Compression English Cur
Compression English Cur
OPERATING INSTRUCTIONS
WINDOWS
VERSION 5.09R18
TYPE 972
SECTION I - OVERVIEW
The Emerson Compression Tester has been designed to determine the compressive
strength of shipping and packaging containers. This can be done with or without
contents. The machine will apply a compressive force, via two parallel platens, to either
the containers faces or its diagonal (opposite) corners measure and record the force
necessary to cause a failure in the specimen.
State of the art computer control with high-resolution graphics allows easy operation
from the computer keyboard. For example, the following functions can be performed:
Plotting
Printing
Control charts
Test results
For quick, on the spot analysis of a group of tests, the operator may superimpose
selected graphs, which can then be overlaid for better viewing.
Test Data is stored in a Microsoft Access database which can be easily used by external
software.
2
SECTION II – TEST TYPES
Your compression tester machine is capable of performing many different types of test.
Each test type offers unique data sets and test conclusion determinations. Use these test
types to produce results per the desired TAPPI and other test specifications.
Test types are settable in the DEFAULTS menu (see Section V for more information).
Peak at Fallback
(Used for general testing)
In this test cycle, a desired test speed, squaring force, graph size, automatic print (test
results or graph), and fallback settings can be selected from a default menu. When
selected squaring force is reached, deflection will begin counting and high resolution
graphing will start. When the test begins to fail and reaches the selected fall back
setting, the machine will read peak force, and deflection at peak force. The platen will
return to its start position ready for the next test. At this time the computer will ask the
operator to save data for statistical purposes, the operator may answer yes or no.
Static Load
This test cycle is used to simulate warehouse-stacking conditions. A desired static load
(force) and amount of time for test can be selected from the default menu. When static
load is reached this force will be maintained and the elapse timer will begin. The test will
terminate reverse off the load at test speed once the elapsed time exceeds the desired
test time. Reversing stops once the recorded load reaches zero. The platen then returns
to start position. The computer will graph deflection verses time.
Profile
In this test cycle, a profile may have up to ten holds and times which can be selected.
This allows a number of forces to be applied to one specimen. When the first hold is
reached, the machine will maintain selected force until the preselected elapsed time
occurs. The machine will then apply/remove force to reach the second selected hold and
maintain that force until elapsed time occurs. This cycle is repeated for each hold
entered. With this feature simulation of stacking and un-stacking warehouse products on
top of this test sample can be obtained.
Peak at Deflection
In this test cycle, a desired deflection limit can be set. When deflection limit is reached
the peak force at deflection will be graphed and/or plotted on the screen.
Load at Deflection
In this test cycle a desired deflection limit can be set when the deflection limit is reached
the force at selected limit will be graphed and plotted on the screen.
3
SECTION III - STARTUP
3. Wait for your computer to indicate that the compression tester machine has
connected:
a. When the compression tester is off or the Ethernet cable is disconnected
you will see on the bottom right of your screen:
Note the red “X” on the icon signifying that there is no communication.
b. When the compression tester is on and initialized, you will see on the
bottom right of your screen:
If you do NOT see the red “X” then you ARE connected.
4. Double click the Compression Tester icon on your desktop to start the Software.
5. Push the green start button on the Compression Tester to energize the motor.
Note: This only has to be pressed when the breaker is turned off then on again.
Push the Red button for emergency stop only.
4
SECTION IV – TEST PROCEDURE
Test Procedure
The following flowchart outlines the typical test procedure that will be used by test
operators.
IDENT numbers are used to group test data for statistical analysis and result reporting;
test data alone is not a test result.
Open Compression
Tester Software
YES YES
Select
Create NEW
Existing
IDENT#
IDENT#
YES
YES
RUN TEST
DATA GOOD
NO Recorded at least 6
sucessful tests of this
type and IDENT?
YES
View/Print
Statistical
Results
5
Test Preparation
• Condition your test samples for temperature and moisture content per TAPPI test
requirements.
