4) INSTALLATION :

Please refer general assembly drawing (G.A.). The machine should rest on reasonably

leveled flat surface. The leveling bolts will rest on this surface.

(5) PREPARING MACHINE READY :

After installing the machine, the machine is to be leveled using level indicator. There should

be sufficient room around the machine to ease for maintenance work. The installation place

must be free from dust and oil. There should not be any machine causing heavy vibrations.

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(6) METHOD OF TESTING :

6.1 Initial adjustment : -

Select suitable grips for the specimen to be tested various types of grips can be

supplied to the customer depending on the requirement. The grips are designed in

such way that they can be mounted easily on the machine by inserting a pin or by

tightening the threads in the joints. Adjust the cross head as per the specimen length

and grips.

If load V/s Elongation curve is to be recorded. Connect the printer to the interface

circuit socket.

(7) ATTENDANCE & MAINTENANCE :

7.1 Lubrication : -

The bearing and screws are to be lubricated by a suitable lubricant every month.

7.2 Cleaning : -

The mains should be put off before starting cleaning of any part of machine. The

remainders of fragments of specimens occurring on breaking tests are to be removed

from machine. The grips should be kept clean.

7.3 Checking the accuracy of the machine : -

The machine before supply will be calibrated using proving ring/Load cells, which are,

in turn calibrated by NPL/FIE Research Institute. The calibration of the machine should

be repeated every year.

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(8) WARRANTY OF MACHINE :

WARRANTY OF MACHINE
The performance, of FIE Four Column Universal Testing Machine

Model - UNITEK-94100 Serial No.1/2021-415 is warranted against defective

workmanship and material for a period of 15 months from the date of supply or

12 months from the date of commissioning. Whichever ends earlier. The warranty

is limited to the free repair / replacement of defective part/s only and dose not

cover part/s worn out /broken due to mishandling or normal wear and tear.

The warranty of following items ceases immediately on commissioning

of the machine, if supplied with the machine -

1. Printer

2. Personal Computer.

For Fuel Instruments & Engineers Pvt. Ltd.

Date : 26/12/2020

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(9) GENERAL ASSEMBLY DRAWING OF MACHINE :

625
400

1000

820
460

275 620
1050
100
400 more 100
2145
1000 MINI DIST. 1000 MINI DIST.
FROMWALL FROMWALL

TOP PLATE-3

COLUMM-7

MIDDLE CROSS
HEAD - 2
ELECTRONIC
CONTROL PANEL

BALL SCREW

LOAD CELL

BOTTEM
PLATE-1

FRAME -8

REDUCTION
MOTR - 10
FEAR BOX

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Universal 2020 Panel

Operation Manual

Manufactured by

FUEL INSTRUMENTS & ENGINEERS PVT. LTD.

Plot No.68 to 89, Parvati Co-op. Industrial Estate,
Yadrav –416145 (Maharashtra -India )

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PRECAUTIONS WHILE USING UNITEK / TNE SERIES MACHINES TO PREVENT

DAMAGE TO LOAD CELL, GRIPS, ETC.

1) Proper earthing is required for the m/c to work the electronic panel without malfunction. A

separate thick earth wire (min. 2.5 sq. mm) is required to connect from m/c body to earth

point. Electrical Panel must receive proper earth from 3 pin power plug. Do not short m/c

body & electrical/electronic panel directly. Improper earthing may-cause malfunction of

electronic panel & may cause damage to m/c parts, Load cell etc. (Neutral to earth

Voltage must be less than 2 V). Also do not install the m/c close to Machines taking

heavy surge currents. e.g. Induction hardening, Furnace, welding machine etc.

2) Set limit switch operating dogs properly, to avoid direct compression of grips or cross

head collision. Also confirm that the end limits are working properly (stops/disables cross

head movement in that direction).

3) While moving cross head with rapid speed or higher speed, there will be some movement

of cross head because of inertia after electrical stop command. So take care while

working with higher speeds during test or manual movements.

4) While testing specimens, first confirm that its peak load is less than the capacity of Load

cell. There is built in overload protection in electronic panel, but still there is possibility of

Load cell damage because of higher speed.

5) While testing compression test, take care that Load cell should not get compressed

directly.

6) While the machine is not in use, keep it in power OFF.

NOTE : - Damaged Load cell, grips etc. because of improper operation, improper

earthing of machine are not covered under warranty.

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UNIVERSAL 2020 PANEL FEATURES

1) Data entry & Parameter selection through keyboard.

2) Non volatile memory, so data entry remain saved during power OFF.

3) RS 232 C serial interface to PC with variety of optional windows based software for data

analysis.

4) Real time graph on PC

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 KEY BOARD :

OPRATION KYES MATRIX KEYBOARD FOR DATA

ENTRY,PARAMETER SETTING,

FIE/UNITEK
RESULT DISPLAY ETC.

MANUAL CROSS HEAD

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MOMENT KEYS
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KEYBOARD DETAILS

I) Operation Keys

PRINT .. NA.

FREEZE : NA.

TARE LOAD : To make load zero.

RESET DISP/EX : To reset displacement or extension which ever is selected.

