AB 2531856 en 20160515 050000 00047151 PDF

Zwick
Materials testing
Aflow
Translation of the original user
manual
Dossier: 725368
Order confirmation: 2531856
Serial number: 725368 / 2016
Year of manufacture: 2016
Zwick
Materials testing
Thank you for your trust in our company, as demonstrated by your purchase of one of
Zwick/Roell's products.
Zwick/Roell products are designed for universal use. They can be used for almost all
national and international standards and test requirements and are also designed to
provide solutions for a wide range of "in house" testing problems.
Of course, the products can be used not only for quality assurance in routine tests, but
also for research where the test specifications must first be defined.
Manufacturer:
Customer service:
Zwick GmbH & Co. KG

August-Nagel-Strasse 11
89079 Ulm
Germany
Zwick GmbH & Co. KG

89079 Ulm
Germany
Telephone:
Fax:
Email:
Internet:
Hotline:
Email:
+49 (0)7305 10-0

07305 10200
info@zwick.de
www.zwick.de
www.zwick.com
07305 10225
hotline@zwick.de
Acceptance report for machines, systems,

and devices
Acceptance report for machines, systems, and devices

Created on: 15.5.2016
Supplier
Customer
Zwick GmbH & Co. KG

89079 Ulm
Division: US
Fax: 07305 10261
KINGFA SCI. & TECH. (Europe) GmbH

Kasteler Str. 45
DE-65203 Wiesbaden
Order data
Dossier:
Order confirmation:
Product:
Type:
725368
2531856
Aflow
Aflow
The machine/system/device named above was
accepted
accepted with slight irregularities which still have to be rectified
not accepted
Notes:
Copyright 2016, Zwick GmbH & Co. KG, D-89079 Ulm
Important!
The consignment and/or performance has been fulfilled compliant to the contractual conditions. Please give
the signed acceptance report to our service technician. If a service technician did not perform
commissioning, please mail or fax us the acceptance report within ten (10) days. The discount as agreed in
writing in the invoice will only be granted if we receive the countersigned acceptance report within the stated
period of time. Furthermore, access to a free-of-charge hotline, which provides help quickly should the
equipment malfunction, will be granted if the acceptance report is returned on time. Please note that a
missing confirmation on the part of the customer does not mean that the machine has not been successfully
installed and commissioned. We will assume that the equipment has been correctly installed and
commissioned if it is used in a satisfactory manner by the customer.
Zwick/Roell department and signature

5.2016
Date
Name and address of the customer

3
Acceptance report for machines, systems,

and devices
5.2016
General table of contents

Information about this manual
1
Legal notice ....................................................................................................................... 13
About this user manual .................................................................................................... 14
Warranty and liability ........................................................................................................ 24
Safety manual
1
Introduction ....................................................................................................................... 29
Testing system .................................................................................................................. 30
Additional national and operational regulations ........................................................... 31
Safety-related equipment ................................................................................................. 32
Intended use ...................................................................................................................... 33
Improper use ..................................................................................................................... 34
Residual risks ................................................................................................................... 35
Safety labels on the testing system ................................................................................ 36
Personnel .......................................................................................................................... 38
10
Workplace .......................................................................................................................... 40
11
Transport ........................................................................................................................... 41
12
Before switching on ......................................................................................................... 42
13
Operating ........................................................................................................................... 43
14
Maintenance work ............................................................................................................. 44
15
Working on electrical equipment .................................................................................... 45
16
Working on pneumatic equipment .................................................................................. 46
17
Cleaning and disposal ...................................................................................................... 47
Technical manual
5.2016
Introduction ....................................................................................................................... 55
Testing system .................................................................................................................. 57
Piston ................................................................................................................................. 66
Automatic extrudate cutter .............................................................................................. 70
Die plug .............................................................................................................................. 72
Separating pane ................................................................................................................ 74
Cleaning and compaction unit ........................................................................................ 76
Test granulate .................................................................................................................... 78
Installation manual
1
Introduction ....................................................................................................................... 87
Requirements .................................................................................................................... 88
Transport ........................................................................................................................... 90
Setup .................................................................................................................................. 91
Initial commissioning ..................................................................................................... 107
Dismantling ...................................................................................................................... 111
User manual
1
Introduction ..................................................................................................................... 123
General safety notes ...................................................................................................... 124
Operational controls ....................................................................................................... 126
Operating ......................................................................................................................... 178
Service and maintenance manual

Introduction ..................................................................................................................... 201
General safety notes ...................................................................................................... 202
Documentation for maintenance and servicing ........................................................... 204
Servicing .......................................................................................................................... 205
Calibration ....................................................................................................................... 206
Service recommendations ............................................................................................. 207
Testing system ................................................................................................................ 208
Troubleshooting .............................................................................................................. 222
Pneumatic weight lifting unit ......................................................................................... 223
10
Pneumatic weight lifting unit with cleaning function .................................................. 226
11
Pneumatic weight lifting unit with peg positions ........................................................ 229
12
Automatic extrudate cutter ............................................................................................ 232
13
Die plug ............................................................................................................................ 241
14
Separating pane .............................................................................................................. 248
15
Cleaning and compaction unit ...................................................................................... 250
16
Cleaning and disposal .................................................................................................... 252
17
Overview of all service intervals ................................................................................... 253
Special test programs

1
testXpert II ....................................................................................................................... 261
Circuit diagrams
5.2016
Certificates/Calibration reports
EC Declaration of Conformity ........................................................................................ 283
Appendix
1
Introduction ..................................................................................................................... 293
Service ............................................................................................................................. 294
Checklists ........................................................................................................................ 295

Data required for your phone call ................................................................................. 296
Calibration ....................................................................................................................... 297
Password ......................................................................................................................... 300
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Table of contents
Table of contents
1
Legal notice ........................................................................................................ 13
About this user manual ..................................................................................... 14

Storage ...................................................................................................... 14
2.2
User manual layout ................................................................................... 14
2.3
Layout of the manuals ............................................................................... 16
2.4
Warning notes ........................................................................................... 17
2.5
Pictograms ................................................................................................ 19
2.6
Graph ........................................................................................................ 23
2.7
Notes for the reader .................................................................................. 23
Warranty and liability ........................................................................................ 24
2.1
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Table of contents
12
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Legal notice
1 Legal notice
Zwick GmbH & Co. KG
The copyright of this documentation remains with Zwick GmbH & Co. KG, 89079 Ulm.
This documentation is intended only for the operator and his or her personnel.
Zwick GmbH & Co. KG
89079 Ulm
Germany
Telephone: +49 7305 10-0
Fax: +49 7305 10-200
Email: info@zwick.de
Internet: www.zwick.de, www.zwick.com
Service addresses are listed on the back of the cover page.
User manual:
Issue date:
Aflow
15.5.2016
All rights reserved

We have done our best to make sure that this user manual is complete and free of errors.
Should you, however, still notice anything at all which is unclear or erroneous please
inform us.
Our products are being continuously improved upon. Therefore it is possible that some
statements in this manual do not always correspond to the latest technology. Precise
information can be obtained by calling Zwick in Ulm if you are not entirely sure.
Tips, notes, and constructive criticism are always welcome. Please direct these to
Zwick GmbH & Co. KG

Technical documentation
89079 Ulm
dokumentation@zwick.de
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13

About this user manual
2 About this user manual

This user manual contains information on the entire service life of the product. It is
intended for qualified personnel and operator personnel who work with the product.
If ambiguities or inconsistencies are identified in the translation of the original user
manual, the original user manual must be consulted to resolve these issues and the
manufacturer must be informed before the product is used.
NOTE
To improve readability, references to persons are not gender-specific. However, both
genders are address in all instances in the name of equal treatment.
2.1 Storage
This user manual is an integral part of the product. It must be stored near the product and
be protected from environmental influences.
At the time of the sale of the product, the user manual must be issued to the buyer along
with the product.
2.2 User manual layout

The user manual is divided into different categories: In its printed form, a user manual is
indexed by section. Some user manuals are optional depending on the components you
purchase.
14
5.2016 1003521

Manuals
Manual
Target group
Section
Safety manual: information Persons authorized to work

on the safe use of the prod- on/with the product
uct
Technical manual: technical

data, function description,
intended use
Persons authorized to work

on/with the product
Installation manual: information on transport, setup,

installation, dismantling, and
storage
User manual: information on
operational controls and
operational procedures
Service and maintenance
manual: information on servicing, service intervals, error
rectification, and circuit diagrams
Working with testXpert:
description of the testing
software
Appendices: checklist, declaration of conformity or
installation declaration, calibration reports, safety data
sheets, and other certificates
Directories: index and table
of figures
Persons authorized to trans- 3

port, set up, dismantle,
pack, and store the product
Persons authorized to oper- 4
ate the product
Persons authorized to service the product
Persons authorized to oper- 6 (optional)

ate the product
on/with the product

on/with the product
Symbol
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15

2.3 Layout of the manuals

The product consists of various components.
The chapters in the individual manuals are often divided into sections for the individual
components. The components are in the following order:
-
Testing system
Sensor
Test tool
Test accessories
One exception to this is in the chapter on dismantling in the Installation manual. There the
order is reversed.
Example in Installation manual
Chapter
Safety
Transport
Setup
Initial commissioning
Dismantling
Order of components
Testing system
Sensor
Test tool
Test accessories
Test accessories
Test tool
Sensor
Testing system
NOTE
Some components may not be included in your manual as the manuals are supplied
for equipment as per the configuration of your testing system.
Some chapters do not require a detailed description for certain components.
Directories
The user manual has a table of contents and an index.
16
The table of contents is found at the beginning of the user manual and at the
beginning of each manual.
The index is found at the end of the user manual and at the end of each manual.
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Header
Each page in the user manual has a header containing information about the contents of
that page:
Pictogram of the manual
Name of the chapter
Name of the component
CTA: 14108
1
2
Chapter
Components
Pictogram
2.4 Warning notes

Warning notes in this user manual point out potential dangers. All warning notes must be
strictly observed!
Warning notes contain the following information:
-
Signal word Indicates the level of danger

A standardizes pictogram (not in the case of a property damage warning)
Type and source of the danger
Possible consequences
Actions to prevent the danger
The signal word indicates the level of danger at four levels.
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Display
Overview of the warning notes at the various danger levels with sample pictograms:
DANGER
Type and source of imminent danger!
Death or grievous bodily harm
WARNING
Type and source of potential imminent danger!
Death or grievous bodily harm
CAUTION
Type and source of a potentially dangerous situation!
Minor physical injury
NOTICE
Type and source of imminent danger!
Damage to surrounding property and/or the product
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Risk of damage to the surrounding property and/or the product also exists in situations
such as those described in the warning notes entitled CAUTION, WARNING, and
DANGER.

Embedded action-related warning notes

Some warning notes refer to a specific step and are a part of the step itself.
Example:
The load cell is mounted on a flange.
NOTICE! Risk of destruction if the load cell falls! Avoid impact and do not drop the
load cell.
1.
Place the load cell with the flange on the crosshead, which has a through bore-hole,
from the test area side.
2.
...
The load cell is mounted.
2.5 Pictograms
This user manual uses the following pictograms:
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Warning signs
Danger warning
Warning about hot surfaces
Warning about cold temperatures
Warning about trapping of parts of the body
Warning about injury to hands
Warning about falling objects
Warning about tipping
Warning about swinging pendulum

Warning about flammable materials
Warning about electromagnetic radiation
20
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Warning about dangerous electrical voltages
Electrostatically sensitive components
Substances dangerous to the environment
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21

Mandatory signs
Wear protective clothing!
Wear hand protection!
Wear safety shoes!
Wear facial protection!
Wear eye protection!
Wear ear protectors!
Unplug the power plug!

Disconnect the voltage!
22
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Symbols for handling notes
Observe the center of gravity!
Observe the permissible temperature(s)!
Other pictograms
Additional information
Notes on servicing
2.6 Graph
It is possible that product drawings do not match the delivered product exactly due to
continual product development.
All dimensions in the product drawings are indicated in mm.
The product drawings in the user manual are not to scale and are for illustration purposes
only.
2.7 Notes for the reader

Symbols
Tool to be used
Prerequisite
Result
Operational controls
<Italics>
<Bold>
Software buttons, option fields, list fields

Hardware keys
Examples:
-
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Select <Desktop> from the <Energy scheme> list field.

Press the <OK> button on the operator panel of the electronics.
23

Warranty and liability
3 Warranty and liability

This user manual, in particular all safety instructions and warnings, must be observed by
all persons authorized to work on/with the product. Furthermore, compliance with rules
and regulations relevant to the product's installation site is required.
Warranty and liability claims are excluded if they are the result of one or more than one of
the following causes below:
-
Non-observance of this user manual

Improper use
Use by unqualified personnel
Use of non-approved spare parts, tools, or accessories
Irregular maintenance and repair work as recommended in the user manual
Missing documentation of the listed maintenance and repair work
Non-approved modifications to the product
Extraneous influences or force majeure
24
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Safety manual
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Safety manual
Table of contents
Table of contents
1
Introduction ........................................................................................................ 29
Testing system ................................................................................................... 30
Additional national and operational regulations ............................................ 31
Safety-related equipment .................................................................................. 32
Intended use ...................................................................................................... 33
Improper use ...................................................................................................... 34
Residual risks .................................................................................................... 35

7.1
Checking and preventive measures .......................................................... 35
Safety labels on the testing system ................................................................. 36
Personnel ........................................................................................................... 38
9.1
Operator's liability ...................................................................................... 38
9.2
Qualified personnel ................................................................................... 39
Workplace .......................................................................................................... 40
11
Transport ............................................................................................................ 41
12
Before switching on .......................................................................................... 42
13
Operating ............................................................................................................ 43
14
Maintenance work ............................................................................................. 44
15
Working on electrical equipment ..................................................................... 45
16
Working on pneumatic equipment ................................................................... 46
17
Cleaning and disposal ...................................................................................... 47
18
Index ................................................................................................................... 48
19
Figure index ....................................................................................................... 49
10
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Safety manual
Table of contents
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Safety manual
Introduction
1 Introduction
This user manual contains information which is important for safe usage when working
with testing systems and accessories.
The user manual must be read and used by all persons authorized to work on/ with the
testing system.
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Safety manual
Testing system
2 Testing system
The testing system is constructed using state of the art and recognized safety rules
based on the EC Declaration of Conformity and Declaration of Incorporation Guidelines.
This, however, does not exclude the possibility of any danger to life and limb of the
operator or third parties which could occur when using the testing system. Damage to the
testing system can also not be excluded.
-
Use the testing system

only if it is in perfect technical order
for its intended use
in awareness of the safety aspects and hazards
while observing the user manual.
In the event of faults that could impair safety, bring the machine to an immediate stop
and arrange for rectification of the cause.
Please comply with all national regulations.
Other rules may apply to the operation of systems in non-European countries.
Inform the new user to check and comply with pertinent safety regulations if the
location of the testing system is changed or if it is sold.
NOTE
Zwick cannot be held liable for failure to comply with these requirements.
30
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Safety manual
Additional national and operational
regulations
3 Additional national and operational regulations

Supplement all manuals with instructions from:
national regulations on accident prevention and environmental protection
operational regulations such as oversight and reporting obligations
Please observe and adhere to:
the valid, binding regulations on accident prevention
the acknowledged technical rules for safety and correct working
the regulations on safety and health protection when preparing and using working
means
the specifications of each safety data sheet for hazardous materials or materials
hazardous to your health/the environment.
Have the safety data sheet ready.
the user manuals
Always keep the entire user manual on hand at the installation site of the testing system.
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Safety manual
Safety-related equipment
4 Safety-related equipment
The safety-relevant equipment of a testing system depends on the respective application,
i.e., the installation site, the type of test, the test tools and the specimens to be tested.
Make sure that the specimens and specimen holders used can be neither propelled away
from the testing machine nor can drop to the floor when under load or in the event of
malfunction. This could lead to damage to test equipment and to injury to persons in the
vicinity of the machine.
The statements made during sales consultations with regards to the above or the
application agreed upon in the order, limit the intended use of the equipment. The
shipped testing system complies with the general safety requirements for running tests as
per the accepted order.
Should you wish to use this testing system for applications other than those for which the
equipment was originally ordered, please contact your Zwick representative for safetyrelevant consultation, or send an email to info@zwick.de.
Creating new test environments
Only personnel with the appropriate safety training may create new test environments.
Reason: Safety-relevant parameters (e.g., safety door limit forces) can be changed when
new test environments are created. If the testing system is operated by personnel without
the appropriate safety training, an "operator level" must be created by someone with the
appropriate safety training. Personnel who have not received the appropriate safety
training must work at the "operator level." This ensures that parameters can be changed
only by authorized personnel.
Setting up the operator level: See the Online help in testXpert under the section on <User
Management>
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Safety manual
Intended use
5 Intended use
The testing system is used to determine the MVR (melt volume rate) and MFR (melt flow
rate) on thermoplastic plastics to the following standards:
DIN EN ISO 1133
ASTM D 1238
BS 2782
The testing system is used to test granulates or other suitable materials with which it can
be filled.
If testing materials contain fluoride, the extrusion barrel and piston must be suitably
designed for testing such materials. The parts used must be acid proof.
The testing system is suitable for use in the following fields of application:
Laboratory
Incoming goods inspections
Production monitoring
Production management
The specified testing system described is designed to perform the following tests:
MFR and MVR tests according to methods A and B to ISO 1133
Material: Plastic granulate
The configuration quoted conforms to current safety requirements when used to perform
the
tests described above.
Also required is the following: Safety glasses, heat-insulated gloves
If this testing system is to be used for additional applications, please contact Mr. Letschert
for additional guidance on safety-related and applicational issues.
The safety of this system is based on the EC Declaration of Conformity stated in the
applying
European Community Directives; the risk assessment is effected according to EN ISO
12100.
Any further standards shall be retrieved separately.
NOTE
The user manual is constructed in modular form. Note the technical manual. This section
describes the intended use of each component.
NOTE
The intended use of the testing system includes the transport, installation, operating, and
servicing instructions.
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Safety manual
Improper use
6 Improper use
Any use other than those expressly stated under intended use is recognized as being
improper use. Zwick does not accept any liability whatsoever for damage resulting from
any application or use not included under intended use. Liability is the sole responsibility
of the user in such a case. The guarantee and warranty for the testing system expires.
Any changes made to the testing system, tools and fixtures, as well as to the testing
software by the customer renders the CE conformity invalid.
Zwick does not and will not accept any liability for tools and devices integrated in the
system by the user. Any necessary safety measures are then the sole responsibility and
liability of the operator/user.
Examples of improper use:
Use of specimens that could cause a potential hazard at the installation location
Changes to the testing system which have not been agreed upon by Zwick
Use of the testing system as a production machine not authorized by Zwick
Overriding protective devices
Non-use of personal safety equipment
Overriding protective device functions
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Safety manual
Residual risks
7 Residual risks
Residual risks could exist in the following cases:
Through sharp edges on the extrudate cutter
Through chemical reactions
Through test material being propelled away from/out of the machine
Through burning by touching a hot die and/or the heating barrel, as well as extruded
test material
Generally, we stipulate that the user be well versed in the safe use of the testing system.
We offer a wide range of safety devices that are aimed at providing protection for the user
and for the vicinity of the test equipment.
7.1 Checking and preventive measures
The following checks and preventive measures must be carried out independent of your
running checks for any evident deficiencies.
An electrician should check the correct functioning of electrical equipment and
systems at least every 4 years.
Please comply to national guidelines.
Have safety devices such as the limit switch, safety housing, safety doors, safety
cage, proximity switch of the testing system checked only by skilled electricians
qualified for this particular work:
Immediately upon detection of damage
Following repair work
At least once a year
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Safety manual
Safety labels on the testing system
8 Safety labels on the testing system

The following safety labels are affixed to this testing system.
CTA: 20051
NOTE
Observe all safety labels affixed to the testing system such as safety remarks.
Warning sign: Warning about dangerous electrical voltages
Warning sign: Warning about hot surfaces
Warning about dangerous electrical voltages!

The warning sign means "Stop" in front of danger zones in which components under
electrical voltages are located.
36
5.2016 1008149
Picture 1: Safety labels
Safety manual
Safety labels on the testing system
Warning about hot surfaces!

The warning sign warns of hot parts and surfaces, in particular the fact that contact with
these parts and surfaces should be avoided.
Parts of the testing system can become extremely hot:

Extrusion barrel
Piston
Die holder
Die
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Safety manual
Personnel
9 Personnel
The User manual differentiates between the managing personnel, the operator, and nonauthorized persons:
Managing personnel: Responsible personnel with authority for giving instructions
Operator: Personnel instructed and authorized by the managing personnel. They
work on/with the testing system.
Non-authorized persons (third parties): Persons who are not trained by Zwick and
thus are not authorized
9.1 Operator's liability

Safety can only be practiced in every day use if all necessary measures are taken.
Determine the responsibilities of the operator personnel for the following:
operating
equipping
Service and repairs
Zwick provides training and tuition on the above topics.
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Safety manual
Personnel
The testing system's user must make sure that the following points are observed (due
diligence):
The testing system may only be used according to its intended use
Only safe tests may be run with the testing system
The testing system may only be used if it is in perfect working order
Anything which could impede safety has neither been added nor converted
Safety devices must not be manipulated
Safety devices such as guard/splash plates must always be checked for visual
damage.
Should the testing system malfunction in any way, further operation is permitted only
following consultation with the responsible safety officer (if necessary please ask
Zwick)
All safety labels and warning signs affixed to the testing system must not be removed
and must be legible.
An air exhaust system for exhaust gases should be installed and functioning
correctly.
Missing or illegible safety labels and warning signs on the testing system must be
replaced immediately.
The user must receive regular instruction on the safe use of the testing system.
The testing system may be operated by qualified and authorized users only.
The user must have knowledge of
safe operation
suitable protective clothing
any potential threats posed by the testing system
The user must be instructed with respect to work safety and environmental protection
as follows:
Before beginning work
About any eventual alterations/amendments to the testing system
At least once a year
The user must be familiar with the safety notes contained in the User manual and
adhere to them.
The user must wear suitable protective clothing such as safety goggles, safety
shoes, protective gloves, tightly fitting clothing, hairnets for long hair.
9.2 Qualified personnel
The User manual differentiates between the following qualified personnel:

Transport specialists: Qualified personnel who are competent in transport issues
Electrical specialists:
Qualified personnel who are competent to work on electrical equipment
Trained persons under the guidance and supervision of a qualified electrician
Hydraulic specialists: Qualified personnel who are competent to work on hydraulic
equipment
Qualified personnel: Qualified personnel other than transport, electrical, and
hydraulic specialists who are competent in their respective work
Safety experts: The operator's qualified personnel who are responsible for safety
during operation as defined by legal requirements
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Safety manual
Workplace
10 Workplace
WARNING
Danger of hot surfaces due to swiveled-out piston!
Persons at the left table edge can touch the hot swiveled-out piston and burn
themselves.
Ensure that the distance of between the testing system and the left table edge is at
least 0.5 m.
NOTE
The testing system must be operated by only one person at a time.
The user's workplace is in front of the testing system during operation.
CTA: 20059
The testing system stands on a table.
1
2
3
40
Testing system
Table
Workplace
Minimum distance to walking lanes: >

2m
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Picture 2: Testing system workplace
Safety manual
Transport
11 Transport
Transport, even in-company repositioning of the testing system or its accessories, may be
performed only by authorized and qualified personnel, such as transport companies, the
transport department, or ZwickService.
-
Adhere to the regulations governing safety and health protection at work (Liability of
the system supervisor) when making work means available. Some examples include:
Instructing employees
Intended use of transport means and load handling attachments
Personal safety equipment
Please pay attention to all safety remarks.
Transport paths and danger zones must be sectioned off for non-authorized persons.
Never work beneath any suspended loads/weights.
The lifting devices, lifting accessories, and load bearing fixtures and accessories
used for transporting must
Be suitable for transporting
Be technically sound
Have sufficient load capacity
Ensure that when lifting/setting up the testing system and its accessories, only
authorized persons are allowed to remain in the working area.
Transport the testing system and its accessories to the installation site in their
original packaging.
Ensure that the system is not thrown about or subjected to impact or strong
vibrations during transport.
Remove accessories from the pallet of the testing system when transporting by
crane.
Remove transport frames, holders, and fastening elements with the necessary care
and secure them from falling.
Secure transport ropes/transport belts with hooks only at the lifting locations
specified by the testing system and its accessories.
Always screw in lift bearing fixtures/load handling attachments completely.
Always pay attention to the center of gravity as indicated on the packing!
Secure the materials testing system against tipping over.
Note that the center of gravity changes when test tools are mounted.
Observe the instructions on the transport label.
Lower the center of gravity before transporting/relocating, if possible.
Before relocating, dismantle heavy parts such as specimen grips, extensometers,
etc.
Remove all lift bearing fixtures/load handling attachments and other accessories
after transporting.
The transport of testing systems and accessories is described in the installation manual.
The following companies do not accept any liability should any types of transport other
than those described in the installation manual be used: Zwick
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Safety manual
Before switching on
12 Before switching on
-
Please become acquainted with what to do in the case of defects/interference.