• Please prepare MORE than 6 samples to allow for mistakes.
• Use care in handling your samples: do not crease or dent your test samples, do
not touch your samples with your bare hands (use gloves to prevent
contamination), use box clips instead of packing tape where possible.
• Place your test sample at the center of the platen (centered left to right, forward
to back).
• Allow 0.25 inches or 0.6 cm headroom (distance between top platen and test
sample) before beginning any test.
6
SECTION V - OPERATION
Operation
(Select one of the following)
Stop Button
Pressing this button will stop a running test. Pressing any key during test operation will
also end the test.
Run Button
Hold the left mouse button down for 2 seconds on this button to run your pre-selected
test. The test type and IDENT number for this test is displayed below your chart.
Platen Up Button
Hold the left mouse button down on this button for 2 seconds to move the platen up.
Note that any button that causes machine movement requires that the button be held for
a count of two as a safety feature. While the machine is in motion you have Buttons to
Stop or Slow the platen movement.
Hold the left mouse button down on the Platen Down Button to move the platen down.
Note that any button that causes machine movement requires that the button be held for
a count of two as a safety feature. While the machine is in motion you have Buttons to
Stop or Slow the platen movement. As an additional safety feature when the platen
encounters any load during the downward movement the machine will stop with an error
message.
7
Defaults
Clicking this button takes the operator to
the default menu where test type and test
parameters are selected. Sections that
require values on this page can be edited
by clicking the button to the right of the
value. This will open a dialog box where
you may enter the desired value. The
dialog box will contain valid ranges for
your entered value and will check your
input for errors.
Test Type
Desired test you would like to run can be selected from this list. Click on the desired
test type to select it. Test types are as follows:
• Peak at Fall Back
• Peak at Deflection
• Load at Deflection
• Static Load
• Profile
Note: Upon selecting (or re-selecting) Profile test, the user will be asked to keep
the existing profile or edit it (in a separate popup dialog).
• Static Load 3 Pots
Note: this test requires the LVDT remote deflection kit. See the LVDT section
for more information.
• Static Load at Deflection
Note: this test requires the LVDT remote deflection kit. See the LVDT section
for more information.
See Section II - Test Types for more information.
Note: Some of the following test settings will NOT be available for certain tests.
Test Speed
Desired test speed can be entered here. Test speeds are typically 0.5 inches per
minute (1.27 cm per minute) for most TAPPI tests. Static Load, Profile, Static Load 3
Pots and Static Load at Deflection tests normally run at 0.4 inches per minute (1 cm
per minute).
Squaring Force
Squaring force is the threshold force that will be applied to the test sample before
graphing begins test stop conditions are considered.
Note: this is the loading force used to square specimen between platens. Fifty
pounds is typical force used in the box industry.
Fall Back
Desired fallback percentage can be entered here, used by auto test, static load, and
profile. Note: When the force on the sample falls this percentage below "Peak Force"
8
the test will automatically be terminated.
Deadband
The deadband is used in tests that require force sensitive motion (Profile, Static
Load, Static Load 3 Pots, Static Load at Deflection). The motor will cease motion
once the actual force applied to the test sample is within Desired Force +/-
deadband. A typical value is 4 Lbs. Increase this value if the machine will not settle
on a force (it constantly moves forward and reverse seeking the desired load). Too
high of a value will decrease the accuracy of applying a desired load. Too small of a
value will cause the machine to constantly seek the desired load. Higher test speeds
will require a higher deadband setting.
Deflection Limit
The test will be aborted if the platens measured deflection (after achieving the
Squaring Force) exceeds this value.
High Limit
If the high limit is reached during a test, the test will end. This value is also used to
determine the full range value of the chart during a run. Select a value that is
somewhat greater than the desired load.
Static Load
The Static Load is the desired force to apply to your test sample for the Static Load
and Static Load 3 Pots test.