START/STOP : START test. STOP if ON.

To start test first press START/STOP. It displays data

Show Offline test mode

If OK, press START/STOP again to start,

Or Function to go to regular display.

EE2 Electronics Extensometer option apper in LCD display.

II) Manual Cross head Movement Keys : - (3 Keys)

: Up movement with test speed.

: Down movement with test speed.

+ : Up Rapid movement with max. speed.

+ : Down Rapid movement with max. speed.

This movement is to load/unload specimen & possible only when panel is not performing

any test or not in data entry or result display mode.

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III) Matrix Keyboard (20 Keys)

For Data Entry, Parameter Setting etc.

IV) LCD JAMBO Displays

V) Data entry
.
1) MAIN WINDOW

2) Pressing FN (function) key goes to calibration Window

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3) Again Pressing FN (function) key goes to input test value Window

4) Pressing CLR (clear) key input SPEED VALUE will be clear as show in below image.

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5) Using matrix key board input SPEED value and for saving press ENT key

6) After save the SPEED value press DN key and cursor goes to PRELOAD value.

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7) For clear & save PRELOAD value follow the step no. 4 and 5 After press the down key

cursor goes to RUPTR

8) For clear & save RUPTR value follow the step no. 4 and 5 After press the down key

cursor goes to SAFE LOAD

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9) For clear & save SAFE LOAD value follow the step no. 4 and 5 After press the down

key cursor goes to AREA

10) For clear & save AREA value follow the step no. 4 and 5 After press the down key

cursor goes to PRE SPEED

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11) For clear & save PRE SPEED value follow the step no. 4 and 5 After press the down

key cursor goes to RET SPEED

12) For clear & save RET SPEED value follow the step no. 4 and 5 After press the down

key cursor goes to TEST mode

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13) Press 1 key for TENSION TEST MODE & Press 2 key For COMPRESION TEST MODE.

14) After selection of test mode goes to Main Windows press FN key and if any single or

more parameter save then go to main window press the FN key.

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Operation Sequence

1) Load the specimen with manual movement keys.

2) Select proper data set, or clear any data set & enter new “Input data” (Rupture %
Peak, Preload and Speed setting etc.), Select proper test type, sensor, stop or return
after test etc.

3) Confirm all Input Data & all Parameters OK, Tare Load & start test with START/STOP
key.

4) You can stop the test any time with “START/STOP” key or there is auto test end since
when load drops below Rupture % Peak load setting.
If any emergency you can make drive OFF with Emergency Off (Red Push Button) on
electrical panel.

5) To conduct test with real time graph, Run windows based software. Select proper file
or create new file as per specimen data. Select Start Test mode by pressing Start Test
button from tool bar. Enter all test data, click Data OK. (First confirm that panel is in
load display mode) You can view “data” in seven segment display of panel which
confirms data is transferred to panel. Then select axis parameters, tare load & start
test. You can stop test from PC or conduct it till rupture sense.

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BACKPLATE DETAILS

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CALIBRATION PROCESS

A) LOAD CALIBRATION-:

1) MAIN WINDOW

2) Pressing FN (function) key goes to calibration Window

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3) If you press the 1 key on matrix keyboard then go to load calibration menu.

4) If you enter the calibration password 1245 and press the enter key on keyboard then next window

will be open on LCD display.

5) Pressing the RSTL button to tare the load cell hard count.and after tare the hard count press the UP

key the next window appear on LCD display.

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6) Enter the readings as per your requirement.

7) Fix the lower compression plate on LOADCELL & upper compression plate to Upper cross
head.
8) Put the Master device on lower compression plate.
9) Bring the Upper cross head near to the master device (Keep distance of 5mm approx
between the master device & cross head).

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10) Before touching to the master device TEST SPEED will be 0.2 mm. Test speed is appear in
input test value.

11) Before touching to the master device, make the count value display zero by TARE button .

12) Now start loading the master device slowly.

13) Check the readings as per your requirement. And press the FREEZE key on keyboard .

14) After pressing FREEZE button remove the load on master device .

15) Switch OFF the electronic panel and again switch ON.

16) After switch on the panel main window is come on LCD display.

17) Before calibration check master device & LOAD value zero by TARE button

18) Check the calibration .

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B) EXTENSOMETER CALIBRATION-:
1) MAIN WINDOW

2) Pressing FN (function) key goes to calibration Window

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3) If you press the 2 key on matrix keyboard then go to EXTEN calibration menu.

4) If you enter the calibration password 1245 and press the enter key on keyboard then
next window

5) Pressing the RSTL button to tare the EXTEN hard count.and after tare the hard count press the UP

key the next window appear on LCD display.

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6) Enter the readings as per your requirement.

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7) Before touching to the master device, make the count value display zero by TARE button .

8) Now start loading the master device slowly.

9) Check the readings as per your requirement. And press the FREEZE key on keyboard .

10) After pressing FREEZE button remove the EXTEN on master device .

11) Switch OFF the electronic panel and again switch ON.

12) After switch on the panel main window is come on LCD display.

13) Before calibration check master device & EXTEN value zero by TARE button

14) Check the calibration .

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