Only authorized persons are allowed in the work area of the testing system.
Please check the testing system for visible defects, especially in
Splash plates
Die holder
Extrusion barrel
Piston
Report any detected defects immediately.
Defects must be rectified before putting the testing system into operation.
NOTE
You must not operate the testing system should defects be present.
Examples of defects:
Damaged or removed splash plates
Damaged or deformed piston
Damaged or deformed cleaning die
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Safety manual
Operating
13 Operating
Chemical reactions
When heating the test material, strong chemical reactions could occur, such as the
formation of poisonous or aggressive vapors or splashing or gumming up of the test
material.
Take suitable measures to avoid bodily and/or material injury/damage.
Please use suitable tools.
Wear suitable protective clothing.
Hot parts
Parts of the testing system can get extremely hot. Burns can occur if contact is made
with the die, die holder, extrusion barrel, piston, and cleaning and compaction rod.
Do not fill up the test material by hand. Use the specimen chute.
Do not touch the die, die holder, extrusion barrel, piston, or cleaning and compaction
rod.
Hot parts during cleaning
Cleaning tools can become very hot. Burns can occur if contact is made with
cleaning tools.
Hot test material
The extruding and cut specimen material is extremely hot. When cut off, hot test
material can be propelled away. Contact with hot test material can cause burns.
Sharp edges
The sharp edges of the extrudate cutter's blade can cause lacerations.
Never touch the blade.
Air exhaust system
Use an air exhaust system.
Personal safety equipment

Facial protection
Safety clothing
Protective gloves
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Safety manual
Maintenance work
14 Maintenance work
Pay attention to the following items to prevent life-threatening injuries or damage to
devices or the environment when servicing the testing system. These items are also listed
for each component in the Service and maintenance manual:
This type of work must be carried out by qualified and trained personnel only.
Inform the user before you begin to work.
You must have the necessary tools and equipment required for all service measures.
Adhere to the prescribed service intervals.
Pay attention to the maintenance instructions.
Only use the indicated operating fuels and lubricants, etc.
Use original Zwick spare parts only
Ensure that you have ecological and safe methods in place for disposing of
replacement parts and operational or auxiliary materials as stipulated by legal
requirements.
NOTE
Maintenance and service work for the pneumatic equipment may be carried out only by
skilled personnel qualified for this particular work.
Before carrying out maintenance and repair work

Unplug the pneumatic hose from the compressed air supply.
Switch the testing system off at the device electronics.
Switch the power supply off via the mains switch.
Unplug the power plug.
Ensure the power plug is not inadvertently plugged in again.
Wait until all parts of the testing system that might be touched, such as the extrusion
barrel, piston, etc., have cooled down to ambient temperature.
After carrying out maintenance and repair work, ensure the following:
All ground wire connections are attached properly again.
All loose threaded connections are re-tightened.
Removed guard/splash plates or container lids/covers have been installed again.
All materials, tools, equipment, etc., which are required for maintenance and
servicing, have been removed from the testing systems working area.
All of the testing system's safety devices, such as limit switches and proximity
switches, are in perfect working order.
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5.2016 1008189
NOTE
The testing system can be operated again by the operator only if all of the above work
has been done correctly and is free of error.
Safety manual
Working on electrical equipment
15 Working on electrical equipment

NOTE
Work on the testing system's electrical equipment may be carried out only by qualified
and authorized electricians.
NOTE
All work on the testing system must be carried out in a zero-voltage state.
There is still a voltage at the power input cable even when the testing system is switched
off.
Please observe the following:
An electrician should check the correct functioning of electrical equipment and
systems at least every 4 years. Please comply with national guidelines.
Please keep the electronics unit/switch console closed at all times! Access is
permitted only for electricians with keys/tools.
Electronics unit/housing/switch consoles/motors must never be hosed down, neither
with steam nor water!
NOTICE
Electrostatically sensitive components!

Electrostatic discharge can damage the components.
The regulations regarding electrostatically sensitive components must be followed.
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Safety manual
Working on pneumatic equipment
16 Working on pneumatic equipment

NOTE
You must set the pneumatic equipment of the testing system to zero-pressure before
carrying out maintenance and service work . Always unplug the pneumatic hoses at
the compressed air supply first.
Check all leads, hoses, and threaded connections regularly for leaking and for
detectable damage. Replace any damaged hoses immediately.
The pneumatic hoses must always be inserted all the way in. Check that they are
tightly in place.
When replacing compressed air hoses, mount them in the same manner/direction.
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Cleaning and disposal
17 Cleaning and disposal

Risk of burns from hot parts of the testing system and hot cleaning tools:
with the die, die holder, extrusion barrel, piston, and cleaning tools.
Always wear protective gloves.
Risk of fire due to high temperatures:
Never leave any remains of cleansing agents in the extrusion barrel.
Do not use plastic-based rags for cleaning.
Use a rag made from cotton or a similar material.
NOTE
Use rags of approx. 50 x 70 mm for cleaning. Zwick offers suitable cleaning pads as an
option.
Special cleaning agents are not necessary. Cleaning tools for cleaning the extrusion
barrel and the die have been supplied together with the extrusion plastometer.
For more information on cleaning the extrusion barrel and die, see the chapter entitled
Cleaning in the User manual.
Adhere to the legal obligations and regulations for preventing waste as well as
disposing of and recycling it properly.
Clean the testing system with non-corrosive and solvent-free cleansing agents.
After each cleaning, treat uncoated and non-surface treated parts of the testing
system with an anti-corrosive agent as specified in the notes on proper care in the
Service and maintenance manual.
When working on the testing system, substances hazardous to water must never be
released into the environment.
Examples of water contaminating substances:
Lubricants and oils
Hydraulic oils
Coolants
Cleansing fluids containing solvents
These substances must be collected in suitable containers and then stored,
transported and disposed of as specified by legal regulations.
For high temperature furnaces, you must follow the instructions on the data sheet.
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Safety manual
Index
18 Index
A
Additional national and operational regulations...... 31
B
Before switching on.................................................42
C
Checking and preventive measures
Safety manual..................................................... 35
Cleaning recommendations.................................... 47
D
Danger of hot surfaces
due to swiveled-out piston!................................. 40
M
Mains cable.............................................................45
Maintenance work...................................................44
N
National regulations................................................ 31
O
Operating................................................................ 43
Operator personnel................................................. 38
P
Personnel..........................................................38, 39
Preventing waste.................................................... 47
R
Residual risks..........................................................35
Responsibility for personnel....................................38
S
Safety labels
On the testing system................................... 36, 37
Safety measures..................................................... 42
Safety-related equipment........................................ 32
Service work
Environmental protection.................................... 47
T
Testing system
Safety labels................................................. 36, 37
W
Work
On electrical equipment...................................... 45
On pneumatic equipment....................................46
Workplace............................................................... 40
48
5.2016
Safety manual
Figure index
19 Figure index
Safety labels .............................................................................................. 36
Picture 2
Testing system workplace ......................................................................... 40
Picture 1
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49
Safety manual
Figure index
5.2016
50
Technical manual
Aflow
Technical manual
Dossier: 725368
5.2016
51
Technical manual
5.2016
52
Technical manual
Table of contents
Table of contents
1
Introduction ........................................................................................................ 55
1.1
Applied standards ...................................................................................... 55
1.2
Remarks on product and manufacturer liability ......................................... 55
1.3
Electronic rating plate ................................................................................ 55
1.4
Serial number plate ................................................................................... 56
Testing system ................................................................................................... 57

2.1
Overview ................................................................................................... 57
2.2
Dimensions ................................................................................................ 58
2.3
Technical data ........................................................................................... 59
2.4
Operating data ........................................................................................... 59
2.5
Electrical connections ................................................................................ 60
2.6
Function description .................................................................................. 60
2.7
Mechanical setup ...................................................................................... 60
2.8
Data backup .............................................................................................. 61
2.9
Interfaces ................................................................................................... 61
2.10 Formulas ................................................................................................... 64

2.11 Statistical evaluation .................................................................................. 65
3
5.2016
Piston .................................................................................................................. 66
3.1
Overview ................................................................................................... 66
3.2
Technical data ........................................................................................... 66
3.3
Intended use .............................................................................................. 67
3.4
Conditions ................................................................................................. 68
Automatic extrudate cutter ............................................................................... 70

4.1
Overview ................................................................................................... 70
4.2
4.3
Technical data ........................................................................................... 70
4.4
Intended use .............................................................................................. 70
4.5
Improper use ............................................................................................. 71
Die plug .............................................................................................................. 72

5.1
Overview .................................................................................................. 72
5.2
5.3
Technical data ........................................................................................... 72
5.4
Intended use .............................................................................................. 73
5.5
Improper use ............................................................................................. 73
Separating pane ................................................................................................. 74

6.1
Overview ................................................................................................... 74
6.2
6.3
Technical data ........................................................................................... 75
6.4
Intended use .............................................................................................. 75
6.5
Improper use ............................................................................................. 75
53
Technical manual
Table of contents
Cleaning and compaction unit ......................................................................... 76

7.1
Overview ................................................................................................... 76
7.2
7.3
Technical data ........................................................................................... 77
7.4
Operating data ........................................................................................... 77
Test granulate .................................................................................................... 78

8.1
Overview ................................................................................................... 78
8.2
8.3
Technical data ........................................................................................... 78
8.4
Intended use .............................................................................................. 79
8.5
Range of application .................................................................................. 79
Index ................................................................................................................... 80
10
Figure index ....................................................................................................... 81
54
5.2016
Technical manual
Introduction
1 Introduction
This manual contains important information about the setup, dimensions, and technical
data of the testing machine.
The user manual must be read and used by all persons authorized to work on/ with the
testing system.
1.1 Applied standards

The standards relevant to the testing systems are listed in the declaration of conformity
and in the Technical manual.
1.2 Remarks on product and manufacturer liability

The error limits stated in our specification(s) (order confirmation) are not infinitely valid.
Regular checks must be made depending upon the measuring accuracy.
You can do this yourself if you have suitable measurement means. If not, it can be done
by accredited centers such as German materials testing authorities (MPA, LGA) or by
Zwick. The Zwick DAkkS calibration laboratory is accredited under registration no. DK-18351-01-00.
NOTE
We recommend annual calibration with respect to EN ISO 9001.
1.3 Electronic rating plate

CTA: 10566
All of the hardness tester's important data is saved to an electronic rating plate.
Picture 1: Electronic rating plate
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Technical manual
Introduction
1.4 Serial number plate
CTA: 12552
The large serial number plate is located on the basic frame of the testing system or on
the housing of the machine electronics.
Picture 2: Serial number plate, large

1
2
3
4
Manufacturer
5
Address
Order number or type of testing system 6
Serial number/year of manufacture
7
Order confirmation number and/or dossier number

Power supply
Nominal value of the testing system
56
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Technical manual
Testing system
2 Testing system
CTA: 18937
2.1 Overview
14
13
2
3
12
11
4
5
6
10
7
9
Picture 3: Overview of Aflow with optional pre-compaction

1
8
9
10
11
12
13
14
Height adjustable screws with plate

nuts
Display
Operator panel
Extrusion barrel
Specimen chute
Piston
Probe head
2
3
4
5
6
7
Pneumatic cleaning and pre-compaction option

Swivel handhold
Cleaning rod
Mains switch
Die holder
Extrudate cutter option
Keypad
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Technical manual
Testing system
CTA: 10660
2.2 Dimensions
Picture 4: Aflow dimensions
58
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Technical manual
Testing system
2.3 Technical data

Type ....................................................................................... Aflow extrusion plastometer
Item no. .................................................................................................... 032295, 032297
Nominal load Fnom ................................................................................................... 500 N
Dimensions:
Height ............................................................................................................ 1021 mm
Width ............................................................................................................... 580 mm
Depth ............................................................................................................... 596 mm
Weight, approx. ....................................................................................................... 114 kg
Test temperature ................................................................................. +50.0 to +450.0 C
Resolution of the temperature display ................................................................. <0.001 K
Time measurement:
Measuring system ..................................... Quartz stabilized electronic time generator
Measurement range ................................................................................... 0 to 99 min.
Resolution ......................................................................................................... 0.002 s
Error limit (Method B) ....................................................................................... 0.01 s
Extrusion barrel:
Diameter ......................................................................................................... 9.55 mm
Length .............................................................................................................. 170 mm
Standard dies according to DIN EN ISO 1133:
Diameter ....................................................................................................... 2.095 mm
Length .................................................................................................................. 8 mm
Piston:
Diameter ......................................................................................................... 9.48 mm
Weight ............................................................................................................. 0.159 kg
Space requirements:
Contact area to the floor ................................................................................. 78.5 cm
Footprint ....................................................................................................... 3,480 cm
Table loading:
In relation to the standard surface area ....................................................... 204 kN/m
With 50% safety ........................................................................................... 306 kN/m
Floor load:
Related to the footprint ..................................................................................... 5 kN/m
With 50% safety ............................................................................................... 8 kN/m
2.4 Operating data

Compressed air connection .............................................................................. 5 ... 10 bar
With recommended oil according to .............................................................. ISO 3448
Viscosity ......................................................................................................... 32 mm/s
Filtered, dehumidified and oiled
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Testing system
NOTE
The testing system must not be operated with unoiled, unfiltered or damp compressed air.
The compressed air's operating pressure must not exceed 10 bar.
2.5 Electrical connections

Power supply voltage .................................................................................... 220 ... 240 V
Cable assignments .............................................................................................. 1 L/PE/N
Power frequency ............................................................................................... 50 / 60 Hz
Power consumption (full load) ............................................................................... 0.6 kVA
2.6 Function description

-
Enter the test parameters via the keypad. You can read both of these inputs and the
temperature from the display.
Then fill the extrusion barrel with test material portion by portion. Compact it after
each portion has been filled.
Press the <START> button on the operator panel to begin the test.
The test load uses a piston to press the molten test material through a standardized
die.
The measurement values are recorded and kept ready for further processing.
NOTE
Control and evaluation can take place on a PC via the USB port.
2.7 Mechanical setup
NOTE
The parts coming into contact with the specimen material are freely accessible for
cleaning and can be easily exchanged.
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The testing system consists of

Basic housing with electrical components
Test chamber
A load unit with a variable speed drive for 0.325 kg up to 50 kg and travel
measurement
Optional extrudate cutter
Optional cleaning and pre-compaction
Technical manual
Testing system
2.8 Data backup

All parameter presets and determined measurement values are saved to the device
electronics for the current test.
NOTE
Always switch off the device electronics of the testing system using the <ON/OFF>
button. The device electronics saves the recorded values before switching off.
CTA: 10673
2.9 Interfaces
Picture 5: Interfaces
1
2
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Compressed air connection

USB connection
Mains supply
61
Technical manual
Testing system
Scales
The serial RS-232 interface X3 required for connecting an optional scale is found on the
rear side of the device electronics.
Data transmission
The recorded results are made available via the RS232 interface X2 (COM 0). They can
be called and processed.
The interface can be configured via the file "HOST.INI". The configuration is evaluated
after the input "COM=". The following is used as standard:
COM=9600,N,8,1
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Testing system
Data record setup

Number of characters
+ <CR> <LF>
Group
Meaning
Identification
6
6
6
Serial number
Specimen number
Number of extrudates
Density, input by the user
Density at test temperature
Total weight of the extrudates
MFR Average value
MVR Average value
Xi MFI (first value)
...
6
...
Xi MFI (last value)
Xi MVI (first value)
...
6
...
Xi MVI (last value)
10
10
6
6
6
6
Results
Detection
<ETX> <ETB>
The test data is transmitted in the following units:
MFR Values in: 10min x 100
Density in: cm x 100

cm
MVR value in 10min x 100

Weight in: g x 1000
Examples of an output:
+000000003
+000000223
+00005
+00548
+00000
+00000
+00535
+00991
+00535
+00536
+00535
+00534
5.2016 1006121
Serial number
Specimen number
Density at ambient temperature, preset
Density at test temperature, not determined
here
Total weight of the extrudates, not determined here
MFR Average value
MVR Average value
MFR value, 1st extrudate
MFR value, 2nd extrudate
MFR value, 3rd extrudate
MFR value, 4th extrudate
63
Technical manual
Testing system
+00535
MFR value, 5th extrudate
+00991
+00992
+00991
+00990
+00991
MVR value, 1st extrudate

MVR value, 2nd extrudate
MVR value, 3rd extrudate
MVR value, 4th extrudate
MVR value, 5th extrudate
End ID
2.10 Formulas
Melt Volume Rate (MVR)
MVR =
42, 7 x
in cm/10 min
Melt Flow Rate (MFR)
MFR =
42, 7 x x
in g/10 min
MFR = MVR x in g/10 min

Density PT (at test temperature)
=
=
42, 7 x
600
in g / cm
in cm
Formula characters used:

l
Length of the piston stroke in mm
t
Measurement time in sec.
PT
Specimen density in g/cm at test
temperature.
V
n
Volume of a single segment in

cm
Number of single extrudates
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Testing system
2.11 Statistical evaluation

The MFR or MVR values are evaluated statistically and the density is calculated.
The following formulas are valid for the statistical evaluation:
Average value
x S Units are xi
Standard deviation
1
1
1
S 2 S 2 Units are xi
Coefficient of variation
x 100 In percent
Conversion tables of the SI and English units
1mm =
1
in
25, 4
1in = 25, 4mm

32
1, 8
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Technical manual
Piston
3 Piston
CTA: 11788
3.1 Overview
Picture 6: Piston, with a radius of R0.4

1
2
3
4
Plate
Isolation
Upper reference mark = End of the
measuring range
Lower reference mark = Start of the
measuring range
5
6
A
B
Piston head
Piston
Diameter = 9.48 mm
Radius R = 0.4 mm
NOTE
The nominal mass of the piston is 159 g.
Type ......................................................................................................................... Piston

Item no. .................................................................................................................. 032298
Weight .................................................................................................................. 0.159 kg
Dimensions:
Nominal diameter, piston head ....................................................................... 9.48 mm
Radius, piston head ......................................................................................... 0.4 mm
Separation of the reference marks .................................................................... 30 mm
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3.2 Technical data
Technical manual
Piston
3.3 Intended use
The piston is suitable for fluorine-free plastics.
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Technical manual
Piston
3.4 Conditions
The piston is designed to the requirements of EN ISO 1133 for the following standards
and materials:
NOTE
Set the temperature and weight by entering the appropriate code in the <Material>
parameter.
Code
(letter)
Temperature
C
Nominal
load
kg
PS (Polystyrene)
200
5.00
PE (polyethylene)
190
2.16
PE (polyethylene)
190
0.325
PE (polyethylene)
190
21.60
PE (polyethylene)
190
5.00
PP (polypropylene)
230
2.16
230
5.00
220
10.00
ABS (acrylonitrile butadiene)
240
10.00
265
10.00
Standard Material
68
PP (polypropylene)
PS-I
200
5.00
E/VAC (ethylene/vinyl acetate)
150
2.16
190
2.16
125
0.325
SAN (styrene acrylonitrile resin)
rev
220
10.00
ASA (acrylic ester styrene acrylonitrile), ACS, AEDPS

ASA (acrylic ester styrene acrylonitrile), AEDPS
ASA (acrylic ester styrene acrylonitrile), AEDPS
rev
220
10.00
240
10.00
265
10.00
5.2016 1009190
ISO
1622-2
ISO
1872-2
ISO
1872-2
ISO
1872-2
ISO
1872-2
ISO
1873-2
ISO
1873-2
ISO
2580-2
ISO
2580-2
ISO
2580-2
ISO
2897-2
ISO
4613-2
ISO
4613-2
ISO
4613-2
ISO
4894-2
ISO
6402-2
ISO
6402-2
ISO
6402-2
Technical manual
Piston
Standard Material
Code
(letter)
Temperature
C
Nominal
load
kg
PC
300
1.20
ISO
8257-2
PMMA (polymethyl methacrylate)
230
3.80
ISO
8986-2
PB (polybutene)
190
2.16
ISO
8986-2
ISO
15876-3
ISO
9988-2
ISO
15494
ISO
10366-2
PB (polybutene)
190
10.00
PB (polybutene)
190
5.00
POM (polyoxymethylene)
190
2.16
PP (polypropylene)
190
5.00
MABS
rev
220
10.00
ISO
7391-2
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Technical manual
Automatic extrudate cutter
4 Automatic extrudate cutter

CTA: 11814
4.1 Overview
1
34
76
13
100
Picture 7: Overview of automatic extrudate cutter

1
2
3
Fixing plate
Screws
Screw
4
3
4
Blade
Limit switch
Housing

The automatic extrudate cutter cuts the extrudate automatically at time intervals or
manually at the touch of a button .
4.3 Technical data

Type ......................................................................................... Automatic extrudate cutter
Item No. ................................................................................................................. 032301
Dimensions:
Height ................................................................................................................ 76 mm
Width (including blade), approx. ............................................................... 134 100 mm
Depth ............................................................................................................... 133 mm
4.4 Intended use

The automatic extrudate cutter is used to cut off extrudates at extrusion plastometers.
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Weight ......................................................................................................................... 1 kg
Technical manual
4.5 Improper use
Cutting of cooled extrudates is not permitted.
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Technical manual
Die plug
5 Die plug
CTA: 21003
5.1 Overview
1
Picture 8: Overview of die plug

1
2
3
Return spring
Reset lever
Die mandrel
4
5
6
Blade
Release clutch

The die plug enables tests on liquid materials. It plugs the outlet from the extrusion barrel
during the pre-heat time, and thus prevents the material being tested from escaping. The
die plug is opened before the beginning of the test.
5.3 Technical data

Item No. ................................................................................................................. 032302
Maximum load ........................................................................................................ 21.6 kg
For the inner diameter of the die .................................................................. 1.0 ... 2.1 mm
Temperature range .............................................................................. +50.0 ... +450.0 C
Weight, approx. ........................................................................................................... 1 kg
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Type ...................................................................................................................... Die plug
Technical manual
Die plug
5.4 Intended use

The die plug is used solely for testing materials which have a high flow rate so as to
prevent premature extrusion of the test material during the pre-heat stage. It plugs the die
during the pre-heat stage.
5.5 Improper use

The die plug must not plug the die during measurements.
The die plug may be used only up to a load of less than 21.6 kg.
The die slide may only be pulled if the die plug is open.
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Technical manual
Separating pane
6 Separating pane
CTA: 10679
6.1 Overview
1
20
173
44
13
260
Picture 9: Overview of the separating pane

1
2
3
4
Hinge
Fixing on the testing system
Rear side
Side part
5
6
7
Magnetic lock
Grip
Movable front part
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5.2016 1009581
This protective screen is manufactured from a high strength, transparent material

(Plexiglass). It is mounted on the front of the testing system. The protective screen
provides protection against extrudates from falling down.
Technical manual
Separating pane
6.3 Technical data

Type ......................................................................................................... Separating pane
Item No.: ................................................................................................................ 032303
Material .............................................................................................................. Plexiglass
Dimensions:
Height, approx. ................................................................................................ 173 mm
Width, approx. ................................................................................................. 260 mm
Depth, approx. ................................................................................................. 200 mm
Material thickness ................................................................................................ 6 mm
Weight, approx. ........................................................................................................... 1 kg
6.4 Intended use

The separating pane must always be closed properly before a test can be conducted with
the testing system.
6.5 Improper use
Tests must not be run with the separating pane open, improperly closed, or defective.
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Technical manual
Cleaning and compaction unit
7 Cleaning and compaction unit

CTA: 10689
7.1 Overview
6
5
4
2
1
Picture 10: Overview of pneumatic cleaning and pre-compaction

1
2
3
4
Extrusion barrel
Cleaning and pre-compaction die
Swivel handhold
<Lower> button
5
6
<Mode change> button