Division Factor
This button will allow you to change the division factor from the default of 1 to allow
you to get results in something besides pounds such as pounds per foot or pounds
per inch. Changing the value to something other than 1 will also allow you to select
the Units of Measure nomenclature.
Platen Limits
The UP and DOWN settings are used when the UP and
DOWN buttons on the main menu are pressed. These
values are the UP and DOWN travel limits for the currently
selected Box. For example, when the UP PLATEN screen is
displayed, the “Stop At” box will contain the value set here.
This is typically used when test runs of several same-size
boxes are used so the platen automatically returns to the
desired position following a test. Changing these values here or in the UP
PLATEN/DOWN PLATEN screen will save the travel limit values for the currently
selected Box.
The Absolute Platen Adj allows the user to calibrate the absolute position of the
platen. Note: This in no way affects the accuracy of the test deflection since
deflection is simply the difference of two values. To restore the factory calibrated
value, please enter in the factory calibrated value in the dialog box.
10
Plots
When Plots Button is clicked you will be presented a sub-menu of options regarding test
plots and test data.
Test Explorer
Use the Test Explorer to navigate through existing test data AND to set up new tests.
Tree View
Use the tree view to navigate through your tests. The tree is a hierarchy of tests.
The top level is called Customers. Under Customers each Customer will be listed
(use your own company/organization if you are running in-house tests). Under each
customer, will be listed all Boxes (products to be tested for this customer). Under
each box (product) will be listed all IDENT Numbers. Ident numbers are used to
group tests statistically. Please try to keep the same test type under each Ident
number for statistical comparison. Under each IDENT number are the recorded
TESTS. Tests will have an icon indicative of the test type performed (see the Test
Icon Legend on the right of the screen to see which test type it is). The Test number
indicated is a uniquely generated test number.
Options
Clicks to Expand and Select
This option changes how you select items in the test explorer’s tree view. By default
this is set to Double Click to Select… You may change it to Single Click to Select…
Selection Mode:
View Single Plot
Select this option to view the plot and data by selecting any test in the tree view
(double click to select by default). After the test is selected the View Plot button will
be enabled. Click the View Plot button to view the selected plot.
11
ACTIONS:
Cut
Cuts the currently selected item to the clipboard. You may then Paste this item
under a different parent node.
Paste
Pastes a previously cut item to a new location from the clipboard.
Rename
Renames the currently selected item in the tree view.
Delete
Deletes the currently selected item in the tree view, as well as any child items.
View Plot
Views the currently selected plot, or list of plots chosen for View Multiple Plots.
New Customer
This allows you to create a new Customer, Box (product), and Ident to begin testing
with. To access this button, you MUST select the CUSTOMERS node at the very top
of the tree view first.
New Box
This allows you to create a new Box (product) and Ident for an existing customer.
To access this button, you MUST select an existing customer in the tree view first.
New Ident No.
This allows you to create a new Ident group for an existing Box (product) and
Customer. To access this button, you MUST select an existing box in the tree view.
Setting Up Tests
To set up tests, you will either use the Select Current Ident selection mode (for
existing test groups you wish to append data to) OR you will use the New Customer,
New Box, New Ident No buttons.
If you are using the New… buttons, you will be asked to enter information in a series
of dialog boxes. Where applicable you will be asked for a customer name, box name
(product code), and Ident Number. For Ident Number, we suggest using the date
and a sequence number for that day. Ex: 10041501 which represents the format
yymmddss, where yy is the last 2 digits of the year, mm is a 2 digit representation of
the month, dd is the 2 digit representation of the day and ss is the sequence number
for that day (starting with 01, 02, 03…). You may use any 8 digit ident code you
wish, however this is what we have found works best.
After entering in all the required information, you will be shown a review of the data
that you must accept or reject. After accepting, your current Customer, Box and
IDENT will be displayed. You will NOT see this information in your tree view until
AFTER you have recorded your first test.