Pneumatic cleaning and pre-compaction

The cleaning and compaction unit is designed for two different applications.
The cleaning and compaction unit is used to clean the extrusion barrel with cotton cloths,
which are supplied with the machine.
Compaction
The cleaning and compaction unit enables the material in the extrusion barrel to be
compacted.
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Cleaning
Technical manual
The compression force is factory set to a load limit of 70 kg. This load can be reduced
one time upon request. This force is used for both cleaning and compaction.
The variable pressure setting can be purchased as an option. This can be used to switch
between the cleaning and compaction loads via the <Mode change> button. You can set
the cleaning load, compaction load, and compaction time on the testing system's
electronics or in the testing software.
7.3 Technical data

Type .................................................................................... Cleaning and compaction unit
Item No. ................................................................................................................. 032304
Compression force .................................................................................................... 75 kg
7.4 Operating data
Compressed air connection .............................................................................. 5 ... 10 bar

With recommended oil according to .............................................................. ISO 3448
Viscosity ......................................................................................................... 32 mm/s
Filtered, dehumidified and oiled
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Test granulate
8 Test granulate
CTA: 10444
8.1 Overview
Picture 11: Test granulate

The test granulate allows errors such as wear, friction and contamination to be detected
quickly.
8.3 Technical data

Type ............................................................................................................ Polypropylene
Quantity .................................................................................................................... 0.5 kg
Storage conditions, dry at ....................................................................... +10 C ... +35 C
s* = standard deviation
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Density:
at 190 C ....................................................................................... 0.76 0.01 g/cm
at 230 C ....................................................................................... 0.74 0.01 g/cm
MFR:
190 C; 5 kg loading weight ................................................. 6.2 g/10 min; s* = 0.19
230 C; 2.16 kg loading weight .......................................... 3.17 g/10 min; s* = 0.10
MVR:
190 C; 5 kg loading weight ........................................... 8.12 cm/10 min; s* = 0.25
230 C; 2.16 kg loading weight ...................................... 4.31 cm/10 min; s* = 0.13
Technical manual
Test granulate
8.4 Intended use

The test granulate is used for quick checks of Zwick extrusion plastometers.
8.5 Range of application

190C
230C
Temperature tolerance
Pre-heat time tv
0.2 C
5 min
0.2 C
5 min
Approach path sv
55 mm
55 mm
Maximum measurement time tmax
25 min
25 min
Maximum measuring path lmax
20 mm
20 mm
Measurement begin at
50 mm
50 mm
Measurement displacement L
Filling quantity
2 mm
4.0 g
2 mm
4.0 g
Test temperature
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Index
9 Index
E
Electronic rating plate............................................. 55
S
Serial number plate
Large...................................................................56
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Figure index
10 Figure index
Electronic rating plate ................................................................................ 55
Picture 2
Serial number plate, large ......................................................................... 56
Picture 3
Overview of Aflow with optional pre-compaction ....................................... 57
Picture 4
Aflow dimensions ...................................................................................... 58
Picture 5
Interfaces ................................................................................................... 61
Picture 6
Piston, with a radius of R0.4 ...................................................................... 66
Picture 7
Overview of automatic extrudate cutter ..................................................... 70
Picture 8
Overview of die plug .................................................................................. 72
Picture 9
Overview of the separating pane ............................................................... 74
Picture 10
Overview of pneumatic cleaning and pre-compaction ............................... 76
Picture 11
Test granulate ............................................................................................ 78
Picture 1
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Figure index
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Table of contents
Table of contents
1
Introduction ........................................................................................................ 87
Requirements ..................................................................................................... 88
2.1
Transport ............................................................................................................ 90
3.1
General safety notes ................................................................................. 88

Testing system ........................................................................................... 90
Setup ................................................................................................................... 91
4.1
Testing system ........................................................................................... 91
4.1.1 Requirements for the installation site ........................................................ 91

4.1.2 Scope of delivery ....................................................................................... 92
4.1.3 Unpacking ................................................................................................. 93
4.1.4 Transportation lock .................................................................................... 94
4.1.5 Installing .................................................................................................... 95
4.1.6 Disposal of the packing material ............................................................... 97
4.1.7 Cleaning .................................................................................................... 97
4.1.8 Aligning the testing system ........................................................................ 98
4.1.9 Die holder ................................................................................................ 100
4.1.10 Specimen chute ...................................................................................... 101
4.1.11 Connections ............................................................................................ 102
4.1.12 Connecting to a PC ................................................................................ 103
5
Initial commissioning ...................................................................................... 107

5.1
Testing system ......................................................................................... 107
5.1.1 Inserting the die holder ............................................................................ 107

5.1.2 Inserting the die ....................................................................................... 108
5.1.3 Switching the testing system on and off .................................................. 109
6
Dismantling ...................................................................................................... 111

6.1
Testing system ......................................................................................... 111
6.1.1 Deinstalling the USB port ......................................................................... 111

6.1.2 Decommissioning .................................................................................... 112
6.1.3 Storing ..................................................................................................... 114
Index ................................................................................................................. 115
Figure index ..................................................................................................... 117
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Table of contents
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Introduction
1 Introduction
This manual contains important information and notes on transporting, installing,
dismantling, packing, and storing the testing system and its accessories.
The user manual must be read and used by all persons authorized to work on/with the
testing system as follows:
Transporting
Installing
Dismantling
Packing
Storing
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Requirements
2 Requirements
2.1 General safety notes
WARNING
Danger of explosion!
The testing system is designed for use in atmospheres which do not represent any
explosion hazards at all.
Never operate the testing system in potentially explosive atmospheres.
Consider the applicable regulations on explosion protection and the required zoning
at the installation site when assessing the explosion hazard.
Select a safe installation site that is not located in a potentially explosive atmosphere.
WARNING
Health risks for persons with active medical implants!
Electrical, magnetic and electromagnetic fields are produced when operating the testing
system. Active medical implants such as pacemakers, etc., can be impaired depending
upon the field strength. This can lead to health risks for the persons concerned. The
type and severity of the impairment depend on the features of the active medical
implants in use and on the frequency and type of fields produced.
Observe the safety values and permissible limit values for active implants as defined
in the standard E DIN VDE 0848-3-1. (E DIN VDE 0848-3-1: Safety in electrical,
magnetic and electromagnetic fields; protection of persons with active implants in the
frequency range of 0 Hz to 300 GHz)
Keep a safety distance of at least 0.40 m from the testing system.
WARNING
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Danger of injury through falling parts!

Falling parts can lead to serious injuries.
Use only appropriate and technically first class lifting tackle.
Use lifting tackle with sufficient lifting capacity.
Fix the individual parts and large assembly groups carefully with lifting tackle.
Secure the individual parts and large assembly groups with lifting tackle.
Ensure that the lifting tackle does not present any sort of danger.
Lift the individual parts and large assembly groups slowly.
Installation manual
Requirements
CAUTION
Risk of injury!
There is risk of injury when working on/with the testing system.
Observe all valid and binding national laws on accident prevention.
Observe the recognized technical rules for safety and correct working.
Observe the safety and health regulations pertaining to preparing and using working
equipment.
Observe national regulations such as accident prevention and environmental
protection.
Read the user manual in its entirety.
Read the user manual and data sheets for external components in their entirety.
Observe all safety notes in the user manual.
Observe all safety labels affixed to the testing system.
Wear suitable protective clothing at all times.
NOTE
The testing system is designed to comply with current applicable EMC guidelines.
The following safety regulations for EMC disturbances have been taken into
consideration when setting up the testing system with electronics:
Enclosed metallic housing, all sides
Screened leads
Connection of all devices and screens to ground
Star shaped reference conductor system
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Transport
3 Transport
3.1 Testing system
NOTICE
Transport damage!
Testing systems and their accessories could be damaged if thrown about, or if they are
subjected to impact or strong vibrations.
Transport testing systems and their accessories to the installation site in their original
packaging.
Ensure that the system is not thrown about or subjected to impact or strong vibrations
during transport.
NOTICE
Observe the center of gravity!
The center of gravity is not always in the middle of the packaging. The position of the
center of gravity is indicated on the packaging.
Note the information regarding the center of gravity on the packaging.
NOTE
Outer dimensions and weight of the packaging can be obtained from the dispatch papers
which are attached to the packaging.
NOTE
The scope of delivery can be found in the dispatch papers.
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Setup
4 Setup
4.1 Testing system
4.1.1 Requirements for the installation site
WARNING
Danger of explosion!
The testing system is designed for use in atmospheres which do not represent any
explosion hazards at all.
Never operate the testing system in potentially explosive atmospheres.
Consider the applicable regulations on explosion protection and the required zoning
at the installation site when assessing the explosion hazard.
Select a safe installation site that is not located in a potentially explosive atmosphere.
NOTICE
Protect the testing system from external influences!
The testing system is a highly sensitive measuring system. External influences could
limit the features of the testing system and negatively influence the test results.
Select an installation site that protects the testing system and makes it easily
accessible.
In order to achieve reproducible and precise measurement results, protect the testing
system from the following influences: jolts, oscillations, vibrations, shock, conducting
air, and corrosive contamination.
NOTICE
Observe clearances!
Inadequate clearances from obstructions can limit the operation of the testing machine.
The testing system must be easily accessible.
It must be possible to open doors, covers, and maintenance openings without
obstructions at all times.
Safety devices must always be freely accessible and be able to be operated without
impediments.
The minimum distance of the testing system to walls is 200 mm
NOTE
The power supply must be in the immediate vicinity of the testing system and be easily
accessible.
Location
This testing system should be on a table. Please pay attention to the table or floor loading
capacity. This information is listed in the section on technical data of the Technical
manual.
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Setup
4.1.2 Scope of delivery

CTA: 10700
The following is supplied as standard with the testing system:

1
4
5
18
17
16
15
14
13
10
12
11
Picture 1: Scope of delivery

1
2
3
4
5
6
7
8
9
Tool kit
Spirit level
Two die
Die cleaner
Receptacle for the cleaning cloths
Pneumatic hose
Replacement blade
Specimen chute
Spare fuse
10
11
12
13
14
15
16
17
18
Ring bolt
User manual
Connection cable
Cleaning cloths
Cleaning rod
Cleaning brush
Piston
Test granulate
USB cable
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Setup
4.1.3 Unpacking
Unpack testing system
1.
Check the packaging for damage.

Please contact the transport agent or Zwick immediately in case of transport
damage.
2.
Read the transport and unpacking instructions attached to the packaging.
3.
Open the packaging as specified in the transport and unpacking instructions.
4.
Compare the delivery with the bills of delivery for their completeness and for any
damage to the packaging units.
If you determine that the package contents are incomplete or damaged,
contact the transport agent or Zwick immediately.
5.
Remove the testing systems packaging as specified in the transport and unpacking
instructions.
The testing system is fixed to a pallet, and is protected against soiling and
corrosion by a sheet of protective film.
6.
Remove the protective film from the testing system.

The testing system is unpacked.
Unpack accessories
1.
Open the packaging with accessories.
2.
Remove the accessories.

Each accessory is contained in its own separate packaging.
3.
Remove the accessory parts from its packaging.
4.
Store the individual accessory parts in a safe place.
The accessory is unpacked.
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Setup
CTA: 10701
4.1.4 Transportation lock
Picture 2: Remove screws

1
Transport lock for the cleaning die
SW17 open-ended spanner
Remove the screws used for safety purposes with an SW 17 wrench.
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NOTE
The transport lock on the pneumatic cleaning and pre-compaction cleaning's die is not to
be removed until the assembly has been installed.
Installation manual
Setup
4.1.5 Installing
CAUTION
Risk of injury if testing system falls!
The testing system can become skewed if lifted. If the eye bolt is not screwed in tightly,
the testing system can fall and cause injuries.
Ensure that the eye bolt is screwed in tightly.
Wear suitable protective shoes.
NOTICE
Electrical, magnetic and electromagnetic fields
system. Although safety regulations have been observed during the setup of the testing
system and its electronics, electric, magnetic, and electromagnetic fields emanating
from the testing system can negatively impact the measurement results.
Place power cables spatially isolated from measurement leads.
Use twisted wire pairs for self-made measuring lines; each wire pair should be
separately shielded (screen mesh).
Shield the testing system from nearby substations, conductor lines, and HF
generators, such as induction ovens, welding equipment, etc.
NOTE
The testing system is designed to comply with current applicable EMC guidelines.
The following safety regulations for EMC disturbances have been taken into
consideration when setting up the testing system with electronics:
Enclosed metallic housing, all sides
Screened leads
Connection of all devices and screens to ground
Star shaped reference conductor system
NOTE
Pay attention to the weight of the testing system.
The weight of the testing system is specified in the User manual in the Technical manual
and on the packing of the testing system.
NOTICE
Risk of damage to the testing system!
Never lift the testing system from below with a forklift.
NOTICE
Risk of damaging the heating unit!
Do not hold at the heating unit.
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Setup
You can remove the testing system from the pallet using the eye bolt.
You can use different lifting devices to lift or align the testing system. Please see overleaf
for a description of how to do the above.
CTA: 10702
Possible lifting tackle:

Crane
Forklift
Other suitable lifting devices
1
2
96
Ring bolt for fixing to a crane, etc.

Do not hold at the heating unit.
3
4
Don not lift here with a forklift!

Lifting positions
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Picture 3: Lifting positions
Installation manual
Setup
4.1.6 Disposal of the packing material

The testing system's packing material can consist of the following materials:
Wood (transport pallets/support slats)
Palette box/cartons
Polyester cord tapes
Retaining tapes
Packing paper
Screws and nails
Polystyrene block
Fastening
VCI foil (volatile corrosion inhibitor)
PE foam foil
PE foil and PE molded parts
Ethafoam (white packing material for padding)
All existing items can be reintroduced into the material cycle by being recycled.
4.1.7 Cleaning
Clean the testing system
Soft cloth
1.
Free the testing system of all packing material.
2.
Remove the dirt or debris that has accumulated during transportation. Visible dirt
should be removed using a soft rag.
3.
Clean external components such as high temperature furnaces, temperature

sensors, control devices, high temperature extensometers, etc., as specified in the
user manuals for these external components.
The testing system is clean.
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Setup
4.1.8 Aligning the testing system

NOTICE
Danger of irreparable damage to the bubble spirit level!
The bubble spirit level can become irreparably damaged.
Align the testing system only if the extrusion barrel is at room temperature.
Place the bubble spirit level on the extrusion barrel only if the extrusion barrel is at
room temperature.
Align the testing system

The testing system must be in a secure position.
Round material < 6 mm or longer hexagon wrench key
Place the bubble spirit level on the cold extrusion barrel.
CTA: 10932
1.
2.
98
Bubble spirit level

Testing system
3
4
1
2
Lock nut
Leveling unit
Loosen each lock nut.
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Installation manual
Setup
Using the leveling elements, place the testing system level on the table so it is
absolutely horizontal. To do so, use the round material < 6 mm or longer hexagon
wrench key.
CTA: 10934
3.
1
2
Marking
Bubble (set incorrectly)
Bubble (set correctly)
The extrusion plastometer is correctly aligned when the bubble in the bubble
spirit level is within its markings.
4.
Turn the lock nuts until they are tight on the testing system.
Please make sure that all four 'feet' have contact with the table-top.
5.
Remove the bubble spirit level and store it in a safe place.
6.
Remove the transport lock on the cleaning and compaction unit.
The testing system is aligned.
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Setup
CTA: 10936
4.1.9 Die holder
Picture 4: Mount the die holder

Die holder
Mount the die holder

1.
Turn the die holder by hand until you can see the arrow on the die holder.
2.
Slide the die holder, with the arrow pointing upwards, into the testing system from
the right until it clicks into place.
The die holder is mounted.
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Setup
CTA: 10936
4.1.10 Specimen chute
Picture 5: Mounting the specimen chute

1
Specimen chute
Mounting the specimen chute

1.
Insert the specimen chute into the testing system from the front.
The specimen chute is mounted.
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Setup
4.1.11 Connections
CTA: 18938
The testing system is fully wired internally. You now only have to establish connection to a
PC or server, to a compressed air supply and to the power supply.
Picture 6: Connections
1
2

USB connection
Mains supply
Connecting to the mains supply

Connect testing system to the mains supply
1.
Plug the testing systems connecting cable into the mains supply.
The testing system is connected to the mains supply.
Connecting to compressed air

WARNING
Connect compressed air

1.
Connect the compressed air hose to the testing system.
2.
Check whether the compressed air hose is securely connected.
3.
Connect the other end of the hose to the compressed air supply outlet.
The testing system is connected to the compressed air.
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Risk of injury due to pneumatic hose whiplash!

The pneumatic hose can be whiplashed about and result in serious injuries.
Connect the pneumatic hose tightly to the consumer before you connect the
pneumatic hose to the compressed air supply.
Installation manual
Setup
CTA: 10720
4.1.12 Connecting to a PC
1
Testing system USB connection
NOTE
If the testing system has not yet been operated together with a PC, adhere to the
following sequence of steps.
Connect the testing system to the PC
The testing system and the PC are switched off.
1.
Connect the USB cable to the USB port on the PC and to the rear side of the testing
system.
The testing system is connected to the PC.
Install software
1.
Switch the PC on.

The PC is ready for operation.
2.
Switch the testing system on.

The LED illuminates green.
The dialog for installing the software appears on the PC monitor.
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CTA: 12479
Installation manual
Setup
3.
Select the <No, not this time> option field.

CTA: 12480
4.
Click on the <Next> button.
5.
Select the <Install the software automatically> option field.
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CTA: 12481
Installation manual
Setup
6.
Click on the <Next> button.

The name of the testing system is displayed.
CTA: 12482
The required drivers are being looked for and loaded when found.
7.
To continue with installation, click the <Continue installation> button.
The <Finish the wizard> dialog appears.
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CTA: 12483
Installation manual
Setup
8.
Select the <Finish> button.

Installation is finished.
NOTE
Simultaneous operation of several extrusion plastometers on a single PC (multi-start)
and/or at operation with creating voluminous data export files could lead to high amounts
of data traffic. In such cases we would suggest uploading the created files (test series/
export files) to a server or to an external hard disk.
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5 Initial commissioning
5.1 Testing system
WARNING
Risk of burns from hot parts of the testing system!
rod.
Always wear facial protection when observing the cutting procedure.
CAUTION
Risk of injury!
equipment.
protection.
NOTE
Work on the testing system may be carried out only by skilled electricians qualified for this
particular work.
5.1.1 Inserting the die holder

Please make sure that the die holder is correctly inserted.
The die holder must be inserted all the way into the testing system.
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CTA: 10600
5.1.2 Inserting the die
Picture 7: Die and extrusion barrel

1
Die
Extrusion barrel
Insert the die

1.
Insert the die (1) into the extrusion barrel (2) from the top.
The die must slip right down to the die holder.
2.
Check the die height in the <Running a test> input mask. Information on this is
found in the User manual.
The die is inserted.
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5.1.3 Switching the testing system on and off
CTA: 18938
The testing system is switched on via the mains switch. The mains switch is located on
the rear side of the testing system.
Picture 8: Mains switch at the rear

1
Mains switch
CTA: 17723
Electronics
Picture 9: Electronics
LED
<ON/OFF> button
Switch on device electronics

1.
Press the <ON/OFF> button.

The testing system device electronics are activated.
The LED next to the <ON/OFF> button lights up.
The testing system runs a self-test.
The testing system indicates that it is ready for operation after about three seconds,
and the main mask in which tests are run appears as well. Both the set and actual
temperatures are displayed.
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Switching off the testing machine

NOTICE
Risk of damage due to improperly switching off the testing system!
The testing system can be damaged if it is improperly switched off.
Switch the testing system off only when it is in the test position.
Before switching the testing system off, move the tower to the front test position.
Switch off testing system at device electronics

The testing system is in test position.
1.
Always switch the testing system off with the <ON/OFF> switch at the device
electronics (press and hold the button for 2 to 3 seconds).
This allows the device electronics to save the current data.
The device electronics is switched off.
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Dismantling
6 Dismantling
6.1 Testing system
6.1.1 Deinstalling the USB port
NOTE
The USB port for the Zwick testing system does not need to be deinstalled from the PC.
If the USB port should be deinstalled, adhere to the following sequence of steps.
To deinstall the USB port for the Zwick test system, proceed as follows:
1.
Click on <Start> in the Windows taskbar.

The start menu opens.
2.
Select <Control Panel> under Settings.

The file folder for the control panel appears.
3.
Choose the <System> setting.

The <System Properties> dialog appears.
CTA: 12515
4.
Select the <Hardware> tab.
5.
Click on the <Device Manager> button.

The <System Properties> dialog appears.
The name of the Zwick testing system is displayed.

6.
Select the testing system port <xxx COMx > by right-clicking on it with the mouse.
7.
Select <Deinstall>.
8.
Confirm deinstallation by clicking on <Ok>.

The USB port for the Zwick test system is deinstalled.
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Dismantling
6.1.2 Decommissioning
NOTICE

1.
NOTE
To maintain the <Automatic switching on> function, do not switch off the testing system
with the mains switch.
Switch off the test system
1.
Switch the testing system off via the mains switch.

The testing system is switched off.
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Dismantling
CTA: 10720
Terminating connections
Picture 10: Back side of testing system

1
2
USB connection
Mains supply
Disconnect
1.
Unplug the mains cable from the power socket.
2.
Then unplug the mains cable at the testing system.
3.
First unplug the compressed air hose from the compressed air supply.
4.
Then unplug the compressed air hose at the testing system.
5.
Any optional devices which may be connected to the testing system must also be
unplugged.
Unplug the USB cable to the PC if necessary.
The connections are disconnected.
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Dismantling
6.1.3 Storing
WARNING
with hot parts.
Before dismantling, allow all parts, including the extrusion barrel, cool to ambient
temperature.
Prepare for storage

1.
Extract the piston from the testing system.
2.
Remove the die from the testing system.
3.
Clean the piston.
4.
Clean the die.
5.
Clean the extrusion barrel.

The testing system is prepared for storing.
We recommend that you pack the testing system if you want to store it for a lengthy
period of time.
Pack testing system
1.
Use the original packing.
2.
Produce a packing list.
3.
Keep a copy of the packing list in a safe place.
4.
Pack the accessories individually.
5.
Place all accessories, the user manual, and the packing list for the testing system
on the pallet.
NOTE! Observe the storage conditions of the testing system and accessories as listed in
the installation manual in the chapter entitled Ambient conditions.
6.
Make sure there is sufficient ventilation or place a dehumidifier near the equipment.
Testing system and accessories are packed.
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Index
7 Index
A
Attention
Electromagnetic fields.........................................95
External influences..............................................91
Observe clearances............................................ 91
Observe the center of gravity..............................90
Transport damage...............................................90
D
Danger of explosion.......................................... 88, 91
Danger of irreparable damage
Bubble spirit level................................................98
Disposal.................................................................. 97
E
Electronics
Switch on.......................................................... 109
EMC
Guidelines..................................................... 89, 95
I
Installation site........................................................ 91
M
Material cycle.......................................................... 97
P
Packaging............................................................... 97
R
Recycling.................................................................97
Risk of burns
Dismantling........................................................114
from hot parts of the testing system..................107
Risk of damage
Switching off the testing system................ 110, 112
Risk of injury
Active medical implants...................................... 88
Safety measures......................................... 89, 107
Warning...............................................................88
T
Testing system
Cleaning..............................................................97
W
Warning
Risk of injury..................................................... 102
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Index
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Figure index
8 Figure index
Scope of delivery ....................................................................................... 92
Picture 2
Remove screws ......................................................................................... 94
Picture 3
Lifting positions .......................................................................................... 96
Picture 4
Mount the die holder ................................................................................ 100
Picture 5
Mounting the specimen chute ................................................................. 101
Picture 6
Connections ............................................................................................ 102
Picture 7
Die and extrusion barrel .......................................................................... 108
Picture 8
Mains switch at the rear .......................................................................... 109
Picture 9
Electronics ............................................................................................... 109
Picture 10
Back side of testing system ..................................................................... 113
Picture 1
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Figure index
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User manual
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User manual
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User manual
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User manual
Table of contents
Table of contents
1
Introduction ...................................................................................................... 123
General safety notes ....................................................................................... 124
Operational controls ....................................................................................... 126

3.1
Testing system ......................................................................................... 126
3.1.1 Operating field ......................................................................................... 127

3.1.2 Display and keypad ................................................................................. 128
3.1.3 Symbols ................................................................................................... 129
3.1.4 Actions for program control ..................................................................... 129
3.1.5 Mask windows ......................................................................................... 131
3.1.6 Navigating in the masks .......................................................................... 132
3.1.7 Mask overview ......................................................................................... 132
Mask <Main menu> ................................................................................. 134
Mask <File> ............................................................................................. 134
Mask <Manual test> ................................................................................ 135
Mask <Result display> ............................................................................ 138
Mask <System> ....................................................................................... 139
3.1.8 Parameters .............................................................................................. 141
3.1.9 Parameter mask <Manual test> .............................................................. 142
<Running a test> ..................................................................................... 143
<Heating/Load application> ..................................................................... 145
<Preheat> ................................................................................................ 146
<Measurement> ...................................................................................... 151
<Automatic.> ........................................................................................... 152
<End of test> ........................................................................................... 158
<Evaluation> ........................................................................................... 159
<Weigh the extrudates> .......................................................................... 163
3.1.10 <System> parameter mask .................................................................... 163
<Automatic switching on> ....................................................................... 163
<Select scale> ......................................................................................... 163
<Display> ................................................................................................ 164
<Adjustment> .......................................................................................... 166

<Date/Clock time> ................................................................................... 173
<Extrude material> .................................................................................. 173
<Settings reference> ............................................................................... 174
<Burning out> .......................................................................................... 175
<Diagnosis> ............................................................................................ 176
<Options> ................................................................................................ 176
<Device data> ......................................................................................... 176
3.2
Cleaning and compaction unit ................................................................. 177
3.2.1 Option for variable pressure setting ........................................................ 177
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Table of contents
Operating .......................................................................................................... 178

4.1
Testing system ......................................................................................... 178
4.1.1 Mechanical operation .............................................................................. 178

4.1.2 Switching the testing system on and off .................................................. 179
4.1.3 Force due to weight ................................................................................. 180
4.1.4 Problematic materials .............................................................................. 180
4.1.5 Carrying out a test according to the standard ......................................... 181
4.1.6 Running a test for precision measurement .............................................. 181
4.1.7 Cleaning .................................................................................................. 183
4.2
Die plug ................................................................................................... 185
4.2.1 Logging the die plug ................................................................................ 186

4.2.2 Closing the die plug ................................................................................. 186
4.2.3 Opening the die plug ............................................................................... 187
4.3
Separating pane ...................................................................................... 187
4.4
Cleaning and compaction unit ................................................................. 187
4.4.1 Swivel options ......................................................................................... 188

4.4.2 Compaction ............................................................................................. 189
4.4.3 Conducting a test .................................................................................... 190
4.4.4 Cleaning .................................................................................................. 191
5
Index ................................................................................................................. 194
Figure index ..................................................................................................... 195
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Introduction
1 Introduction
This manual contains important information and notes on operating the testing system
and conducting tests.
The user manual must be read and used by all persons authorized to work on/with the
Operating
Equipping
Troubleshooting during the work sequence
Disposing of production waste
Maintaining
Disposing of operating materials and auxiliary materials
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General safety notes
2 General safety notes

WARNING
Health risks for persons with active medical implants!
system. Active medical implants such as pacemakers, etc., can be impaired depending
upon the field strength. This can lead to health risks for the persons concerned. The
type and severity of the impairment depend on the features of the active medical
implants in use and on the frequency and type of fields produced.
Observe the safety values and permissible limit values for active implants as defined
in the standard E DIN VDE 0848-3-1. (E DIN VDE 0848-3-1: Safety in electrical,
magnetic and electromagnetic fields; protection of persons with active implants in the
frequency range of 0 Hz to 300 GHz)
Keep a safety distance of at least 0.40 m from the testing system.
WARNING
Danger of injury due to overriding functions of the safety devices!
Overriding functions of the safety devices can lead to serious injuries.
Never ever let the functions of safety devices be shut down or overridden.
Never carry out tests with overridden safety devices.
Never tamper with safety devices.
Adhere to all safety notes.
WARNING
rod.
Risk of burns due to hot test material!

The extruding and cut specimen material is extremely hot. When cut off, hot test
material can be propelled away. Contact with hot test material can cause burns.
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WARNING
Risk of injury through chemical reactions when heating the test material!
When heating the test material, strong chemical reactions could occur, such as the
formation of poisonous or aggressive vapors or splashing or gumming up of the test
material.
Take suitable measures to avoid bodily and/or material injury/damage.
Use an air exhaust system.
Always wear suitable protective clothing, including gloves and facial protection.
CAUTION
Risk of injury!
equipment.
protection.
NOTE
particular work.
NOTE
The testing system must be operated by only one person at a time.
The user's workplace is in front of the testing system during operation.
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3 Operational controls
3.1 Testing system
CTA: 18941
The testing system's operating functions are divided into three parts: mechanical
operation (mains switch), operator panel, and device electronics with display and keypad.
Picture 1: Operational controls

1
2
126
Mains switch
Electronics
Operator panel
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3.1.1 Operating field
CTA: 10968
The operator panel consists of five buttons. The left button controls the optional extrudate
cutter.
Picture 2: Operating field buttons

<STOP> button
Press this button to stop any motion and to switch the drive of the testing system off.
<START> button
Press this button to start the test or to start a sequence. Drive via the PC software is
only possible if this button was pressed beforehand.
<DRIVE UP> button
Press this button to drive the probe head upwards.
<LOWER> button
Press this button to drive the probe head downwards.
<CUT-OFF> button
Pressing this button enables an optional, automatic extrudate cutter to cut off the
extrudate and and release an optional die plug.
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3.1.2 Display and keypad

1
6
10
Picture 3: Electronics
1
2
3
4
5
Monitor
<ESC> button
<UP> button
<OK> button
Digit buttons
6
7
8
9
10
<ON/OFF> button
LED
Language swap
<DOWN> button
Action buttons
<ON/OFF> button
Press the <ON/OFF> button to switch the testing system's electronics on or off.
Press the button briefly to switch the system on. The LED illuminates. The device
electronics are switched on.
Press the button two to three seconds to switch the system off. The LED extinguishes.
LED
If the device electronics of the testing system are switched on, the LED illuminates.
Language swap
<UP> and <DOWN> button

The <UP> and <DOWN> buttons move the selected line (cursor) upwards or
downwards in the masks. The selected line appears inversely (white lettering with black
background).
<OK> button
Confirm the selection you made by pressing the <UP> and <DOWN> buttons.
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Press this button to change the language displayed. The order is German, English,
French, German ... .
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Use the button to move to the right-hand input side of the input lines and to return
following input.
<ESC> button
This button enables you to exit the screen or prevents acceptance of values.
Digit buttons
You can make numerical inputs via the numerical buttons.
The button <+/-> changes the leading sign.
Action buttons
Three action buttons are not always active. You can see the function you are currently
using on the display above the action buttons.
3.1.3 Symbols
Operation of the electronics takes place via different masks. These masks can be
accessed via the action keys. Active action buttons can be detected by the symbol above
them.
<Main menu>
Access the <Main menu> mask.
<File>
Call up the <File> mask. Display and continued selection of parameter set properties.
<Test definition>
Access the <Test definition> mask. Display and continued selection of test relevant
properties and parameters.
<System>
Access the <System> mask.

The mask makes it possible for you to set parameters for the testing system and
calibrate it.
3.1.4 Actions for program control

The program is controlled by the following actions; these actions allow the user to
alternate from one mask to another.
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<Acknowledgment>
This action button is used to acknowledge the selection or preset.
<Negation>
This action button is used to discard the input or the result and to quit the mask.
<Up>
This action button is used to go one page up on the screen.
<Down>
This action button is used to go one page down on the screen.
<Next mask>
This action button is used to to the next mask.
<Previous mask>
This action button is used to go one mask back.
<List field selection>
Call up selectable inputs as a list. In additional you can also use the number pad to
enter your inputs.
<Zero the load>
This action button sets the weight's load to zero, thus adjusting the weight.
The piston must be freely suspended!
<Single values>
Shows the determined single values.
<Results>
Shows the determined results.
<Statistics>
Switches to or toggles between different statistical results.
<Heating switched on>

This symbol shows that the heating is switched on, and that it heats up to the preset
temperature.
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Status indication
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Test-relevant action
This action enables to intervene in the test.
<End test>
This action button is used to end a currently running test.
It can also be done with the stop button.
3.1.5 Mask windows
CTA: 17723
The first mask appears a few seconds after the system switches on. The following is
displayed:
Type of testing system
The current version of the electronics software
Zwick Aflow
Version V1.0
Picture 4: First mask

The display changes to the <Ready for operation> mask after approximately five
seconds. The current time is displayed at the right of the uppermost line.
NOTE
A dot (period) is used as the decimal point.
CTA: 17771
The action buttons depict the actions which are currently possible.
Picture 5: Possible mask calls
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PC Operation
CTA: 17772
PC operation is shown on the monitor if the extrusion plastometer has been connected to
a PC and if the PC user program testXpert II has been started. The masks can be seen
on the electronics' screen, however inputs are not possible. The extrusion plastometer's
control is transferred to the electronics again after the testXpert II program has been
closed (Approx. 10 seconds after closing).
Picture 6: PC Operation
Simultaneous operation of several extrusion plastometers on a single PC (Multi-start)
and/or at operation with creating voluminous data export files could lead to high amounts
of data traffic. In such cases we would suggest uploading the created files (test series/
export files) to a server or to an external hard disk.
3.1.6 Navigating in the masks

<UP> and <DOWN> button
The <UP> and <DOWN> buttons move the selected line (cursor) upwards or
downwards in the masks. The selected line appears inversely (white lettering with black
background).
<OK> button
Confirm the selection you made by pressing the <UP> and <DOWN> buttons.
Use the button to move to the right-hand input side of the input lines and to return
following input.
<ESC> button
This button enables you to exit the screen or prevents acceptance of values.
To access the <Main menu> mask, press the right action button.
3.1.7 Mask overview

Operation of the testing system is made in the masks via the keypad.
Following is a quick overview of all available masks. A description of the respective
parameter is contained in the following chapters.
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<Main menu>
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Switch on
Mask <Ready for operation>
Set temperature
T = ...
s = ...
m = ...
<Start> button
Mask <Test>
Next paragraph :
T = ...
Remaining time = ...
Remaining travel = ...
Test time = ...
Total travel = ...
Action button <File>
Mask <File>
Parameter set, load
Parameter set, save
Reset the parameter
Mask <Manual test>
Mask <Manual test>
Running a test
Heating/Load application
Preheat
Measurement
End of test
Evaluation
Weigh the extrudates
Action button <Auto/Man.>
Mask <Automatic test>
Running a test
Heating/Load application
Automatic
End of test
Evaluation
Weigh the extrudates
Action button <Auto/Man.>
Mask <Manual test>
Action button <Results>
Mask <Result display>
MFR Average value
MVR Average value
Density
Total weight
Action button <System>
Mask <System>
Automatic switching on
Select weighing scales
Display
Adjustment
Date/Clock time
Extrude material
Reference drive
Burning out
Diagnosis
Options
Device data
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Mask <Main menu>
Picture 7: Mask <Main menu>

1
2
3
The heat is switched on.

Set temperature
Actual temperature
4
5
6
Symbol for mask <System>

Symbol for mask <Manual test>
Symbol for mask <File>
The preselected set temperature can be seen on the upper part of the screen. The
current actual temperature is displayed below the temperature.
The symbol for heating switched on appears in front of the set temperature when the
heating is switched on.
Mask <File>
Further masks for setting/saving parameter sets can be called in the <File> mask.
Mask <Load parameter set>
Mask <Save parameter set>

This mask enables a parameter set to be selected and from the list which appears, it also
enables your parameter settings to be saved.
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This mask enables a parameter set to be selected and loaded from the list which
appears.
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Mask <Reset the parameter>

The current parameter can be reset to the factory settings in this mask. Whereby a
question asking whether or not this function is required appears.
NOTICE
Possible loss of data!
This function deletes all of your entries.
Use this function with care.
Mask <Manual test>

Further test relevant masks can be called from this mask.
Mask <Running a test>

General files can be preset in this mask.
Extrudates are cut at time intervals when using method A. These extrudates have to be
weighed to calculate the MFR.
Method B calculates the extruded volumes or weights of material per 10 minutes. This
results in the MVR or MFR. The density at test temperature can be determined from the
volume and weight. If the density is known, The MFR can be determined without
weighing.
The extrudates can be cut off with an optional extrudate cutter. You must ensure that the
time between two extrudates is no less than 1 second.
Mask <Heating/Load application>
The test is carried out at a constant temperature and constant weight; these are defined
in the standards and depend on the material in use. To simplify the process material
designation letters are used that define both parameters. Working with these material
designation letters is optional.
If, for some reason, the temperature is not reached when the test starts, this appears.
The test can still be started.
If a single measurement indicates that the temperature has not been reached within the
valid limits, these values are identified in the report.
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Mask <Preheat>
NOTE
This mask appears only in manual mode.
After the test starts the material must be melted; at this time, the piston temperature
drops. The objective of the preheat process is to press as much material through the die
so that after the melting time, a position is reached which lies far enough before
measurement begin. This must ensure a constant outflow of material (conditioning phase)
with the weights that have now been applied correctly.
A variety of settings are required depending on the viscosity.
Mask <Measurement>
NOTE
The measurement starts at the specified position or time. Gage length or measurement
time is dependent upon the material and can be preselected. If a measured value is
outside of the tolerance, an additional measurement is made.
Mask <Automatic>
NOTE
This mask appears only in automatic mode.
The automatic function sets the preheat and measurement parameters automatically,
depending on the corresponding MVR. The setting is made using a table that contains
these parameters. You can edit this table via the PC.
If the determined parameters lead to the desired result, you should always used these
parameters. This helps you avoid a continual toggling back and forth.
If it is necessary to redetermine the parameters, you must restart the Automatic function.
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Mask <Test end>

Use this mask to enter the end criteria for the test and define actions for after the test.
The end of measurement can be restricted in terms of time and/or per position. You can
decide if the remaining material should be automatically extruded after the test.
In general, a cooled piston is harder to clean than a heated one. Therefore you should
drive the piston automatically from the extrusion barrel only if you have time to
immediately clean the piston.
The best way to clean the die is if, when the piston approaches the die, the extrudate
cutter makes a cut at the same time. This ensures that the upper and lower surfaces of
the die are clean. Approaching the die can be damaging to filled material; for this reason
you can enter a desired distance.
Mask <Evaluation>
The result memory allows you to view the results of a test with multiple measurements.
The measurements of the test are prepared statistically.
Various standards use active piston areas that differ slightly (71.0 mm or 71.2 mm). As a
result, the calculation factor differs (426 or 427). You can select this and freely-definable
factor here.
Mask <Weigh the extrudates>
You must place and weigh extrudates together on the scale. The number of extrudates
can be changed should one of them no longer be available. It is possible to evaluate each
individual extrudate with density results only in connection with the PC program.
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Mask <Result display>

You can look at the determined results here following a correctly finalized test.
The following is displayed as results:
MFR Average value
MVR Average value
Density
Total weight
<Single values>
Press the left hand action button <Single values> to get a mask with a display of the
determined single values MFR and MVR .
<UP> and <DOWN> buttons
The display of a screen page can be scrolled via the <UP> and <DOWN> action
buttons.
<Statistics>
Press the <Statistics> middle action button to get a mask with a display of the calculated
statistical values for the individual values MFR and MVR from a test. The display shows
the number of measurements used for calculating the statistics.
Result display of deviations

The temperature and load is determined during measurement and compared to the
presets. Deviations are displayed in the result display if resulting deviations have been
exceeded/undershot. The characters in front of the result indicate:
~
<
>
#
(Value)
The temperature was too high or too low during measurement

The temperature was too low during measurement
The temperature was too high during measurement
Exact load control was not possible as the material behavior was too
instable.
The measurement is an outlyer and is not included in the statistics, a
substitute measurement (extrudate cut) is made.
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Example of a result display

Single values
No.
1
2
3
4
5
MFR
g/10'
MVR
< 1.71
1.99
(2.12)
1.97
1.79
< 2.50
2.53
(2.30)
2.84
2.66
cm3/10'
Statistics
m=4
x
s
v
MFR
1.96
0.23
10.25
MVR
2.68
0.28
8.25
Mask <System>
Further masks can be called up from this mask.
Mask <Automatic switching on>

The time and the day of the week when the testing system should be automatically
switched on again can be entered in this mask. The testing system is switched off when
this mask is activated. It will then switch on again at the preset time.
Mask <Select weighing scale>

Connected weighing scales are determined in this mask. The scale must be connected to
the PC in PC operation!
Mask <Display>
The units for the current display are set in this mask. You can also influence the display
on the screen.
Mask <Adjustment>
Adjustment of the device can be made in this mask. The set values can be protected by a
password.
Mask <Date/Clock time>

You can adjust the date and the time in this mask.
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Mask <Extrude material>

Remains of material are left in the extrusion barrel after a measurement has been made.
Here you can preset how the material is to be extruded.
Mask <Reference drive>

The travel measurement path relates its position to the upper edge of the die. The path
reference can be readjusted at the reference drive.
Mask <Burning out>

An extremely fine film could cover the surfaces of the die bore after the tests. Removing
the film through burning out can be preselected here to remove the film.
Mask <Diagnosis>
This mask serves to display the controller values as well as the inputs and outputs for
error search.
Mask <Options>
The device configuration mask enables optional auxiliary functions to be selected/
deselected.
Mask <Device data>

The device-dependent data and versions can be viewed in this mask.
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3.1.8 Parameters
The following diagram shows the different parameters available for the test sequence.
It is followed by the parameter description for the different masks.
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Picture 8: Travel-time diagram of a test

Test start
Start measuring
End of measuring
Upper test ring
Lower test ring
Remaining material
Die
Travel zero-point
Test material (not melted)
Extrusion barrel
Piston
Pre-heat position
sM Measurement begin position

ds Measurement travel (length of an
extrudate)
se End of the measurement displacement
tv Pre-heat time
tk Conditioning time
tM Time up to measurement begin
dt Measurement time (length of an extrudate)
tm Measurement
te Maximum duration (Test)
3.1.9 Parameter mask <Manual test>

Further test relevant masks can be called from this mask.
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2
3
4
5
6
7
8
9
10
11
sv
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<Running a test>
This mask enables data referring to the specimen, e.g. the density, to be preset.
<Method>
Two methods, A and B, are available for selection.
Method A
Method A is to test by weighing the extrudates per unit of time; the result is the MFR.
The interface for the weighing scale can be defined under System in the Select
scales mask when PC mode is not being used. Thus enabling the specimen masses
to be accepted directly after the end of test. Weighed extrudates can be entered
manually after the end of testing if weighing scales are not connected.
Method B inclusive of A
is to test with travel recording, possibly with weighing, as in method A. Method B
inclusive of A is a measurement procedure with which the volume over the
measurement path is determined, and is calculated together with the measurement
time for MVR. MFR can be calculated if the extrudates are weighed.
<Density>
Describes the ratio of the mass to volume (or MFR to MVR). The known density at test
temperature enables conversion from MVR to MFR.
The known value at test temperature is entered here as g/cm. The density at test
temperature can also be determined from MFR and MVR.
NOTE
The following two parameters appear only if method B inclusive of A for the Running a
test parameter is selected (each and every extrudate must be cut for method A).
<Cut>
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Extrudates are not cut off. However, the optional die plug is open.
Cut-off
Cut-off is made at the beginning of and after each measurement. Measurement
must, however, be made for at least one second.
Measurement begin
Only one cut-off is made at the beginning of measuring.
Begin+end
The extrudate is cut off only at the start and end of measurement.
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<Weigh the extrudates>

The following parameter is also displayed if this parameter is selected.
Enter the required number of extrudates.
Total weight
Only the total weight is adopted by the evaluation if this parameter is selected.
Deselect this parameter if you want to weigh each extrudate separately.
NOTE
The following three parameters appear only if the option Pneumatic cleaning and
compaction device has been purchased together with the option Cleaning unit.
<Compaction time>
Enter the duration here with which the compaction load is to act on the test material.
<Compaction load>
Enter the compaction load at which the material is to be pre-compacted after it has been
placed in the extrusion barrel.
<Cleaning load>
Enter the load here with which the extrusion barrel is to be cleaned.
NOTE
The following parameter is always at the last position in this mask.
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<Height of the die>

NOTICE
Risk of damage due to improper insertion of the die height!
Please make sure that the actual die height coincides with that of the input height,
otherwise there is a high risk of the piston colliding with the die. This would lead to
malfunctioning.
Ensure that the die height is entered correctly.
Select the height of the currently installed die The following die heights are available:
4 mm
8 mm (always required for the reference drive)
25.4 mm
NOTE
The testing system is protected from a load that is too high by the downward-driving
piston
<Heating/Load application>
This mask enables presets and settings with respect to the test temperature and the
loading weight to be made.
<Test conditions>
The material code found in EN ISO 1133 can be selected here. The selected material
code sets the temperature and the loading weight.
The material codes are found in the standard. These are listed for you in the Technical
manual in the description of the piston in the section on conditions.
<Loading weight>
You can select or enter the load weight to be used here. Selection of the material code for
the <Method> parameter sets the correct loading weight according to the pertinent
standard.
The standardized loading weights are available here.
<Set temperature>
Pre-selection of the set temperature for the heating control. The temperature preselection is limited to a maximum 450 C (842 F). Selection of the material code for the
Test conditions parameter sets the correct set temperature according to the pertinent
standard.
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<Temperature monitoring>
Select the checkbox to activate temperature monitoring during measurement. The
<Maximum deviation> parameter appears.
NOTE
The following two parameters appear only if the Temperature monitoring parameter is
selected.
<Maximum start deviation>

The permitted temperature deviation at the start of test can be entered here. A message
is generated if the temperature monitoring is overshot at the start of measurement. You
can confirm this message as having been read by choosing <Acknowledge>; the test is
then started. Cancel the test by pressing the <ESC> button.
<Maximum deviation>
You can enter the permitted temperature deviation during measurements here.
<Heating>
Activate the heating by selecting this checkbox.
Heating is also automatically activated if you enter a value in temperature adjustment and
approach this temperature value.
<Preheat>
NOTE
The Preheat mask offers various combinations. These are shown at the end of the
parameter description for this mask.
<Control Preheat>
The mode can be used to select whether a minimum load of 325 g or zero-load should be
used.
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This mask enables presets and settings with respect to the times, paths and loadings
before measurement to be made.
Preheating is melting test material. The conditioning time with the test weight begins
when this phase has finished.
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<Pre-heat End>
You can define the pre-heat end here.
<Pre-heat time tv>

This is the time of initial melting.
Enter the minimum time here which must be strictly adhered to. The input is made in
seconds or minutes. The pre-heat time begins at the start of test.
<Pre-heat pos. sv>

You can enter the position at which conditioning is to begin here. The input can be either
in millimeters or inches.
<Load at start>
If you select the parameter, the test weight will immediately be applied at the start of test.
If you deselect the parameter, the machine waits with minimal load until the preheat time
has expired
<Dev. pre-heat load>

Another parameter, Preheat load, is offered when the above is selected. The test weight
is not used for loading in this case, but rather the value entered for the Preheat load
parameter.
<Preheat load>
Enter the load which is to be applied for the preheat phase here.
NOTE
The following parameters appear if the Die plug option has been purchased and activated
in the mask <Options>:
<Die plug>
The optional die plug is automatically removed after the preheat time if and when this
parameter is selected. When using a die plug, ensure that a stop time is entered for the
preheat time. This is because it may never be possible to reach the Travel end.
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Possible combinations
The following lists the various possible combinations if "Mode 1" is selected for the
<Control Preheat> parameter:
Control Preheat
Preheat End
Pre-heat time tv
Preheat pos. sv
dev. Preheat
load
Mode 1
Pos./Time
sec
mm
No
The test load is used up to the preheat position sv and is then unloaded until the preheat
time tv has expired.
Finally, conditioning with the test load is begun.
Control Preheat
Preheat End
Preheat time tv
Pre-heat pos. sv
dev. Preheat
load
Mode 1
Pos./Time
sec
mm
x kg
The entered preheat load is used up to the preheat position sv and is then unloaded until
the preheat time tv has expired.
Control Preheat Mode 1
Preheat End
Time
Pre-heat time tv sec
Die plug
Waiting without load is made here until the preheat time tv has expired
Then conditioning with the test load begins. The die plug is opened now if it has been
activated.
Pre-heat End
Pos
Pre-heat pos. sv mm
Drive carefully to the pre-heat position at the test load.