12
Print
Click this button to send the current chart and related data to the default windows
printer. Make sure your printer is connected, online, and set as the default printer
before clicking this button.
Options
Click this button to change the way data is plotted on the chart. You may check or
uncheck each of these values:
• Enable Temperature and Humidity
Check this option to display the temperature and humidity on the printouts as
well as on the main screen of the program.
• Offset Chart
Check this option to stagger the start point of each of your plotted tests on the
chart when viewing multiple plots. This option is useful when comparing curves
that are very similar.
Exit
Closes the Plots sub-menu.
13
Statistics
This selection reports statistical results
for test data grouped by IDENT# and
Test Type. Results are displayed via
Control Chart, Histogram, and Text Data
via an integrated report. By default,
the information displayed if for the
currently selected Customer, Box,
IDENT# and Test Type. You may also
view any other identification (ident)
number or numbers (combining different
data groups for comparison) from past
tests. The customer, box and ident that
you are currently viewing statistical data
for is located at the bottom right of the screen (under the range chart).
Print
Click this button to send the statistical report to the printer.
Exit
Returns you to the main screen of the program.
Under the buttons you will see the High Spec limit, Low Spec Limit (user settable) for the
currently viewed customer, box and ident test group. You will also see the subgroup
number (number of different groups combined for statistical analysis).
At the bottom left you may view the test group population.
14
In the center you will see the statistical data for the test group(s).
R: Range. The difference between the highest value and the lowest
value of a group on the chart. A group is when 2 or more values are displayed
in one vertical bar under the bell curve. This value indicates that all the
values grouped together under one vertical bar are within R value of
eachother.
-3s: Lower Setpoint Limit: The lowest limit for a test value allowable for a good result.
+3s: Upper Setpoint Limit: The highest limit for a test value allowable for a good result.
Cp: CP is a capability indicator. CP shows the process capability potential but does not
consider how centered the process is. CP may range in value from 0 to infinity, with a large value
indicating greater potential capability. A value of 1.33 or greater is usually desired. This is an
indicator of how much the variance of the tests compares to the desired variance of the limits
entered by the user.
Cpk: Cpk has a value equal to cp if the process is centered on the nominal value; if Cpk is
negative, the process mean is outside of the specification limits; if Cpk is between 0 and 1 then
some of the spread falls outside of the tolerance limits (+/- 6s). If Cpk is larger than 1 then the all
the test values are within the tolerance limits. A value of 1.33 or greater is usually desired. This
value is also known as Zmin/3. This is an indicator of how much the samples fall outside the range
centered around the half way point between the limits entered by the user.
Lclx: Lower Control Limit (mean). The limit above which the process (sample mean values)
remains if it is in control. When sample values fall below this value, the process is out of control
(too far below the desired value).
Uclx: Upper Control Limit (mean). The limit above which the process (sample mean values)
remains if it is in control. When sample values are above this value, the process is out of control
(too far beyond the desired value).
Lclr: Lower Control Limit (range). The minimum limit of variation among the individual
tests as a function of time. When sample values are below this value, the variation between this
sample and the previous sample is too negative to be in control.
15
Uclr: Upper Control Limit (range). The maximum limit of the variation among the individual
tests as a function of time. When the sample values are above this value, the variation between
this sample and the previous one is too positive to be in control.
Cell Size: The width (force range) of each of the histogram bars. The range of values considered
similar in the histogram for grouping count of each histogram bar.
To the right you will see three charts. From the top to the bottom these charts are:
Histogram, Control and Range Charts. These charts are also included in the printout of
the statistics.
16
DATA LOGGING RS232
The Emerson Apparatus compression tester machine has data logging capabilities.
On the back of the computer, you will find a DB9 Male serial port connector. This is a 9
pin RS-232C communications port which transmits data.
Data is transmitted after an individual test is completed and the operator elects to save
the data. If the operator elects to NOT save the data, no data is transmitted.