(generally not meaningful)
Control Pre-heat
Preheat End
Pre-heat pos. sv
dev. Preheat
load
Mode 1
Pos
mm
x kg
Drive carefully to the preheat position sv at the entered test load.
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The following lists the various possible combinations if "Mode 2" is selected for the
<Control Preheat> parameter:
Control Preheat
Preheat End
Pre-heat time tv
Preheat pos. sv
Load at start
Mode 2
Time/Pos
sec
mm
No
Drive carefully to the preheat position sv at 325 g,

or
Drive with 325 g is used until the preheat time tv has expired.
Control Preheat
Preheat End
Pre-heat time tv
Preheat pos. sv
Load at start
dev. Preheat
load
Mode 2
Pos./Time
sec
mm
Yes
No
The test load is used up to the preheat position sv and then with 325 g until the preheat
time tv has expired.
Control Pre-heat
Pre-heat End
Pre-heat time tv
Pre-heat pos. sv
Load at start
dev. Pre-heat
load
Mode 2
Pos./Time
sec
mm
Yes
x kg
The entered pre-heat load is used up to the pre-heat position sv and then with 325 g until
the pre-heat time tv has expired.
Control Preheat
Preheat End
Pre-heat time tv
Load at start
Die plug
Mode 2
Time
sec
No
Drive with 325 g is used until the preheat time tv has expired.
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Finally, measurement is begun with the test load. The die plug is opened now if it has
been activated.
Control Preheat
Preheat End
Pre-heat time tv
Load at start
dev. Preheat
load
Mode 2
Time
sec
Yes
No
Die plug
The test load is used until the preheat time tv has expired.
Finally, conditioning with the test load is begun. The die plug is opened now if it has been
activated.
Control Preheat
Preheat End
Pre-heat time tv
Load at start
dev. Preheat
load
Die plug
Mode 2
Time
sec
Yes
x kg
The entered preheat load is used until the entered preheat time tv has expired.
Finally, conditioning with the test load is begun. The die plug is opened now if it has been
activated.
Control Preheat
Preheat End
Pre-heat pos. sv
Load at start
Mode 2
Pos
mm
No
Drive to the preheat position sv at 325 g.

Mode 2
Pos
mm
Yes
No
Control Preheat
Preheat End
Pre-heat pos. sv
Load at start
dev. Preheat
load
Drive carefully to the preheat position at the test load.

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Preheat End
Pos
Pre-heat pos. sv mm
Load at start
Yes
dev. Preheat
x kg
load
Drive carefully to the preheat position sv at the entered test load.
<Measurement>
This mask enables presets and settings for the measurement to be determined.
<Measurement begin>
This parameter is used to select the type of measurement begin. The selection
possibilities position, i.e. die distance and time are available.
<Pos. measurem. begin>

NOTE
The following parameter appears only if <Position> is selected for the <Measurement
begin> parameter.
Use this parameter to define the measurement begin in relation to the travel. This is
denoted by sM in the travel time diagram of the test.
<Time measurem. begin>

NOTE
The following parameter appears only if <Time> is selected for the <Measurement begin>
parameter.
Use this parameter to define the measurement begin in relation to the time. This is
denoted by tM in the travel time diagram of the test.
<Number of extrudates>
Enter the number of single extrudates which are to be determined here. The permitted
deviations are to be entered in the parameter "Deviation Average value" in the mask
"Evaluation". The program checks the individual extrudates for the input tolerance
deviation. Invalid extrudates are discarded and are replaced by new extrudates. Example:
You entered 5 extrudates and the program detected 2 deviations. This results in 7
extrudates being made and 5 valid extrudates being evaluated.
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<Measurement>
This parameter is used to select the type of measurement. The selection options
<Position>, i.e., travel-related, and <Time> are available.
<Measurement travel>
NOTE
The following parameter appears only if <Travel> is selected for the <Measurement>
parameter.
Enter the length of the single measurements here.
<Measurement time>
NOTE
The following parameter appears only if <Time> is selected for the <Measurement>
parameter.
Enter the measurement time of the single measurements here.
<Automatic.>
Use this mask to define the presets and settings for pre-heating and measuring. The
automatic function defines the best possible parameters according to the sample. All
subsequent tests are conducted in manual mode using these parameters. If you want to
redetermine the parameters, you must restart the automatic function.
<Automatic mode>
The settings according to the following test standards can be made with this parameter.
ISO 1133 (MR)
ISO 1133 (AC)
ASTM D 1238
The corresponding parameters are occupied with the presets from the test standards.
Meaning of the abbreviations:

MR: there is a high number of measurements.
AC: Measurement takes place to the greatest accuracy.
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The presets are in three separate tables.

Structure of automatic tables:
NAME=
PREHEATPOS=
STARTPOS=
STARTTIME=
MAXSTARTTIME=
STABILIZETRAVEL=
SABILIZETIMEL=
MVR
Cuts
Channel
Value
Example:
NAME=ISO1133
PREHEATPOS=56.0
STARTPOS=50.0
STARTTIME=330.0
MAXSTARTTIME=360
STABILIZETRAVEL=9.0
SABILIZETIMEL=60.0
MVR
Cuts
Channel
0.4;
5;
1;
1.0;
5;
0;
20.0;
6;
0;
9999; 5;
0;
Value
240.0
2.0
5.0
10.0
Lines used:
The MVR determined shortly before measurement is compared to the MVR column. The
corresponding line is then used.
Example: The second line is used if an MVR of 0.8 has been determined.
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Meaning of the rows:

Name=
Name of the file; this text is provided as the name for the <Automatic> parameter.
PREHEATPOS=
Position (mm) at which the test load is lifted.
STARTPOS=
Position (mm) at which the measurements starts
STARTTIME=
The preheat time in seconds (melting time)
MAXSTARTTIME=
Latest possible time (sec.) at which measurement starts The position of the piston is
of no importance.
STABILIZETRAVEL=
Position (mm) at which the start position should be reached.
STABILIZETIMEL=
Time (sec) at which the start time should be reached.
Input under MVR
This row is used for the control up to the entered MVR. Note the following example.
Input under Cuts
Number of measurements which are to be made (extrudates)
Input under Channel
Input 1 is the time pre-selection.
Input 0 is the travel pre-selection.
Input under Value
Value of the type of preset set for the channel
The semicolon (;) is the delimiter between the inputs.
A maximum of 10 lines can be preset.
Contents of the preset tables:
Value
1.0
1.5
5.0
2.0
NAME=ISO1133(MR)
PREHEATPOS=56.0
STARTPOS=50.0
STARTTIME=300.0
MAXSTARTTIME=750
STABILIZETRAVEL=4.0
SABILIZETIMEL=60.0
MVR
Cuts
Channel
10.0;
30;
0;
25.0;
20;
0;
100.0; 6;
0;
9999; 3;
1;
NAME=ISO1133(AC)
PREHEATPOS=56.0
STARTPOS=50.0
STARTTIME=300.0
MAXSTARTTIME=750
STABILIZETRAVEL=4.0
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SABILIZETIMEL=60.0
MVR
Cuts
Channel
Value
0.4;
1.0;
20.0;
9999;
5;
5;
6;
3;
1;
0;
0;
0;
240.0
2.0
5.0
10.0
NAME=ASTM D 1238
PREHEATPOS=54.0
STARTPOS=46.0
STARTTIME=420.0
MAXSTARTTIME=750
STABILIZETRAVEL=8.0
SABILIZETIMEL=120.0
MVR
Cuts
Channel
10.0;
3;
0;
9999; 1;
0;
Value
6.35
25.5
Creating your own automatic test

You can create your own automatic tests and use these specifications to control the
testing system. For this purpose you need a PC with USB connection to the testing
system, the PC program DVToolSuite and an editor.
The DVToolSuite is to be found on the supplied testXpert II DVD.
The above enables up to a maximum of four tables to be created. The files must have the
following names:
USER1.DAT
USER2.DAT
USER3.DAT
USER4.DAT
NOTE
Save your created file under one of the four allowed file names.
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DVToolSuite
Install table
To install a table the extrusion plastometer must be connected to the PC.
The supplied testXpert II DVD contains a program for updating.
Switch the PC and the extrusion plastometer on.
2.
Insert the testXpert II DVD in the DVD drive.
3.
Go to the following directory: <\Support\DVToolSuite\>
4.
Call the program <DVToolSuite.exe>
5.
Click the <Download File...> button in the dialog.
CTA: 11099
1.
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Select the file you created, for example <USER1.DAT>.
7.
Click the Open button.

The file will then be transferred.
8.
Switch the testing system off with the On/Off switch. Switch the testing system on
again with the ON/Off switch after about three seconds.
CTA: 11101
CTA: 11100
6.
The data has not been taken over.

Sample file <USER1.DAT>:

Name=TestLab
PREHEATPOS=56.0
STARTPOS=50.0
STARTTIME=300.0
...
You can select this information in the<Automatic> parameter
ISO 1133 (MR)
ISO 1133 (AC)
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ASTM D 1238
Test laboratory
CTA: 11102
Additional DVToolSuite functions
Any files which have been saved to the extrusion plastometer can be viewed in the
DVToolSuite program. The <Upload File> and <Delete File> buttons are now released for
access. We have depicted one of many possibilities here.
<Upload File> button
The selected files can be uploaded to your PC via this button. Then you can further
process or edit the files. . The <Download File> button enables the processed files to be
copied back to the extrusion plastometer. New files can first be used after the extrusion
plastometer has been switched on anew.
<Delete File> button
The selected files can be deleted from your extrusion plastometer's memory with this
button. The files are neither copied to the PC nor saved to anywhere else. Files deleted
by the <Delete File> button no longer exist!
The range limits for measuring can be entered in this mask.
<Monitor measurement travel>

The next parameter, End of measurement travel, appears by selection of the checkbox.
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<End of test>
User manual
<End of the measurement travel>

Measuring ends when this travel has been reached, regardless of whether or not the
required number of extrudates have been successfully determined or not.
<Monitor the duration>

The next parameter, Max. duration, appears by selection of the checkbox.
<Maximum duration>
Measuring ends after this time has expired, regardless of whether or not the required
number of extrudates have been successfully determined or not.
<Piston Drive up>

The piston is automatically driven upwards at the end of test if the checkbox is selected.
<Extrude>
If you select the checkbox
any remaining material is pressed out of the extrusion barrel after the end of test.
the next parameters become visible.
<Extrusion load>
Any remaining material is extruded out of the extrusion barrel using the load entered
here.
<Extrusion up to Pos.>
If the checkbox is deselected
the machine drives to die contact.
If the checkbox is selected

the machine drives to a certain die distance (die extrusion position).
the next parameter becomes visible.
<Extrusion position>
Enter the position to be reached here. This value refers to the distance to the die's upper
edge.
<Evaluation>
The type of evaluation is determined here.
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<Outlier test>
Use this parameter to select or suppress the outlier test.
None:
Test does not take place.
Deviation:
A deviation test is conducted.
NOTE
The following parameter appears only if <Deviation> is selected for the <Outlier test>
parameter.
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<Average value deviation>

The permissible deviation (tolerance) from the average value can be entered here for
calculation. All deviating single measurements are repeated.
Example for MVR determination:
Entries:
<Average value deviation> of 3%
<Number of extrudates> 5
Results of the first calculation:
No.
1
2
3
4
5
Average value of 5 extrudates
Permitted upper deviation at 3%
Permitted lower deviation at 3%
MVR
g/10'
1.81
1.99
2.06
1.97
1.94
1.95
2.01
1.90
The results of the first and third extrusions are not included in the preset tolerance
(Permissible deviation). The strongest deviating result (1.81) is eliminated from the
results.
Tolerance violators are marked with the characters ().
An additional extrudate is determined if the first extrudate has dropped out of tolerance.
Results of the second calculation:
No.
1
2
3
4
5
6
Average value of 5 extrudates (no. 2, 4, 5
and 6):
Permitted upper deviation 3%
Permitted lower deviation 3%
MVR
g/10'
(1.81)
1.99
2.06
1.97
1.94
1.92
1.98
2.04
1.92
The result of the third extrusion is not included in the preset tolerance (permissible
deviation).
A new extrudate is determined when an extrudate has dropped out of tolerance.
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Results of the third calculation:

No.
MVR
g/10'
1
2
3
4
5
6
7
Average value of 5 extrudates (no. 2, 4, 5,
6 and 7):
Permitted upper deviation 3%
Permitted lower deviation 3%
(1.81)
1.99
(2.08)
1.97
1.94
1.92
2.01
1.97
2.03
1.92
The 5 extrudates, which are within the allowed deviation, are now determined for the
result according to the preset .
The single measurements are repeated until either all results are within the preset
tolerance, or until an end criteria has been happened. The tolerance presets must be
adapted accordingly for strongly fluctuating results for the tested material.
<Calculation factor>
A selection for MVR is offered here.
ISO (427.0)
ASTM (426.0)
User def.
(This factor contains the relevant piston cross-section and 600 seconds.)
The melt volume-flow rate (MVR) will be calculated with this test standard preset.
Customized or deviating calculation presets can be entered in the following parameter by
selecting Customized.
NOTE
The following parameter appears only if <Customized> is selected for the <Calculation
factor> parameter.
A customized factor for calculation of the melt mass-flow rate (MFR), the melt volumeflow rate (MVR), and the density can be entered here.
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<User factor>
User manual
<Weigh the extrudates>

Enter the number of extrudates to be weighed in this mask.
Press the corresponding button to transfer data to the scale (for example the <Print>
button).
<Number of extrudates>
Determine the number of extrudates which are to be weighed here.
3.1.10 <System> parameter mask

Further system related masks can be called from this mask.
<Automatic switching on>

We recommend automatic switching on if the testing system is being used neither
overnight nor over the weekend (energy saving) so as to keep it tempered for the
beginning of the working week.
Switch the testing system off by activating the <Acknowledgment> action button after
the day of the week and the time have been entered. It will then switch on again at the
preset time.
Switching on before the set time can be done at any time with the <ON/OFF> button.
<Weekday>
The day of the week can be entered here. The following selection possibilities are
available:
<For each>:
The testing system is automatically switched on at the entered time every day.
<Weekday>:
The testing system is automatically switched on at the entered time on that day
which has been preset here.
<Switch-on time>
Enter the time here at which automatic switching on is to take place.
<Select scale>
Connected weighing scales are determined in this mask.
You can select between
<No scale>
<Kern ABS>
<Mettler>
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<Display>
The units for the current display are set in this mask. You can also influence the display
on the screen.
<Temperature unit>
The temperature unit for display and for the results can be set here.
The following selections are available:
<C>: Celsius
<F>: Fahrenheit
Conversion:
C =
F 32
1.8
F = C * 1.8 + 32
<Travel units>
Enter the travel units for the display here.
<mm>: Millimeters
<in>: inch
Conversion:
1 in = 25.4 mm
1mm = 1 / 25,4 in
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<Force unit>
Enter the force unit for the display here.
<N>: newton
<kg>: kilogram
<lbf>: Pound force
<lb>: Pound
Conversion:
1 N = 0.1020 kg
1 N = 0.2248 lbf
1 kg = 9.80665 N
1 kg = 2.2046 lbf
1 lbf = 4.4482 N
<Hide low load>

Selection of the checkbox means that the weight of the piston is not displayed.
<Illumination>
The background lighting of the screen can be switched on and off here.
-
<on>: the illumination is switched on

<off>: the illumination is switched off
<Contrast>
The screen's contrast can be altered here. A number between 1 and 10 can be selected
in the list field. The higher the number the darker will the screen be.
<Screen saver>
This function is activated by selection of the checkbox. Finally, the screen's lighting is
switched off after a waiting time.
NOTE
The waiting time parameter appears only if the screen saver parameter is selected.
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<Waiting time>
This parameter is used to enter a period of time after which the screen saver will be
activated.
<Adjustment>
The adjustment factors are split up into
-
ZwickService functions that are protected by a Zwick password

User functions that are optionally protected by your password
Masks that contain only displays (calibration) and do not contain adjustment.
<New password>
Passwords protect your machine's specific settings against unauthorized use.
The password protects the inputs in the user masks. A password is not entered as
standard for the initial commissioning. The Zwick masks are only accessible for
ZwickService.
Passwords are entered via the numerical buttons. Whereby the <Dot> button and the
<Plus/Minus> buttons are available.
Enter and change password for the first time
1.
Access the <New password> mask. You will be prompted to enter a new password
2.
Enter a numerical combination which is only known to yourself.
3.
Finalize the input with <OK>.

The new password will be accepted and it protects the selected masks against
unauthorized access.
Change or remove a password already entered

Access the <New password> mask. You will be requested to enter the current
password
2.
Enter the password.
3.
4.
You will be prompted to enter a new password
5.
Enter a numerical combination which is only known to yourself.

(If no entry is made, the password is deleted).
6.

The password is changed or removed.
NOTE
Information for the testing system user:
We have foreseen a superordinate, non-changeable password for your safety. This
password is found in the appendix. Remove the page with the password from your user
manual and keep it together with your paperwork.
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<Load Zero>
The load measuring system for controlling the generated weight force is zeroed at every
test start. This procedure can also be done manually.
The display the shows <--->
<Zero the force>
The measurement channel can be adjusted anew with the action button <Zero the
force>.
-
<Piston weight>
The weight of the piston currently in use can be seen here.
<Acceleration due to gravity>
The acceleration due to gravity used is shown here.
The preset acceleration due to gravity bears refers to that at the manufacturer's
premises, i.e. 9.80665 m/s.
NOTE
The <Acceleration due to gravity> mask is protected by a Zwick password. ZwickService
can make corresponding settings in this mask.
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<Temp. adjustment, user>

The temperature measurement device can be adjusted at any two values; to do this, a
master temperature measuring device is needed.
After selecting the first or second adjustment value, the temperature controller starts up
without the current temperature adjustment. The value read at the master is entered
when it has been regulated. This can be done at one or two values. The respective point
remains unchanged. All other temperatures are calculated by a straight line function.
NOTE
The device's actual temperature can be permanently altered in the <Temperature
adjustment, user> mask.
<Heating>
Select whether or not and, if yes, which set value you want to adjust. You can select
between:
<Normal>
The <Normal> setting uses the test parameter's settings.
<1stset value>
<2ndset value>
<1stset value>
The temperature to which initial heating is to be made is entered here.
<1streference value>
A temperature value which has been measured by an external measuring device is
entered here.
NOTE
After adjusting the 1st set value, you can adjust the 2nd optional set value.
NOTE
The user adjustment does not alter the <Temperature adjustment Zwick>. If the reference
value and the set value are identical then only the <Temperature adjustment Zwick> will
be effective.
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<2ndset value>
The temperature to which heating is to be made is entered here.
It is useful to select the first and the second set values far apart from one another
such as 190 and 390 degrees.
<2ndreference value>
A temperature value which has been measured by an external measuring device is
entered here.
<Raw act. value>
The currently measured, uncorrected temperature is displayed for the raw actual
value. The external temperature measuring device can be read and the value can be
entered as a reference value if the above preset set value is stable on the display.
User manual
<Temp. adjustment, Zwick>
ZwickService can make corresponding settings in this mask. This mask is protected by a
Zwick password.
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<Force calibration>
Force calibration takes place at any four points. Compare the display value to the master
value.
The current force (F) and the current travel (s) are displayed on the bottommost line.
-
<Travel speed>
This entered speed is used to approach the start position.
NOTICE
Danger of irreparable damage!
A high travel speed can irreparably damage the master load cell!
Use an appropriate setting.
<Test load>
The electronics controls the drive to the entered test load; the entered test load is
adjusted.
<Linear factor Quadratic factor>
The calculated factor of the current load cell is displayed here.
NOTE
The following parameters are of an informatory nature.
<Acceleration due to gravity>

<Piston weight>
<Zero the force>
Use the <Zero the force> action button to zero the currently displayed force.
The piston must be freely suspended!
<START> button
To enable machine movement, you must press the <START> button to activate the
drive.
<Pos.> action button
The approached test load is that test load displayed by the electronics and is not the
master load cell's test load!
NOTE
You can also read the current travel during force calibration. A master load cell must not
be mounted if the travel is checked with the control gage.
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Start the force calibration with the <Pos.> action button.
User manual
<Force adjustment, user>

The load measuring system can be adjusted at any two values; to do this, a master
temperature measuring device is needed.
The respective load is approached at the adjustable speed, and the value read off at the
master force measuring device will be recorded. When both points are determined the
new adjustment parameters are calculated and saved with the conditioning command.
Adjustment must be made together with the piston as the piston's weight is included in
the adjustment.
The current force (F) is displayed on the bottommost line.
-
<Travel speed>
This entered speed is used to approach the respective set load.
NOTICE
<1stset load>
Enter the set load to which the machine is to drive at the travel speed. Enter the set
load in kg.
This force should be between 0.200 kg and 0.325 kg.
<1streference force>
Enter the quantity measured at your master load cell in newtons here.
<2ndset load>
Enter a second set load here to which the machine is to drive.
<2ndreference force>
Enter the second quantity measured at your master load cell at the second set load
in newtons.
NOTE
The following parameter is displayed for your information.
<Piston weight>
<START> button
To perform calibration, you must press the <START> button to activate the drive.
<1stload> action button
Choose the <1stload> action button to start the adjustment drive to the first set load.
<2ndload> action button
Choose the <2nd><load> action button to start the adjustment drive to the second set
load.
<Set> action button
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The <Set> action button is used to calculate and save the new adjustment parameter.
<Force adjustment, Zwick>

Zwick password.
<Travel calibration>
A master travel measuring device is needed for travel calibration.
Place the master travel measuring device on the probe head with a normal magnetic
support. Record the probe head's movement with the master travel measuring device.
Travel calibration takes place at any target position. Zero at the master's position and the
travel display. Then you can drive in steps and can always compare the values to the
master.
NOTE
Check gages should not to be used for this travel calibration. Settings with the control
gage guide you through the mask "Force calibration".
The two lines below show the current travel value (s) and the entered distance of travel
(ds).
-
<Travel speed>
This entered speed is used for the travel calibration.
<Target position>
The piston is driven to this entered target position.
<Distance of travel>
The piston is driven for this entered value.
<START> button
To perform calibration, you must press the <START> button to activate the drive.
<To zero> action button
The <To zero> action button is used to set the travel (s) to zero (0).
<Pos.> action button
<Drive> action button

Use the <Drive> action button to drive the entered distance of travel when the target
position is reached.
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Use the <Pos.> action button to approach the target position.
User manual
NOTE
The controllers are factory set and influence measurements. The controllers should only
be readjusted in special cases and only if you have first class knowledge of controlling.
<Temperature controller, alterations>

Zwick password.
<Force controller, alterations>

Zwick password.
<Pneumatic adjustments>
Zwick password.
<Date/Clock time>
You can adjust the date and the time in this mask.
<Date format>
Select the type of input here.
<DD.MM.YYYY>: Day, month, year or
<MM.DD.YYYY>: Month, day, year
<Date>
You can see and alter the date here depending on the date format selected.
<Clock time>
The clock time is shown in the 24 hour mode, alterations must also be made in the 24
hour mode.
<Extrude material>
Any remaining material can now be forced out of the extrusion barrel.
<Extrusion load>
Enter the desired extrusion load here.
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<Extrusion up to Pos.>
You can choose as to whether you want to drive to die contact or to a certain position.
The function can be altered by selecting the checkbox. Subsequently the following
parameter is displayed:
-
<Extrusion position>
Enter the position value up to which you want to extrude remaining material here.
<START> button
Press the <START> button to activate this function.
<Settings reference>
Travel measurement always relates its position to the upper edge of an 8mm die. The
setting is only possible via this standard die or via the 8 mm blind die.
This means that the actual distance to the die does not correspond to the displayed
position for a differently sized die.
The electronics detects the distance from the upper edge of the die to the upper limit
switch's position. Thus the extrusion plastometer knows where it is when switching on the
limit switch's upper position.
You will have to hit the upper limit switch if the probe head is not at the upper position
when it is switched on. Press the <Up> button. The path up to the upper limit switch will
be readjusted at the reference drive.
<Travel speed>
This entered speed is used to drive just up to the die position (fast speed).
NOTICE
<Reference speed>
<Change in force>
The reference drive is terminated at a load increase by this entered force value.
<START> button
Press the <START> button to activate this function.
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This entered speed is used to drive until contact is made with the die (slow speed).
User manual
<Burning out>
Plastics quite often leave a thin film on surfaces. They cannot be dimensionally detected
and cannot be mechanically removed. This film imparts the next material with unexpected
good gliding properties which could lead to higher results.
In such a case it can help to heat the die, extrusion barrel, and piston to a temperature
high enough to burn these organic materials (pyrolysis). This is possible when using this
parameter. The procedure is extremely long; heating up to 100 degrees takes about 10
minutes and waiting for the equipment to cool down takes considerably longer. Therefore,
we recommend that you carry out this procedure in the evening.
You can utilize the automatic switch-on function so your extrusion plastometer heats up to
the set operating temperature the next morning.
<Acknowledgment> action button
Start this function by choosing the <Acknowledgment> action button.
WARNING
Risk of fire!
Burning out must always be done under supervision!
<Burning out time>

Enter the length of time burning out should last (e.g., 3 hours).
<Temperature>
Burning out is performed using the temperature set here. Enter a tried and trusted
temperature value (e.g. 400 C).
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<After burning out>

What should occur after burning out? The following options are available:
<Switch off>
The extrusion plastometer is switched to Standby after the burning out function has
finished.
<Auto. switch on>
Select <automatic switching on> to activate the settings made in the <Automatic
switching on> mask after burning out has ended.
<Operation>
You can continue with normal tests once burning out and cooling down are complete.
NOTE
Cooling down can last for several hours.
<Diagnosis>
Inputs and outputs can be tested in this mask.
This diagnosis mask can be of use should fault finding have to take place. The individual
parameters are not explained in this user manual. Important settings are treated under
Error rectification.
<Options>
Optional parts must be selected/deselected here.
The options listed in this mask are dependent upon the device configuration. You must
use the checkbox to select/deselect the options offered here.
NOTICE
Incorrect inputs could lead to dangerous situations happening.
The options stated in this mask must be available.
Please keep the following information handy. This makes it easier to answer questions
about the testing system and the test conditions quickly.
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<Device data>
User manual
The individual abbreviations mean:

WN-Aflow: Serial number and type of extrusion plastometer
SN-KA: Load cell's serial number
GE-SW: Version of the device electronics
GE-HW: Inbuilt electro-p.c.bs
LE-SW: Software version of the power unit
LE-HW: Version of the power board
LE-PLD: PLD version
CTA: 11124
3.2 Cleaning and compaction unit

2
Picture 9: Operational controls for cleaning and compaction unit

1
<Lower> button
NOTE
Purchasing the option for variable pressure setting allows you to input the pressure force
in the testing system's electronics or in the testing software.
3.2.1 Option for variable pressure setting
The load can be varied if you have also purchased the variable compaction setting option
for use with the cleaning and compaction unit. The standard smaller compaction load is
indicated by the illuminated ring on the <Mode change> button.
Switch to the standard larger cleaning load by pressing the <Mode change> button. The
illuminated ring on the <Mode change> button indicates that load switching was
successful.
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4 Operating
4.1 Testing system
4.1.1 Mechanical operation
The probe head is mounted on the testing system and the optional cleaning unit is
mounted on a swivel-tower The tower's swivel mechanism enables the probe head or the
cleaning unit to be swiveled above the test chamber. The swivel movement is blocked
when it is at either of the tower's end positions, and before either the piston or the
cleaning die is lowered. This blockage of the tower prevents damage to the piston and
also prevents it from jamming.
NOTE
The probe head can only be lowered if it is equipped with the piston in place.
The electronics detects erroneous usage and generates error messages.
CTA: 18937
The extrusion barrel can be inspected optically for impurity if the tower is not at its end
position. Test material can be fed in via the swivelable specimen chute.
4
Picture 10: Mechanical operation

1
2
178
Cleaning die
Specimen chute that can be swiveled
3
4
Piston
Tower
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Operating
4.1.2 Switching the testing system on and off
CTA: 18938
The testing system is switched on via the mains switch. The mains switch is located on
the rear side of the testing system.
Picture 11: Mains switch at the rear

1
Mains switch
Operating with a PC
Power-up sequence when operating with a PC
1.
Switch on the PC.
2.
Switch on the testing system with the mains switch.
3.
Switch on the device electronics with the <ON/OFF> button.
4.
Start the testXpert II software on the PC.

The testing system is switched on.
Operating a scale
A scale can be connected direct to the extrusion plastometer's electronics if a PC is not

being used for operating the machine.
Weighing scales must be connected to the PC when one is being used for operating the
machine.
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NOTICE

1.
4.1.3 Force due to weight

The testing system is equipped with a variable speed drive. This variable speed drive
exerts pressure on the test material at the preselected weight. The piston weight is known
by the test system and is allowed for accordingly.
Force measurement is protected by an overload protector.
The testing system makes it possible to switch among pre-loads, different test loads, and
a selectable extrusion load.
4.1.4 Problematic materials

High flow rates
The pre-heat phase must take place with a piston with no applied load or with a very low
applied load.
You must use an optional die plug when melt flow rates are very high. The die plug is
opened after the pre-heat time.
Piston overloading
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If at all possible, overload of the material must be avoided.

Overload must take place within one minute and must be finished two minutes before the
beginning of measuring. The extrudate must be cut off and discarded. Then the piston
under load must be allowed to descend under the measuring load.
User manual
Operating
4.1.5 Carrying out a test according to the standard

Carry out a test
The piston must be left in the empty extrusion barrel as it must be tempered.
Standard compaction rod
1.
Enter all test parameters.
2.
Drive the piston upwards
NOTE! The filling and compaction process must be done as quickly as possible, i.e. in
less than one minute (required by test standards).
3.
Fill up the test material in the extrusion barrel.

-
4.
You must compact the test material (approx. 5 fillings) during filling.
Please use the standard compaction rod or the optional pneumatic cleaning
and compaction unit for this purpose.
Swivel the piston until it is above the extrusion barrel.
NOTE! Depending upon the flow property of the test material, either the test load can be
applied to the piston at start or it can be left without a load.
5.
Start the test by pressing the <START> button.

The test is started.
4.1.6 Running a test for precision measurement
We recommend the following for precision measurements as running a test for

measurements with increased accuracy (2% standard deviation) is highly dependent
upon the material:
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The test should always be carried out uniformly, preferably by the same person.
If possible, always use the same material for one device.
Single specimens should have a L = 2 mm at least.This corresponds to an
extrudate length of 20 to 30 mm and a measurement time of at least 10 seconds.
The number n should be at least 3.
The test should be run at 50 mm to 20 mm above the die.This corresponds to the
distance between both rings on the piston. Please make sure that the entire
measurement path for single tests is always the same.
Test in the test axis middle.Ensure that the piston does not touch (friction) anything
when entering the extrusion barrel.
Please adhere to your test conditions. If you must compare the results with your
supplier, you must then make sure that the test conditions are exactly the same as
those of your suppliers.
Always proceed to the same, logged methods when performing comparison
measurements
Run test for precision measurement

Different test materials must be dried before the test. This would otherwise result in
falsified values!
NOTICE! Danger of irreparable damage to the bubble spirit level! Align the testing
system only if the extrusion barrel is at room temperature. Place the bubble spirit level on
the extrusion barrel only if the extrusion barrel is at room temperature.
Place the tester in an absolute vertical position. Use the bubble spirit level to check
the position.
2.
Heat the device for a long time, more than 2 hours. Whereby the piston should be in
the extrusion barrel.
3.
Adjust the temperature very precisely (0,1 C). Always use the same method and
the same type of sensor. Zwick uses an exact fitting brass sleeve.
4.
Clean the tester meticulously. Some materials build a glide film on the die's surface.
5.
Weigh or measure the amount of the filled test material exactly.
6.
Insert the material in portions, approx. 5 times and compress it each time you insert
material. Use a uniform pressure of approx. 300 N (30 kg).
7.
Swivel-in the piston immediately and start the test
8.
Determine the preheat setting. It is correct if there is enough travel left for
compaction after the material has been preheated.
9.
Determine the correct quantity of test material. This is correct if the beginning of
measurement under continuous loading has been reached shortly after the end of
the minimum melting time (300 s).
10.
Select the correct result tolerance. This should eliminate all outliers (specimen with
air bubbles), for example 2%.
11.
Look at the single values. The material is too instable if the values increase or fall.
Deviations to the fill quantity mean a temporally different test start, which would
result in different results for such material.
12.
Clean the piston and the die when they are warm.
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Operating
NOTE! The heat-up pauses must always be of the same length of time.
13.
Pre-heat the piston again by driving it completely into the clean and empty extrusion
barrel. The temperature becomes stable after 2 to 3 minutes and the next test
material can then be filled.
The test for precision measurement has been run.
Discard the results if there are deviations in the preparation. Otherwise you
shouldn't evaluate the results of the first filling of a series. This is also valid for the
first test after a lengthier pause.
4.1.7 Cleaning
WARNING
Risk of burns from hot parts of the testing system and hot cleaning tools!
with the die, die holder, extrusion barrel, piston, and cleaning tools.
WARNING
Risk of fire due to high temperatures!
Cleaning tools such as rags, etc. could ignite.
Never leave any remains of cleansing agents in the extrusion barrel.
Do not use plastic-based rags for cleaning.
Use a rag made from cotton or a similar material.
NOTE
Use cloth approx. 50 x 70 mm in size for cleaning the extrusion barrel. Zwick offers
suitable cloths as an option.
You must clean the extrusion barrel, die and piston after each test.
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Clean extrusion barrel, die, and piston

Non-melting cloth
Use cloth approximately 50 x 70 mm in size made of cotton or a similar material; no
plastic!
Die cleaner
CTA: 18957
Cleaning tools
1.
Remove the piston.
2.
Wipe the piston clean while it is still warm. Use a non-melting rag for this purpose.
3.
Safety gloves
Rag
CTA: 10441
4.
Pull the die holder to the stop. Now catch the hot die as it drops down. If the die
does not drop out on its own, use the cleaning tool to push it out from above.
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Die cleaner
Die
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Wearing protective gloves, hold a rag below the extrusion barrel's opening.
User manual
Operating
CTA: 10442
Clean the die while it is still hot. Use the die cleaner to do this.
6.
Cleaning tools
Cloths
Clean the extrusion barrel.

Clean the extrusion barrel with the cleaning tools and a cloth until it shines brightly
again.
7.
Clean the die holder by pressing the pin to release it and pull the die holder out all
the way. Pay attention to the arrow when replacing the holder.
The extrusion barrel, die, and piston are clean.
Other, more time consuming cleaning procedures may be necessary depending upon the
test material.
NOTE
You can purchase the pneumatic cleaning and compaction device to ensure meticulous,
energy saving and rapid cleaning.
4.2 Die plug
The die plug enables tests on highly fluid materials. It plugs the outlet from the extrusion
barrel during the pre-heat time, and thus prevents the material being tested from
escaping. The die plug is opened after the pre-heat phase.
The die plug's die mandrel is pressed against the testing system's die with spring force.
WARNING
Risk of burns if contact is made with the die plug!
Die, die plug, and test material become very hot and could cause burns.
Always wear protective gloves when closing the die plug.
Never open the die plug by hand.
Always use the extrudate cutter to open the die plug.
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4.2.1 Logging the die plug

Logging the die plug
1.
Select the die plug in the <Options> mask.
2.
Select <auto.+dieplug> in the <Extrudate cutter> parameter.

The die plug is logged.
4.2.2 Closing the die plug

CTA: 21003
The die plug must be closed before inserting the test material.
2
Picture 12: Close die plug

1
2
Die plug
Reset lever
3
4
Die mandrel
Die
Close die plug

1.
Press the return lever upwards.

You will be able to feel it clicking into place.
The die plug is closed.
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4.2.3 Opening the die plug

The die plug can be opened by pressing the <CUT> button or via the test program.
Open die plug with button
1.
Press the <CUT> button.
The die plug is open.

Open die plug via test program
An optional automatic extrudate cutter must be installed and activated.
1.
The test program controls the optional automatic extrudate cutter to open the die
plug.
The die plug is open.
4.3 Separating pane

WARNING
Risk of injury due to unexpected startup of blade!
The blade of the optional, automatic extrudate cutter also runs when the separating
pane is open. The unexpected startup of the blade can result in serious lacerations.
Never intrude in the range of the blade with parts of your hands.
Only open the separating pane to remove the extruded extrudates.
Close the separating pane before filling the extrusion barrel.
A closed separating pane prevents
the blade being touched inadvertently
the falling of extrudates on the floor
4.4 Cleaning and compaction unit

The cleaning and compaction unit is used to clean the extrusion barrel and to compact
the granulate.
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CTA: 20206
4.4.1 Swivel options

8
7
2
5
4
Picture 13: Swivel options for the cleaning and compaction unit
1
2
3
4

Probe head
Piston
Specimen chute
5
6
7
8
Cleaning and compaction rod

<Lower> button
Specimen chute
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4.4.2 Compaction
Add the test material
The die holder must be inserted correctly.
The die must be located in the extrusion barrel.
Weigh the material (granulate) to be tested.
2.
Then fill the extrusion barrel with granulate in portions via the specimen chute.
CTA: 11126
1.
Swivel the cleaning and compaction rod over the extrusion barrel.
CTA: 11129
3.
Specimen chute

The specimen chute is automatically slightly swiveled out.
4.
The illuminated ring of the <Mode change> button must illuminate. Press the
<Mode change> button if it is not illuminated.
5.
Press and hold the <Lower> button.
CTA: 11128
The cleaning and compaction unit clicks into place.
The cleaning and compaction rod is lowered.

The granulate is compacted.
Air escapes.
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6.
Release the <Lower> button.

The compaction rod is lifted again after the set compaction time has expired,
or by releasing the <Lower> button.
Repeat the process of filling the testing system with material and compacting until
all of the material is added.
We recommend you compact the material five times.
CTA: 11127
7.
The testing system is filled with material.
CTA: 11130
4.4.3 Conducting a test
Picture 14: Swiveled-in probe head and piston

Start the test
1.
Swivel the cleaning and compaction unit out, and swivel the probe head with piston
in.
2.
Start the test.

The test is started.
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4.4.4 Cleaning
The cleaning and compaction unit is used to clean the extrusion barrel with the supplied
cotton cloth. The cleaning and compaction rod must be positioned just above the
extrusion barrel.
NOTE
The cleaning and compaction unit must be switched off immediately if the cleaning and
compaction rod should become bent, broken, or out of alignment. The cleaning and
compaction rod must not be unscrewed!
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CTA: 11362
User manual
Operating
Picture 15: Cleaning with the cleaning and compaction unit

1
2
3
Die holder removed or pulled to the

stop
Cotton cloth
The die must be removed from the
extrusion barrel
4
5
6
7
8
Cotton cloth
<Lower> button
Once the cleaning and compaction unit is swiveled in, you must insert the cotton cloth
between the cleaning and compaction rod and the extrusion barrel.
Clean extrusion barrel
The die must be removed from the extrusion barrel.
The die holder must be removed or in its outermost position.
1.
192
Press the <Lower> button. The button's illuminated ring must be extinguished. The
cleaning and compaction rod is pressed into the barrel with the set force until you
release the button again.
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The cotton cloth must be placed flat above the extrusion barrel with the cleaning and
compaction unit swiveled out. Swivel in the cleaning and compaction unit over the cotton
cloth that are lying flat.
User manual
Operating
2.
Please make sure that the cotton cloth does not get trapped in the extrusion barrel
(risk of combustion). Check that the extrusion barrel is bright and that there are no
material remains in it.
3.
You can move the cotton cloth up and down several times if the remains are difficult
to get rid of. The cotton cloth is removed the first time it emerges at the bottom of
the barrel. A cotton cloth that is folded once can be used, depending on the set
pressure.
The extrusion barrel is clean.
NOTE
The load can be varied if you have also purchased the variable compaction setting option
for use with the cleaning and compaction unit. The set cleaning load is indicated by the
non-illuminated ring on the <Mode change> button.
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Index
5 Index
A
Attention
Data loss........................................................... 135
D
Bubble spirit level..............................................182
High travel speed..............................170, 171, 174
Die
Cleaning............................................................184
E
Extrusion barrel
Cleaning............................................................184
P
Piston
Cleaning............................................................184
R
Risk of burns
Cleaning............................................................183
due to hot test material!.................................... 124
from hot parts of the testing system..................124
if contact is made with the die plug!..................185
Risk of damage
Incorrect die height........................................... 145
Switching off the testing system........................180
Risk of fire............................................................. 183
Risk of injury
Active medical implants.................................... 124
Chemical reactions........................................... 125
Due to unexpected startup of blade..................187
Functions of the safety devices........................ 124
Safety measures............................................... 125
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Figure index
6 Figure index
Operational controls ................................................................................ 126
Picture 2
Operating field buttons ............................................................................ 127
Picture 3
Electronics ............................................................................................... 128
Picture 4
First mask ................................................................................................ 131
Picture 5
Possible mask calls ................................................................................. 131
Picture 6
PC Operation ........................................................................................... 132
Picture 7
Mask <Main menu> ................................................................................. 134
Picture 8
Travel-time diagram of a test ................................................................... 142
Picture 9
Operational controls for cleaning and compaction unit ........................... 177
Picture 10
Mechanical operation .............................................................................. 178
Picture 11
Mains switch at the rear .......................................................................... 179
Picture 12
Close die plug .......................................................................................... 186
Picture 13
Swivel options for the cleaning and compaction unit .............................. 188
Picture 14
Swiveled-in probe head and piston ......................................................... 190
Picture 15
Cleaning with the cleaning and compaction unit ..................................... 192
Picture 1
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User manual
Figure index
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196
Aflow
Dossier: 725368
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Table of contents
Table of contents
1
Introduction ...................................................................................................... 201
General safety notes ....................................................................................... 202
Documentation for maintenance and servicing ........................................... 204
Servicing .......................................................................................................... 205
Calibration ........................................................................................................ 206
Service recommendations .............................................................................. 207
Testing system ................................................................................................. 208
8
9
10
7.1
Overview ................................................................................................. 208
7.2
Mechanical setup .................................................................................... 209
7.3
Function description ................................................................................ 209
7.4
Service intervals ...................................................................................... 210
7.5
Control gages for checking the travel ...................................................... 212
7.6
Replacing the battery .............................................................................. 213
7.7
Troubleshooting ....................................................................................... 215
Troubleshooting .............................................................................................. 222

Pneumatic weight lifting unit .......................................................................... 223
9.1
Overview ................................................................................................. 223
9.2
Function description ................................................................................ 223
9.3
Servicing .................................................................................................. 224
9.4
Troubleshooting ....................................................................................... 225
Pneumatic weight lifting unit with cleaning function ................................... 226

10.1 Overview ................................................................................................. 226
10.2 Function description ................................................................................ 226
10.3 Servicing .................................................................................................. 227
10.4 Troubleshooting ....................................................................................... 228
11
Pneumatic weight lifting unit with peg positions ......................................... 229

11.1 Overview ................................................................................................. 229
11.3 Servicing .................................................................................................. 230
12
Automatic extrudate cutter ............................................................................. 232

12.1 Overview ................................................................................................. 232
12.3 Service intervals ...................................................................................... 233
12.4 Replacing the blade ................................................................................. 234
12.5 Clotted blade ........................................................................................... 236
12.6 Dismantling the blade holder ................................................................... 236
12.7 Removing the slide guide and extrusion barrel ....................................... 237
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Table of contents
13
Die plug ............................................................................................................ 241

13.1
Overview ................................................................................................ 241
13.2 Mechanical position ................................................................................. 241

13.5 Replacing the plug ................................................................................... 243
13.6 Adjusting the die plug .............................................................................. 244
14
Separating pane ............................................................................................... 248

14.1 Overview ................................................................................................. 248
14.3 Service recommendations ....................................................................... 248
15
Cleaning and compaction unit ....................................................................... 250

15.1 Overview ................................................................................................. 250
16
Cleaning and disposal .................................................................................... 252
17
Overview of all service intervals .................................................................... 253
18
Index ................................................................................................................. 254
19
Figure index ..................................................................................................... 255
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Introduction
1 Introduction
This manual contains important notes and information on servicing and maintaining the
testing system and its accessories.
The user manual must be read and used by all persons authorized to work with/on the
Repair work
Maintenance
Inspection
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2 General safety notes

WARNING
Risk of injury due to inadvertent switching on
Risk of injury exists when working on electrical systems.
Switch the power supply off via the main switch.
Secure the main switch by locking it so that inadvertent switching on does not occur
and remove the key.
Lock the main switch if necessary and remove the key.
Disconnect the power supply.
Ensure the power plug is not inadvertently plugged in again.
WARNING
Risk of burns if contact is made with hot surfaces and parts of the testing system!
There is a risk of burns if contact is made with hot surfaces and parts of the testing
system.
Always wear suitable protective clothing, including gloves and facial protection.
Wait until any surfaces and parts of the test system that you may touch have cooled
to ambient temperature.
CAUTION
NOTICE
202
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Risk of injury!
equipment.
protection.

NOTE
NOTE
Zwick can only accept liability for guarantee if the maintenance and service work as
described in the in the user manual is carried out regularly and if it is correctly
documented.
A list of the documentation for maintenance and service work is found later on in this
manual.
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Documentation for maintenance and
servicing
3 Documentation for maintenance and servicing

The documentation for maintenance and servicing assists you in keeping the testing
system in good working order.
Remember that any possible guarantee liabilities can only be accepted if the
documentation of repair work is complete and correct.
Document all maintenance and servicing work that you perform.
Document all maintenance and servicing work by entering the date and the
abbreviation of the employee who carried out the work.
Maintenance work to be done, when and how, is described for each component.
204
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Servicing
4 Servicing
To ensure the highest testing system availability and minimize testing system downtimes
Perform servicing work as defined by the processes and intervals described.
Please note that the necessary tools and equipment are required for all service work.
Keep to the schedules indicated in the user manual for repetitive tests/inspection
work.
Keep the testing system clean and in good working order.
Check all screw connections regularly. The time interval depends upon the intensity
of usage.
Following repair work

-
Re-tighten the loose screw connections.

Reinstall removed casing covers.
Remove all materials, tools, equipment, etc., that are required for maintenance and
servicing from the testing machines working area.
Check all of the testing system's safety devices.
Ensure that you have ecological and safe methods in place for disposing of
replacement parts and operational or auxiliary materials.
NOTE
Zwick offers all service work according to DIN 31051: from maintenance, inspection,
repair work and even DAkkS (German calibration service) calibration. A pre-printed form
for requesting inspection and calibration can be found in the appendix.
Complete the pre-printed form for requesting inspection and calibration.
Send your request to Zwick via fax, email, or postal service.
You will promptly receive a service offer in writing, customized for your testing
system.
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Calibration
5 Calibration
The testing systems measurement and control unit must be calibrated at regular intervals
to ensure consistent and reproducible measurement results.
The user is responsible for adhering to suitable calibration intervals.
We recommend annual inspection and calibration (according to DIN 51220, DIN EN ISO
7500-1, and DIN EN ISO 9513).
Zwick has a test laboratory that has been accredited by DAkkS (German Accreditation
Body) to DIN EN ISO/IEC 17025.Our service technicians are available to assist you with
professional inspection and calibration. Your testing system will be checked on site by our
qualified and authorized personnel for its functionality and accuracy and can, if
necessary, be readjusted if deviations are found.
NOTE
system.
206
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Service recommendations
6 Service recommendations
-
Always keep the testing system clean.

Always remove all specimen remains.
Clean the testing system with non-corrosive and solvent-free cleansing agents If you
have questions, please contact Zwick.
NOTE
For more information about regular servicing and cleaning, see the chapter on service
intervals.
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Testing system
7 Testing system
CTA: 18937
7.1 Overview
14
13
2
3
12
11
4
5
6
10
7
9
Picture 1: Overview of Aflow with optional pre-compaction

1
2
3
4
5
6
7
Pneumatic cleaning and pre-compaction option

Swivel handhold
Cleaning rod
Mains switch
Die holder
Extrudate cutter option
Keypad
8
9
10
11
12
13
14
Height adjustable screws with plate

nuts
Display
Operator panel
Extrusion barrel
Specimen chute
Piston
Probe head
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Testing system
7.2 Mechanical setup

The testing system consists of
Basic housing with electrical components
Test chamber
A load unit with a variable speed drive for 0.325 kg up to 50 kg and travel
measurement
Optional cleaning and pre-compaction
NOTE
The parts coming into contact with the specimen material are freely accessible for
cleaning and can be easily exchanged.