Connectivity
Data Packets
Line 1: Ident #.
This is the test group ident number as entered by the operator. This value along with the
Test Type Name (see below) assist in grouping the data for statistical analysis.
Line 2: Data1.
This is the first test value. The data is based on the test type. See the data vs test type
chart below.
Line 3: Data2.
This is the second test value. The data is based on the test type. See the data vs test
type chart below.
Line 4: Fallback.
Where applicable, this is the %fallback used to determine the test ending condition.
17
Line 5: Test Type Name.
This is the type of test which produced these data logging results.
Test types are:
ECT, Pin Adhesion, Flat Crush, Ring Crush, CMT, CFC, Peak And Fallback, Force At
Deflection, Peak At Deflection, Tensile.
Note that Tensile tests will only be available on machines fitted for tensile testing. These
machines typically have a suffix of T on their model numbers.
Line 6: UOM.
This is the unit of measure name for the test which produced these data logging results.
UOM Names supported are:
LBS, IN, PSI, PLI, IN/min, PLF, InLBS/In, N, mm, kpa, kNm, cm/min, N/m, N-m/mm.
DATA1
Data1 is actual force read at the load cells and is always in LBS without scaling.
Data1 is NOT the scaled force result you see on the screen when the test completes!
The division factor is factory set for the first 7 test types (these values ARE
changeable by the end user) . The division factor is user controlled for the last 4
test types.
The division factor can be seen by entering the Defaults (Test Settings) screen
for each test type.
Example:
Data1 = 74.23 (this is in LBS)
Test Type = ECT
UOM = PLI (LBS / Linear Inch)
Division Factor (from the Defaults screen) = 2.0
18
DATA2
Data2 is the distance in Inches and represents either the Deflection at Peak Force or the
User Deflection Value, which is the maximum deflection parameter set by the operator for
the Force At Deflection test or the Peak At Deflection test.
19
MAINTENANCE
Adjustments and Calibrations
In normal use, calibration is not necessary.
Lubrication
• Every six months, wipe the vertical guide columns with a CLEAN rag dipped in SAE10
synthetic oil or synthetic hydraulic fluid.
• Wipe off all existing grease from the screws. If your screws are ACME screws, apply a
fresh coating of NOOK PAG-1 grease (no substitutions) using a clean rag.
• Please be sure to use the appropriate protection materials (such as Nitrile gloves)
when working with lubrications.
PAG-1. For Ball Nut Power Screws, lubricate the ball circuits with 10W motor oil.
DO lubricate vertical guide shafts and lead screws once every three months.
DO protect the operator from flying objects from failed test specimens.
DO NOT use tester for any purpose other than what is was designed for, determining
compressive strength of packaging materials.
DO NOT test any specimen without first making sure its failure will not send out flying glass,
wood particles, etc., toward the operator.
20
TROUBLE SHOOTING
Platen does not go up
Check and adjust the lower software limit stop in the Defaults menu AND check the
Wait for the network indicator to indicate that the machine connection has been
established (you will not see the red “X” on the network indicator). Restart the software.
Switch the machine’s circuit breaker on. Wait for the network indicator to indicate that
the machine connection has been established (you will not see the red “X” on the
21
CONTACT
Service Information
Telephone
1-800-445-1055 or 1-207-856-0055
Should you call during off hours or when all technicians are
unavailable, please leave a message. Your message will be
delivered to our service manager and you will be contacted as soon
as possible.
22
E-Mail
Enter your service information into the body of the message and
send it.
Fax
1-207-856-1117
In the fax heading, place the following:
Attention: Service Department
Enter your service information into the body of the fax and send it.
Support
23
Sales
Email: [email protected]
Should you call during off hours or when all sales personnel are
unavailable, please leave a message. Your message will be
delivered a salesperson and you will be contacted as soon as
possible.
24
WARRANTY
1-800-445-1055 or 1-207-856-0055
25