-
Enter the test parameters via the keypad. You can read both of these inputs and the
temperature from the display.
Then fill the extrusion barrel with test material portion by portion. Compact it after
each portion has been filled.
Press the <START> button on the operator panel to begin the test.
The test load uses a piston to press the molten test material through a standardized
die.
The measurement values are recorded and kept ready for further processing.
NOTE
Control and evaluation can take place on a PC via the USB port.
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Testing system
7.4 Service intervals

Overview
Interval
Sub-component
Task
When necessary
Painted surfaces
Anodized surfaces
Plexiglas/polycarbonate panes
Die
Clean painted surfaces

Clean anodized surfaces
Clean Plexiglas/polycarbonate panes
Clean the die with a cotton cloth
only, do not use cleansing agents.
Clean the piston with a cotton cloth
Clean the extrusion barrel with a cotton cloth only, do not use cleansing
agents.
Lubricate lead screws and lead
screw nuts
Before each test
Piston
Extrusion barrel
Monthly
Lead screws and lead screw nuts
See page
210
210
210
210
211
211
211
Service work
Painted surfaces
When necessary

1.
Clean the testing system only with a soft cloth and a commercially available
cleaning agent, such as a pH-neutral detergent.
2.
Avoid scratching.
Painted surfaces are clean.
Anodized surfaces
When necessary

1.
Only use a soft cloth for cleaning.
2.
Avoid scratching.
Anodized surfaces are clean.
Plexiglas/polycar- Clean Plexiglas/polycarbonate panes

bonate panes
1.
Remove soiling with a microfiber cloth and water and a pH-neutral dish washing
When necessary
liquid if necessary.
Do not perform mechanical cleaning with (rotating) brushes, wipers, or abrasive
cleaning agents.
3.
Never rub dusty parts off when dry.
4.
Wipe dusty parts with a soft cloth or sponge and water.

Plexiglas/polycarbonate panes are clean.
Die
Before each test
210
Clean the die with a cotton cloth only, do not use cleansing agents.
5.2016 1006583
2.

Testing system
Piston
Before each test
Clean the piston with a cotton cloth only, do not use cleansing agents.
Extrusion barrel
Before each test
Clean the extrusion barrel with a cotton cloth only, do not use cleansing agents.
Lead screws and Lubricate lead screws and lead screw nuts
lead screw nuts
Monthly
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211

Testing system
7.5 Control gages for checking the travel

Check the travel
The extrusion barrel must be cooled down to ambient temperature.
NOTE! Use the same presets for the <Force calibration> mask as those used for the
<Settings reference> mask.
1.
Enter the same presets as those in the <Settings reference> mask for the <Drive
speed> and <Test load> parameters.
2.
Insert the die holder.
3.
Guide the die into the extrusion barrel.
4.
Swivel the piston in.
5.
Switch on the drive system with the <START> button.
6.
Start determination with the <Pos.> action button.

A measurement path of 0 (zero) millimeters (inches) must appear on the
display in the <Force calibration> mask.
The reference drive in the <Settings reference> mask must be repeated if
there were any deviations.
7.
Pull the piston out of the extrusion barrel by hand.
8.
Swivel the piston out.
9.
Guide the control gage (e.g. 10 mm) into the extrusion barrel.
10.
Swivel the piston in.
11.
Start determination with the <Pos.> action button.

A measurement path that corresponds to the control gage (for example, 10
millimeters/0.39 inch) must appear on the display in the <Force calibration>
mask.
The travel check has been performed.
NOTE
Repeat this for all required control gage checks.
End travel check

1.
Pull the piston out of the extrusion barrel by hand.
2.
Swivel the piston out.
3.
Hold one hand under the extrusion barrel.
4.
Remove the die holder and catch the die and the control gage.
The travel check is concluded.
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Testing system
NOTE
Store the control gages in a safe place.
7.6 Replacing the battery

The device electronics contain a Lithium battery (AA, type SL-360/PT LS14500 3PF) for
data buffering. This battery is a long-life battery.
NOTE
NOTICE

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213

Testing system
Dismantling the battery

SW5 hexagon wrench key
Crosstip screwdriver
Unplug the power plug of the materials testing machine.
2.
Unscrew the screws on the base frame with the hexagon wrench key.
3.
Carefully pull the electronics as far forwards as necessary so that the left power
plug of the electronics is accessible.
CTA: 12702
1.
Picture 2: Pull out the device electronics

1
Basic frame
Electronics
Unplug the power plug of the electronics.
5.
Pull the electronics completely out to the front.
6.
Unplug all the plugs of the electronics.
7.
Unscrew the 12 screws on the lid of the electronics using a crosstip screwdriver.
8.
Remove the cover.
9.
Unsolder the battery.
CTA: 12707
4.
Picture 3: Battery in the device electronics

1
214
Battery
5.2016 1105392

Testing system
The battery is now dismantled.

Mounting the battery
SW5 hexagon wrench key
Crosstip screwdriver
1.
Solder the new battery with the correct polarity.
2.
Place the lid on the electronics.
3.
Screw in the 12 screws using a crosstip screwdriver.
4.
Plug in all the plugs of the electronics.
5.
Carefully push the electronics into the base frame.
6.
Screw the electronics tightly onto the base frame.
7.
Plug in the power plug of the materials testing machine.

The battery is now mounted.
7.7 Troubleshooting
WARNING
with hot parts.
Before maintenance and service work, allow all parts, including the extrusion barrel,
cool to ambient temperature.
WARNING
NOTE
particular work.
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215

Testing system
Errors are indicated by a three-fold acoustic signal and are displayed on the display field.
The error code is always indicated in the error message's top line. Write down these
numbers in case you have questions and before you rectify the cause of error or
acknowledge the error.
The action fields for acknowledging the messages appear delayed with respect to the
error message. You can close this error message by
choosing the <Acknowledgment> action button
pressing the <ESC> button
The Emergency Stop state is an exception. All consumers such as heating and the motor
switched off here. You must switch off the testing system at the mains switch. First rectify
the error and then switch on the testing system again at the mains switch.
The extrusion plastometer drives slowly upwards.

- The reference point was lost. The extrusion plastometer was switched off during a drive
action.
- Let the extrusion plastometer drive slowly to the upper limit switch. This allows
the extrusion plastometer to determine the reference point.
The probe head does not go any higher.

- A display appears informing that the extrusion plastometer's motor is not running
smoothly enough.
- The extrusion plastometer's heating is switched off. The extrusion plastometer
must be heated up again so that any remaining material is melted again.
Compaction is not possible.

- If an acoustic signal was generated then the position of the probe head is incorrect.
- Swivel the probe head to the stop.
The test cannot be started.
The piston is lifted slightly upward during its downward drive.

- The piston has hit an obstruction.
- The extrusion barrel was not cleaned correctly. There are still specimen material
remains in the extrusion barrel. Clean the extrusion barrel again; you may even
have to burn it out.
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Testing system
It is not possible for you to perform the cleaning process.

The cleaning and compaction unit cannot press the cloths through the extrusion
barrel.
- You selected compaction with a variable pressure setting for the cleaning and
compaction unit. The <CHANGE MODE> button's ringlight illuminates.
- Switch on the cleaning pressure by pressing the <CHANGE MODE> button. The
<CHANGE MODE> button's ringlight must not be lit!
- The selected cleaning load is too small.
- Change the cleaning load in the <Running a test>mask.
- The external pressure is too low.
- Set a higher pressure (> 5 bar). The highest pressure must not exceed 10 bar.
All drive buttons are passive and generate a short acoustic signal.
- The EMERGENCY STOP state has been triggered.
1.
Switch the extrusion plastometer off at the mains switch.
2.
Wait for approx. three seconds.
3.
Switch on the extrusion plastometer again at the mains switch.
The weight display is at an incorrect value (unloaded), e.g. 3 kg.

- Zero balance is made at the start of a test. The load measuring system must be
unloaded at this moment in time.
- Ensure that the load measuring system is unloaded at the start of the test.
The probe head does not drive all the way down. The display indicates that There is
an object in the extrusion barrel
- The wrong die has been inserted

- Remove this die and insert the correct one.
- Two dies have been inserted.
- Remove both dies and insert the correct one.
- The control gage was left inside.
- Remove the control gage and insert the correct one.
- Material still remains in the extrusion barrel.
- Melt the material and clean the extrusion barrel.
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Testing system
Crackling noises are heard in the optional pneumatic system's servo unit the after
the piston or the cleaning and compaction unit start to move.
- This is a normal control noise.
- This control noise stops after a short time.
The piston or the cleaning and compaction unit moves very slowly upwards.
- The extrusion plastometer has been turned off in the meantime and must now be
reinstalled.
- Switch the extrusion plastometer off (by pressing the on/off switch) and then on
again after about 5 seconds.
The piston or the cleaning and compaction rod moves slowly downwards.
- Compressed air is not available.
- Check the compressed air supply.
The probe head cannot be swiveled.

- The probe head or the piston is not at the top, or there is no more compressed air.
Check the following:
Probe head's position
Compressed air supply
The cleaning and compaction rod is clotted with material during compaction.
- The entered compaction time is too long.
- Check the "Compaction time" parameter in the "Running a test" mask.
The die holder cannot be moved.
The die cannot be pressed out.

smoothly enough.
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smoothly enough.

Testing system
The die is clotted with material.

- The remaining material has not been extruded.
- Clean the die and the extrusion barrel and piston, as needed.
The measured values are too high.

- The die's surface is covered by a layer of lubrication.
- Heat the extrusion barrel and die or clean both with a solvent.
- The temperature is too high.
- Check the presets for the temperature.
- The test load is too high.
- Check the presets for the test load.
- The test load in the preheat phase is too high.
- Check the presets for the test load.
- The material is not dry.
- Dry the moisture-absorbing material with a suitable granulate dryer immediately
before the test.
- There is still air in the extrusion barrel.
- Compress the material more.
The measured values are too low.

- There is friction in the extrusion barrel.
- Clean the following:
The piston
The extrusion barrel
The die
- The extrusion barrel is not vertical (bubble spirit level).
- Using the bubble spirit level, align the extrusion barrel when it is cool.
- The temperature is too low.
- Check the temperature controller.
- The test load is too low.

- Calibrate the test load.
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Testing system
The measured values scatter.

- There is still air in the extrusion barrel.
- Compress the material more.
- The extrusion barrel is not clean.
- Clean the extrusion barrel.
- The conditioning phase before measurement was too short.
- Comply with the values in accordance with the standards.
- You have compacted the material in different ways.
- Ensure you add and compact the material in the same way each time.
- There was a lengthy pause in the measurement series.
- Ensure that the time intervals within a measurement series have the same
duration.
- The material is not dry.
- Dry the moisture-absorbing material with a suitable granulate dryer immediately
before the test.
An existing option is not functioning.

- The option has not been selected in the extrusion plastometer.
- Check the corresponding parameters for the option in the Options mask.
The extrusion plastometer is not connected to the PC.

- The connector cables are not plugged in.
- Plug in all connector cables.
- The power-up sequence was not adhered to.
- If you operate the testing system with a PC, you must adhere to the following
power-up sequence:
Switch off the PC and the extrusion plastometer at the main switch. Wait for
approximately three seconds.
2.
Switch the PC on.

Wait until the PC indicates it is ready for operation.
3.
Switch on the extrusion plastometer at the main switch.
4.
Switch on the electronics by pressing the <ON/OFF> button.

Wait until the extrusion plastometer indicates it is ready for operation.
5.
Start the testXpert II software on the PC.
The rotary encoder is defective.

- The error cannot be rectified.
- Please contact ZwickService. The address is located in the appendix.
220
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1.

Testing system
The power measurement is malfunctioning.

Device not running smoothly

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221

Troubleshooting
8 Troubleshooting
WARNING
with hot parts.
WARNING
NOTE
particular work.
Aflow, Mflow extrusion plastometers:

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5.2016 1082852
Aflow extrusion plastometer:

Pneumatic weight lifting unit
9 Pneumatic weight lifting unit

This chapter contains information about servicing the accessory.
CTA: 21297
9.1 Overview
1
Picture 4: Overview of pneumatic weight lifting unit

1
2
3
4
Optional supplementary weights

Testing system
Operator panel
Leveling elements with lock nuts
5
6
7
Pneumatic unit of the weight lifting unit

Latch knob
Lifting arm

The pneumatic weight lifting unit applies the placed test load to the piston depending
upon the test conditions.
The pneumatic weight lifting unit lifts the test load after the end of test.
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223

9.3 Servicing
NOTE
NOTE
NOTE
The factory set pneumatic pressure must not be altered.
There are no maintenance and service stipulations for the pneumatic weight lifting unit.
-
Always keep the pneumatic weight lifting unit clean.

Repair work to the pneumatic weight lifting unit should only be done by
ZwickService.
Be careful if you must replace a part yourself.
CAUTION
Risk of crushing fingers or hands!
There is a risk of crushing fingers or hands when working with weights.
Handle the weights carefully.
Avoid situations where fingers or hands could come between the weights.
224
5.2016 1009319

9.4 Troubleshooting
WARNING
with hot parts.
WARNING
NOTE
particular work.

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225

Pneumatic weight lifting unit with cleaning
function
10 Pneumatic weight lifting unit with cleaning

function
CTA: 62338
10.1 Overview
1
5
8
7
6
Picture 5: Overview of pneumatic weight lifting unit with cleaning function

1
2
3
4
Optional supplementary weights

Lifting arm
Latch knob
Pressure control valve
5
6
7
8
Pneumatic unit of the weight lifting unit

Testing system
Operator panel

The pneumatic weight lifting unit applies the placed test load to the piston depending
upon the test conditions.
The pneumatic weight lifting unit lifts the test load after the end of test.
You can clean the extrusion barrel by means of the cleaning function and suitable cloths.
226
5.2016 1077583

function
10.3 Servicing
NOTE
NOTE
NOTE
-

ZwickService.
CAUTION

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227

function
10.4 Troubleshooting
WARNING
with hot parts.
WARNING
NOTE
particular work.

228
5.2016 1082852

Pneumatic weight lifting unit with peg
positions
11 Pneumatic weight lifting unit with peg positions

CTA: 21299
11.1 Overview
1
2
4
10
5
6
Picture 6: Overview of pneumatic weight lifting unit with pegging
1
2
3
4
5
6
Peg's park position

Pegged weights
Pin
Lifting arm
Optional travel measuring system
Testing system
7
8
9
Optional separating pane

positions
10 Latch knob

The pneumatic weight lifting unit with pegging applies the test load (no longer pegged) to
the piston depending upon the test conditions.
The pneumatic weight lifting unit with pegging lifts the test load after the end of test.
5.2016 1009399
229

positions
11.3 Servicing
NOTE
NOTE
NOTE
-

ZwickService.
CAUTION
230
5.2016 1009399

positions
WARNING
with hot parts.
WARNING
NOTE
particular work.

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231

12 Automatic extrudate cutter

CTA: 11814
12.1 Overview
1
Picture 7: Overview of automatic extrudate cutter

1
2
3
Fixing plate
Screws
Screw
4
3
4
Blade
Limit switch
Housing

The automatic extrudate cutter cuts the extrudate automatically at time intervals or
manually at the touch of a button .
232
5.2016 1009039


WARNING
with hot parts.
WARNING
Risk of injury due to sharp blade edges!
Contact with the blade can result in serious lacerations.
Disconnect the testing system from the mains supply before you work on the
extrudate cutter.
Hold the blade carefully.
NOTE
NOTE
Dismantling the automatic extrudate cutter should be done only by ZwickService.
Overview
Interval
Sub-component
Task
Before each test
Inspection check for damage.
See page
233
Service work
Before each test
5.2016 1009039

Damaged blades must be replaced.
233

CTA: 20435
12.4 Replacing the blade

1
Picture 8: Blade for the automatic extrudate cutter

1
Blade
Screw
NOTE
The blades are consumables.
Remove old blade

Size SW 2.5 hexagon screwdriver
1.
Disconnect the testing system from the mains supply:
2.
Undo the screw at the mounting.
3.
Removed the old/damaged blade carefully.

The old blade is removed.
234
5.2016 1009039

Install new blade

Size SW 2.5 hexagon screwdriver
NOTE! Make sure that the angled part of the blade support shows away from the blade.
Place the new blade and the blade support on the screw as shown.
CTA: 20436
1.
1
2
3
4
Blade support
Screw
Screw in the screw together with blade and blade support on the inner side of the
holder.
CTA: 20435
2.
Support plate
Blade
1
2
Holder's stop
Holder
3
4
Blade
Screw
See the drawing. The blade must be aligned correctly with respect to the die slide
holder to ensure optimum cutting movements and blade-life.
3.
Tighten the screw.

The new blade is installed.
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235

12.5 Clotted blade

The extrudates are not cleanly cut if the blade is clotted.
Clean the blade.
We recommend applying silicone oil to the blade to protect it from becoming clotted. The
silicone oil can be purchased from Zwick.
Order ID:
Silicone oil, order no. 001473
NOTICE
Incorrect test data!
Silicone oil in the extrusion barrel falsifies measured values!
Ensure that no silicone oil reaches the die or the extrusion barrel.
12.6 Dismantling the blade holder

You must dismantle the blade holder in the following instances:
The blade holder is contaminated.
The blade is contaminated and cannot be cleaned.
The slide guide must be dismantled.
Dismantle blade holder
Size SW 2.5 mm hexagon screwdriver
NOTE! Unscrew the screw by 1/4 turn at the most
1.
Loosen the stud screw that fixes the holder to the axis.
2.
Remove the holder

The blade holder is dismantled.
Mount blade holder

Ensure that the holder is mounted only in the position in which you removed it.
The screw must be in contact with the leveled part of the shaft.
1.
Push the holder on up to the stop.
2.
Tighten the screw.

Move the screw back and forth while tightening it in order to find the middle position
easily.
The blade holder is mounted.
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5.2016 1009039
Size SW 2.5 mm hexagon screwdriver

12.7 Removing the slide guide and extrusion barrel

The slide guide and extrusion barrel must be removed in the following instances:
Cut-off extrudate remains stuck on the slide guide.
The cutting channel is clotted.
The die holder cannot be moved easily.
Remove slide guide
Size SW 3 mm hexagon screwdriver
1.
Dismantle the blade holder as described in the chapter entitled, Dismantling the
blade holder.
2.
Loosen the lower plate's four retaining screws.
3.
Now carefully pull out the plate
4.
Loosen the lower plate's four retaining screws.
5.
Remove the slide guide by pulling it downwards.

The extrusion barrel is now free at the bottom and can be removed.
Normally it can be pushed downwards with the help of the brass-wire brush. If the above
is not possible, then it cannot be pressed down from above.
NOTICE
Damage to the device
The upper flange must always be removed in the upwards direction.
Dismantling the upper flange is only to be done by ZwickService staff.
NOTE
Please make sure that the glass wool is neither damaged nor trapped when
assembling the machine.
The screws must not be mistaken.
The insulating plate is sensitive and must be handled with great care. It can be
ordered as an accessory.
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237

WARNING
with hot parts.
WARNING
NOTE
particular work.

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5.2016 1082852

The extrudates are not being cut with precision.

- The blade is clotted with the test material or it is bent.
- Apply a thin layer of silicone oil to the blade.
Silicone oil may never touch the die or enter the extrusion barrel.
WARNING
with hot parts.
WARNING
NOTE
particular work.
5.2016 1082852
239

The material is not cut although the motor is running.

- The extrudate cutter's blade is broken.
- Replace the defective blade!
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5.2016 1082852

Die plug
13 Die plug
CTA: 21003
13.1 Overview
1
Picture 9: Overview of die plug

1
2
3
Return spring
Reset lever
Die mandrel
4
5
6
Blade
Release clutch
13.2 Mechanical position

The die plug is mounted below the testing system's die.

The die plug enables tests on liquid materials. It plugs the outlet from the extrusion barrel
during the pre-heat time, and thus prevents the material being tested from escaping. The
die plug is opened before the beginning of the test.
5.2016 1082301
241

Die plug

WARNING
Risk of burns when cleaning the die plug!
Hot parts belonging to the testing system can cause burns when cleaning the die plug.
Always wear protective gloves when cleaning the die plug.
NOTE
Wipe off any eventual soiling with a clean cloth.
Overview
Interval
Sub-component
Task
Before each test
Die plug
Cleaning
See page
242
Service work
Die plug
Before each test
Cleaning
Clean the die plug each time it gets soiled. Remove all specimen remains from both the
die plug and the die.
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5.2016 1082301

Die plug
13.5 Replacing the plug

You can replace a plug if it is damaged.
CTA: 32025
NOTE
The die plug and plug must be cooled to ambient temperature.
Picture 10: Replace the plug view in lifted up (extended) position

1
Plug
Pressure spindle, SW 3.5 open-end

wrench
Replace the plug

Die plug and plug are cooled.
The die plug is lowered.
SW 3.5 open-end wrench

1.
Carefully unscrew the plug from the pressure spindle.
2.
Screw the new plug into the pressure spindle.
3.
Set the position of the plug in relation to the die. See the section entitled "Adjusting
the die plug."
The plug is replaced.
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243

Die plug
13.6 Adjusting the die plug

WARNING
with hot parts.
NOTE
Adjusting the die plug must be done extremely carefully. Thus adjustment work should be
done only by qualified and competent precision engineers and/or by ZwickService.
Check the lateral position

1.
Illuminate the die from below with a very bright light (flashlight).
2.
Look into the extrusion barrel from above. Check the die's position via the light spot
which can be seen at the bottom of the extrusion barrel.
A correctly adjusted die plug does not let any light into the die opening.
Check the height

1.
Check the height of the die plug with the piston.

The piston sinks by approx. 0.5 mm to 1 mm when the die plug is released provided
it is in the correct position. This procedure makes sure that the die is in plane
contact with the die plug.
If this is not the case, the die plug must be readjusted.
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5.2016 1082301
CTA: 21202

Die plug
Picture 11: Screws for adjusting the die plug

1
2
Fixing screws
Screws for the height
Screws for the lateral position
Adjusting the lateral position and height

1.
Slightly loosen the die plug's adjustment screws.
2.
Adjust the die plug's height by lightly tapping its holder upwards or downwards
3.
Adjust the lateral position via the corresponding four screws.
4.
Tighten the screws.
5.
Recheck the position.
The lateral position and height are adjusted.
5.2016 1082301
245

Die plug
WARNING
with hot parts.
WARNING
NOTE
particular work.

246
5.2016 1082852

Die plug
Test material escapes even though the die plug is closed.

- The plug is damaged.
- Replace the plug (see the chapter entitled "Replacing the plug").
- The die is soiled.
- Clean the die.
- The die is damaged.
- Replace the die.
- The die plug does not close properly.
- Readjust the die plug (see the chapter entitled "Adjusting the die plug").
The die plug does not open.
- The die plug sticks to the die; the blade has hit the plug and has jammed.
- Clean the die plug and return the blade to the initial position.
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247

Separating pane
14 Separating pane
CTA: 10679
14.1 Overview
1
Picture 12: Overview of the separating pane

1
2
3
4
Hinge
Fixing on the testing system
Rear side
Side part
5
6
7
Magnetic lock
Grip
Movable front part
This protective screen is manufactured from a high strength, transparent material

(Plexiglass). It is mounted on the front of the testing system. The protective screen
provides protection against extrudates from falling down.
14.3 Service recommendations

Clean with a commercial glass cleaning medium.
248
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Separating pane

Overview
Interval
Sub-component
Task
Before each test
Separating pane
Check the separating pane for damage. If necessary, replace the separating pane.
See page
249
Service work
Separating pane
Before each test
5.2016 1008904
249

15 Cleaning and compaction unit

CTA: 10689
15.1 Overview
7
6
5
4
1
3
2
Picture 13: Overview of pneumatic cleaning and pre-compaction

1
2
3
4
Die holder
Extrusion barrel
Cleaning and pre-compaction die
Swivel handhold
5
6
7
<Lower> button
Pneumatic cleaning and pre-compaction
Cleaning
The cleaning and compaction unit is used to clean the extrusion barrel with cotton cloths,
which are supplied with the machine.
Compaction
The cleaning and compaction unit enables the material in the extrusion barrel to be
compacted.
250
5.2016 1008881
The cleaning and compaction unit is designed for two different applications.

The compression force is factory set to a load limit of 70 kg. This load can be reduced
one time upon request. This force is used for both cleaning and compaction.
The variable pressure setting can be purchased as an option. This can be used to switch
between the cleaning and compaction loads via the <Mode change> button. You can set
the cleaning load, compaction load, and compaction time on the testing system's
electronics or in the testing software.

Overview
Interval
Sub-component
Task
Before each test
Clean the cleaning and compaction

rod.
See page
251
Service work
Clean the cleaning and compaction rod.
Cleaning and
compaction rod
Before each test
5.2016 1008881
251

Cleaning and disposal
16 Cleaning and disposal

-
Adhere to the legal obligations for preventing waste as well as its proper disposal
and recycling.
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Overview of all service intervals
17 Overview of all service intervals

Interval
When necessary
Before each test
Component
Sub-component
See page
Testing system
Painted surfaces
210
Testing system
Anodized surfaces
210
Testing system
Plexiglas/polycarbonate panes
Testing system
Die
Testing system
Piston
Testing system
Extrusion barrel
Clean Plexiglas/polycarbonate panes
210
Clean the die with a cotton cloth

210
Clean the piston with a cotton cloth

211
Clean the extrusion barrel with a cotton cloth only, do not use cleansing
agents.
211
233
Cleaning
242
Clean the cleaning and compaction
rod.
249
Lubricate lead screws and lead

screw nuts
211

Die plug
Die plug
Separating pane
Separating pane
Testing system
Lead screws and lead screw nuts
251
Monthly
Task
5.2016 1000876
253

Index
18 Index
A
Attention
Incorrect test data............................................. 236
C
Calibration............................................................. 206
Caution
Risk of injury..................................... 224, 227, 230
Cleaning
Anodized surfaces.................................... 210, 253
Painted surfaces....................................... 210, 253
Plexiglas/polycarbonate panes................. 210, 253
F
Function description
Pneumatic weight lifting unit with cleaning function
.......................................................................... 226
O
Overview
.......................................................................... 226
P
Function description..........................................226
Overview........................................................... 226
R
Risk of burns
if contact is made with the die plug!.........215, 222,
225, 228, 231, 238, 239, 246
Servicing.......... 215, 222, 225, 228, 231, 233, 238,
239, 244, 246
When cleaning the die plug.............................. 242
Risk of injury
due to inadvertent switching on........................ 202
Due to sharp blade edges!................................233
Safety measures............................................... 202
254
S
Servicing............................................................... 205
Separating pane........................................249, 253
Spindle.............................................. 210, 211, 253
5.2016

Figure index
19 Figure index
Overview of Aflow with optional pre-compaction ..................................... 208
Picture 2
Pull out the device electronics ................................................................. 214
Picture 3
Battery in the device electronics .............................................................. 214
Picture 4
Overview of pneumatic weight lifting unit ................................................ 223
Picture 5
Overview of pneumatic weight lifting unit with cleaning function ............. 226
Picture 6
Overview of pneumatic weight lifting unit with pegging ........................... 229
Picture 7
Overview of automatic extrudate cutter ................................................... 232
Picture 8
Blade for the automatic extrudate cutter ................................................. 234
Picture 9
Overview of die plug ................................................................................ 241
Picture 10
Replace the plug view in lifted up (extended) position ......................... 243
Picture 11
Screws for adjusting the die plug ............................................................ 245
Picture 12
Overview of the separating pane ............................................................. 248
Picture 13
Overview of pneumatic cleaning and pre-compaction ............................. 250
Picture 1
5.2016
255

Figure index
256
5.2016
Aflow
Dossier: 725368
5.2016
257
5.2016
258

Table of contents
Table of contents
1
testXpert II ........................................................................................................ 261

1.1
First steps ................................................................................................ 261
1.2
Starting testXpert II .................................................................................. 262
1.3
Installation of testXpert II ......................................................................... 263
1.3.1 Rights on your PC ................................................................................... 264

1.3.2 Windows standard ................................................................................... 264
1.3.3 Installation ............................................................................................... 264
1.4
Screen elements ..................................................................................... 265
1.4.1 Series layout ............................................................................................ 266

1.4.2 Curve graph ............................................................................................. 268
1.4.3 Test configuration wizard ......................................................................... 269
1.4.4 Context menu .......................................................................................... 270
1.5
Figure index ..................................................................................................... 274
Running a test ......................................................................................... 271
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Table of contents
5.2016
260

testXpert II
1 testXpert II
This chapter contains important information about the testing software.
1.1 First steps

This description gives you an overview of the most important steps in testXpert II.
It contains the following information:
Installation of testXpert II
Start testXpert II
Introduction to screen elements
Running a test with testXpert II
NOTE
The program functions are described in the online help only.
Online help
CTA: 36942
The online help is opened via the <Help> menu, or via the <Help> button in the dialogs.
The description is split into manuals, so you can also print the desired description.
1
Picture 1: Access online help

1
2
5.2016 1027941
<Help> menu
Contents and index
3
4
Online help end identifier

Manuals
261

testXpert II
1.2 Starting testXpert II

Start testXpert II
1.
Start the program.

In the <Start> menu, select the <testXpert II> program group, and from here, the
<testXpert II> program.
NOTE! testXpert II supports different types of machine electronics, however it can also be
used without any machine electronics, i.e., in the simulation mode.
2.
Select the machine electronics.

Detection of machine electronics:
Compare your machine electronics with those displayed here. Enter the type
of machine electronics you are using.
CTA: 36493
1.
1
2.
3.
testControl II
testControl
Simulation mode
If you don't enter a type of machine electronics here, testXpert II starts
simulation mode (no machine operation) . The following step is not necessary
in simulation mode.
Enter the current tool separation.
262
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testXpert II
CTA: 36943
If you selected a machine electronics, you must enter the current tool separation
when you start testXpert II. Enter the free, mobile distance between the test tools
here.
1
1
2
3
Tensile tests
Flexure tests
Compression tests
4 Specimen
LE Tool separation
testXpert II is started.
1.3 Installation of testXpert II
The minimum system requirements are listed on the reverse side of the inlay for the
testXpert II DVD.
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testXpert II
1.3.1 Rights on your PC

testXpert II saves configurations. You require the following read, write, and deletion rights:
for the Zwick system directory
for subdirectories of the Zwick system directory
for all directories of the environment variable TMP and TEMP
Should you require access to additional directories, you will also need those
corresponding rights.
The Zwick system directory is found under the following paths as standard:
Prior to V3.5:
C:\Zwick\testXpert II\
From V3.6 on:
C:\Programme\Zwick\testXpert II\
C:\ProgramData\Zwick\testXpert II\
Details regarding the installation of testXpert II are available on the DVD in the directory
\SUPPORT\IT-doc.
NOTE
Administrator rights are needed to install and deinstall testXpert II.
1.3.2 Windows standard

The testing software uses Windows standard elements.
We assume that you are acquainted with operation of Windows programs.
If you do not know how to navigate through a Windows program, then look at the
operating system's help, or run its tutorial.
1.3.3 Installation
Install testXpert
Insert the testXpert DVD in your DVD drive.
2.
Installation starts automatically.

If it does not start automatically, proceed as follows:
1.
Start explorer or open the workplace window.
2.
Double click on the drive icon for the DVD drive.
3.
Double click on the icon for the setup program (setup.exe).
NOTE! Installation must be to a different, separate directory if the installation program

finds an older version of testXpert II.
3.
Follow the instructions on the screen.

The testXpert II program group is found in the <Start> menu after installation has
been finalized.
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1.

testXpert II
1.4 Screen elements
CTA: 36944
You can purchase a wide range of test programs for use with testXpert II. Pre-configured,
fixed screen layouts are integrated into these test programs. The screen layouts used in
testXpert II contain graph, table, display and/or input windows.
Picture 2: Screen elements

You can compile the elements in different manners, which in turn adjusts the screen
layouts to meet your own requirements.
Basically three screen elements are offered:
Series layout
Specimen layout
Test configuration wizard.
CTA: 36945
You can toggle between the available screen layouts (depending upon the license) via the
tab card symbols above the running display. The current screen layout is indicated by a
tab card symbol highlighted in color.
1
Picture 3: Screen layouts display

1
5.2016 1028004
Current screen layout
Tab symbols
265

testXpert II
1.4.1 Series layout

All values required and recorded for the test are visible in this layout screen.
Specimen requirements
Graphical display of the test
Results
Calculated statistical values
CTA: 36946
The representation can vary from test program to test program.

1
Picture 4: Series layout

<Series layout> tab symbol
Menu bar
Tool bar
Results table
Statistics table
6
7
8
9
Input field
Continuous display
Curve graph
Specimen tree
Menu bar
You can select entries such as <Open>, <Save>, <Print report>, <Printer setup> etc.
and also the help functions in the menu bar.
Specimen tree
You can manage a series, sub-series or specimen in the specimen tree. You make
settings in the context menu. You do this by clicking in the specimen tree area with the
right mouse button.
266
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1
2
3
4
5

testXpert II
Tool bar
testXpert II has numerous actions for simple and rapid operation of the program and the
testing system. You can access these and other functions by using the buttons on the
toolbar.
You can customize the toolbar in the various test programs and master test programs.
For an explanation of the function of a button on the toolbar, move the mouse pointer
over the corresponding button. A short description of the function appears after a short
period of time (Tool tip). This function always works even if the program layout is
different from other layouts.
Results table
Here, the determined results are displayed. Make settings for results via the context
menu. This menu can be accessed by right clicking on this element.
Statistics table
Here, the calculated statistical values are displayed. You can make settings for
displaying statistics via the context menu. This menu can be accessed by right clicking
on this element.
Input field
You enter the data required for the test here. You can select the displayed parameters
and their settings via the context menu. This menu can be accessed by right clicking on
this element.
Continuous display
The running display shows the measurement values during the test and when not
performing a test. You can select them and their unit via the context menu. This menu
can be accessed by right clicking on this element.
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267

testXpert II
CTA: 36947
1.4.2 Curve graph

1
Picture 5: Curve graph

1
2
<Specimen graph> tab symbol

Specimen tree
Curve graph
A graphical display can be obtained in a curve graph for:

Current test
Current test series
You can zoom in on the curve graph.
Zoom in on the curve graph
1.
Keep the left hand mouse button pressed and drag the mouse pointer over the
section you would like to zoom in on.
A rectangular marking will then appear.
2.
Release the mouse button.

This procedure can be repeated several times, increasing the size each time it is
repeated until the required size is achieved.
Return to the initial graph by pressing the left mouse button.
268
5.2016 1028004
The area within the selection will be magnified.

testXpert II
1.4.3 Test configuration wizard
CTA: 36957
You configure the test in the testXpert II wizard. There are different pages for the wizards
depending upon the test program being used. The different pages group parameters
which are content related.
1
Picture 6: Test configuration wizard

1
2
3
Wizard navigator
Wizard modes: <Standard>/<Expanded>
Wizard layout
4
5
6
7
Wizard edit page

Control box
Button
List field
Wizard navigator
The wizard's navigator contains the pages to be processed. Pages which have already
been scrolled through are marked by a tick sign. Pages requiring alteration to data are
highlighted in color.
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269

testXpert II
1.4.4 Context menu

testXpert II often uses context menus. To call up the context menu, right click on a screen
element.
CTA: 36958
These context menus allow for a wide range of configuration possibilities.
Picture 7: Calling-up context menus

1
Context menu
270
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testXpert II
1.5 Running a test

Run a test
1.
Load the test program

1.
Select the <Open... > in the <File> menu.
NOTE! The last test program/series that was open is automatically loaded at the
next start of testXpert II.
Select a suitable test program for your test requirements in the <Open>
dialog. Observe the detailed explanation(s) in the <Notes> field.
CTA: 36966
2.
1
2
Toggle help topics on/off
First inputs in testXpert II

Test relevant data must be entered once the test program has been loaded. This
data is usually reduced to a minimum. An input field exists in testXpert II specifically
2.
Optional industry packages

Comment
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271

testXpert II
CTA: 36946
for this data. By default, you can find it in the bottom right-hand corner of the series
layout. Enter the required data for the specimen there.
Input field
3.
Set the testing system to its initial position

Set your testing system according to the requirements of your testing task. Notes on
the loaded test program are included in the online help.
4.
Position the specimen

Place your specimen in the specimen grip.
5.
Check load
The type of test determines how the prevailing force is to be treated.
Tensile test:
Grip the specimen with the specimen grip connected to the load cell.
Tare the force.
Close the second specimen grip.
Flexure test:
Place the specimen on the support.
Tare the force.
6.
Start test
Start the test either:
at the testing system
via the keyboard using the accelerator <SHIFT>+<F10>, or
by clicking with the left mouse button on <START> in the toolbar
272
5.2016 1027941
Compression test:
Place the specimen on the compression platen.
Tare the force.

testXpert II
7.
testXpert II controls the test sequence. You will be requested, if necessary, to run
actions such as
-
close a safety device

attach/detach a manual extensometer
...
The testing system returns to its initial position at the end of test depending upon
the test program being used. Remove the specimen and prepare the next test.
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273

Figure index
2 Figure index
Picture 1
Access online help .................................................................................. 261
Picture 2
Screen elements ..................................................................................... 265
Picture 3
Screen layouts display ............................................................................ 265
Picture 4
Series layout ............................................................................................ 266
Picture 5
Curve graph ............................................................................................. 268
Picture 6
Test configuration wizard ......................................................................... 269
Picture 7
Calling-up context menus ........................................................................ 270
274
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Circuit diagrams
Aflow
Circuit diagrams
Dossier: 725368
5.2016
275
Circuit diagrams
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276
Aflow
Dossier: 725368
5.2016
279
5.2016
280
Table of contents
Table of contents
EC Declaration of Conformity ........................................................................ 283
Index ................................................................................................................. 288
5.2016
281
Table of contents
282
5.2016
EC Declaration of Conformity
Zwick GmbH & Co. KG . August-Nagel-Strasse 11 . 89079 Ulm
according to EC Machinery Directive 2006/42/EC, Appendix II 1 A
The manufacturer hereby declares that the construction of the materials test system
Dossier:
Order confirmation:
Serial number:
Product:
Type:
725368
2531856
725368 / 2016
Aflow
Aflow
complies with the provisions

of the aforementioned EC Machinery Directive and
the Electromagnetic Compatibility Directive 2014/30/EU in accordance with its intended use as set forth
in the user manual.
Regarding electrical risks, the safety objectives of the Low Voltage Directive 2014/35/EU have been
complied with as defined by Annex I No. 1.5.1 of the EC Machinery Directive.
Applied, harmonized standards, in particular

EN ISO 12100:2010
Safety of machines - General principles for design - Risk assessment and risk reduction
EN 61326-1:2013
Electrical equipment for measurement, control and laboratory use EMC requirements - Part 1: General
requirements
The signatory is, at the same time, authorized to compile the relevant technical documents and communicate
the information therein to the appropriate national authorities upon substantiated request.
Ulm, 15.5.2016
i.V. M. Flock
Identification of the signatory:
CE authorized signatory (series products)
5.2016 1000878
283
284
5.2016 1000878
21.05.2015 Ed.3
Product safety information sheet
Polypropylene
BC245MO
1. Identification of the substance/mixture and of the company/undertaking
Trade name:
Material use:
Manufacturer:
BC245MO
raw material for plastics industry
Borealis
E-mail address: product.safety@borealisgroup.com
2. Hazards identification
Health: The product is not classified as hazardous. Inhalation of dust may irritate the respiratory tract.
Prolonged inhalation of high doses of decomposition products may give headache or irritation of the respiratory
tract.
Fire: The product burns, but is not classified as flammable.
Environment: The product is not considered hazardous for the environment.
3. Composition/information on ingredients
The product is a polypropylene polymer.
Contains no substance classified as hazardous in concentrations, which should be taken into account according
to EU regulations.
4. First aid measures

No specific instructions needed.
Skin contact: Cool melted product on skin with plenty of water. Do not remove solidified product.
5. Firefighting measures
Suitable extinguishing media: Water in spread jet, dry chemicals, foam or carbon dioxide.
Special exposure hazards: Principal toxicant in the smoke is carbon monoxide.
6. Accidental release measures

Vacuum or sweep up spill. All spill of material must be removed immediately to prevent slipping accidents.
7. Handling and storage

Handling: During processing and thermal treatment of the product, small amounts of volatile hydrocarbons may
be released. Provide adequate ventilation. Local exhaust ventilation may be necessary. Avoid inhalation of dust
and decomposition fumes. Dust from the product gives a potential risk for dust explosion. All equipment shall be
grounded.
Storage: Safety aspects do not require any special precautions in terms of storage.
Borealis AG | Wagramerstrasse 17-19 | 1220 Vienna | Austria

Telephone +43 1 224 00 0 | Fax +43 1 22 400 333
FN 269858a | CCC Commercial Court of Vienna | Website www.borealisgroup.com
Page 1 of 3
21.05.2015 Ed.3
Polypropylene
BC245MO
8. Exposure controls/personal protection
Provide adequate ventilation. Local exhaust ventilation may be necessary.
9. Physical and chemical properties

Appearance: solid, natural colour
Odour: odourless
Melting point/range: 130 - 170 C
Density: 0,9 - 1,0 g/cm
Ignition temperature: > 320 C

Solubility(ies): insoluble in water
10. Stability and reactivity

The product is a stable thermoplastic, with no chemical reactivity.
11. Toxicological information

The product is not classified as hazardous according to Regulation (EC) No 1272/2008. Inhalation of dust may
irritate the respiratory tract. Prolonged inhalation of high doses of decomposition products may give headache
or irritation of the respiratory tract.
12. Ecological information

The product is not considered hazardous for the environment.
13. Disposal considerations

Reuse or recycle if not contaminated. The product may be safely used as fuel. Proper combustion does not
require any special flue gas control. Check with local regulations.
14. Transport information

The product is not regulated by ADR/RID, IMDG or IATA.
15. Regulatory information

In accordance with Regulation (EC) No 1272/2008, the product does not need to be classified nor labelled.
Label:
Trade name:
Manufacturer:
BC245MO
Borealis

Telephone +43 1 224 00 0 | Fax +43 1 22 400 333
Page 2 of 3
21.05.2015 Ed.3
Polypropylene
BC245MO
16. Other information
Issued in accordance with Article 32 of Regulation (EC) No 1907/2006, and its amendments.
Issuer: Borealis, Group Product Stewardship / Niina Kerttula
Disclaimer
To the best of our knowledge, the information contained herein is accurate and reliable as of the date of
publication; however we do not assume any liability whatsoever for the accuracy and completeness of such
information.
Borealis makes no warranties which extend beyond the description contained herein. Nothing herein
shall constitute any warranty of merchantability or fitness for a particular purpose.
It is the customer's responsibility to inspect and test our products in order to satisfy itself as to the
suitability of the products for the customer's particular purpose. The customer is responsible for the
appropriate, safe and legal use, processing and handling of our products.
No liability can be accepted in respect of the use of Borealis' products in conjunction with other materials. The
information contained herein relates exclusively to our products when not used in conjunction with any third
party materials.

Telephone +43 1 224 00 0 | Fax +43 1 22 400 333
Page 3 of 3
Index
1 Index
D
Declaration of Conformity............................. 283, 284
E
EC Declaration of Conformity....................... 283, 284
288
5.2016
Appendix
Aflow
Appendix
Dossier: 725368
5.2016
289
Appendix
5.2016
290
Appendix
Table of contents
Table of contents
Introduction ...................................................................................................... 293
Service .............................................................................................................. 294
Checklists ......................................................................................................... 295
Data required for your phone call .................................................................. 296
Calibration ........................................................................................................ 297
Password .......................................................................................................... 300
Index ................................................................................................................. 301
5.2016
291
Appendix
Table of contents
5.2016
292
Appendix
Introduction
1 Introduction
This manual includes

the ZwickService address for the following requests:
Refurbishment
Retrofit
Used machines
Software updates
Zwick hotline for help with malfunctioning of
the testing system
the software
Checklist for testing device functions on your own
Information on the accredited Zwick calibration service
5.2016 1002270
293
Appendix
Service
2 Service
Zwick GmbH & Co. KG
ZwickService
August-Nagel-Str. 11
D - 89079 Ulm-Einsingen
Tel.: +49 7305 10-225
Fax: +49 7305 10-432
e-mail: hotline@zwick.de
Internet http://www.zwick.de / www.zwick.com
Please contact the following for information on refurbishment, retrofitting, used machines
and software updates:
Tel.: +49 7305 10-0
If you have inquiries about the PC and monitor, please contact either the service center of
the manufacturer directly or ZwickService.
Hotline
Our hotline is open on workdays (Monday to Friday) from 8 a.m. to 6. p.m.
Tel.: +49 7305 10-225
Tel.: 0800 9942585 (for Germany)
Fax: +49 7305 10-432
e-mail: hotline@zwick.de
294
5.2016 1003609
Appendix
Checklists
3 Checklists
Our hotline will also provide assistance should any malfunctioning of the testing system
or software arise. Your contact person will coordinate and organize quick and efficient
shipment of spare parts and, if necessary, will arrange a visit to your firm by a technician.
Our Support Desk is available for detailed consultation (i.e., support for technical
applications, software adaption, tuition).
Before calling the hotline, please check the basic functions of your testing system using
the following checklist as a guide.
Checklist for checking functions
1.
Is the testing system ready for testing?
2.
Is the <ON> button illuminated?

Switch the testing system on and off via the <ON/OFF> button.
3.
Is an error displayed on the electronics display or on the computer's monitor?

Observe and follow the error messages and notes on the electronics display
or the computer's monitor to arrive at a solution.
The functions are checked.
Checklist for testing test conditions

1.
Do your test requirements correspond to the required test standard?

Check your requirements with those of the required test standard
(international standards such as EN, ISO, etc., national standards such as
DIN, BS, ASTM, etc., or company-internal standards).
Read them and check the requirements, i.e., required test sequence.
2.
Please note the following:

The exact wording of the error message with error number
The corresponding details and the frequency at which they occur
The procedure that was carried out directly before the error message occurred
3.
Please note features such as the following:

Material properties
Special environmental conditions such as temperature fluctuations, air
humidity, etc.
Voltage fluctuations or mains problems
Transmitters, electro-ovens, or large punching or pressing machines in the
vicinity
Other particulars
The device functions have been checked.
5.2016 1028854
295
Appendix
Data required for your phone call
4 Data required for your phone call

Please keep the following information handy. This makes it easier to answer questions
about the testing system and the test conditions quickly.
Manufacturer data
AB/ Dossier number:
Type
Serial number
Software used:
(License stage? => Title bar)
Software version
Language of the software
This information can be found on the first page of the user manual
Data about your company
Name of your company
Postal code and city
Address (house number and street)
Department
Telephone or fax number
Email address, if available
Your name or the name of the contact person
Hotline
Quick assistance for defects and malfunctions on work days from
Monday to Thursday between 7:30 a.m. to 6:00 p.m.
and on Friday from 7:30 a.m. to 5:00 p.m.
+49 (0) 7305 - 10 225
0800 - 99 42 585 / 0800- ZWICKUL (for Germany)
Email: hotline@zwick.de
296
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Appendix
Calibration
5 Calibration
The testing systems measurement and control unit must be calibrated at regular intervals
to ensure consistent and reproducible measurement results.
The user is responsible for adhering to suitable calibration intervals.
We recommend annual inspection and calibration (according to DIN 51220, DIN EN ISO
7500-1, and DIN EN ISO 9513).
Zwick has a test laboratory that has been accredited by DAkkS (German Accreditation
Body) to DIN EN ISO/IEC 17025.Our service technicians are available to assist you with
professional inspection and calibration. Your testing system will be checked on site by our
qualified and authorized personnel for its functionality and accuracy and can, if
necessary, be readjusted if deviations are found.
NOTE
system.
5.2016 1090964
297
Inspection and calibration

Request
Request for maintenance to
Request for maintenance and service
ZwickService
Fax: +49 7305 / 10-261
D- 89079 Ulm
Please provide us with an offer for periodic maintenance and calibration for the following items:
Device
Type
Serial no.
Dossier / AB no.
............................
..................
.......................
..................................
Required schedule:
........ Quarter-year
First maintenance: ...........
[
[
[
] With Zwick calibration certificate(s) only, or

] With Zwick calibration certificate(s) and documentation on traceability to ISO 9000, or
] With DAkkS calibration certificate.
The following temperatures and load stages should be calibrated during inspection:
Temperatures:
Units:
.........................................
.........................................
.........................................
.........................................
.........................................
.........................................
[
[
[
[
[
[
Load stages:
] C
] C
] C
] C
] C
] C
[
[
[
[
[
[
]
]
]
]
]
]
F
F
F
F
F
F
............................................
............................................
............................................
............................................
............................................
............................................
kg
kg
kg
kg
kg
kg
Measurement devices:
[ ] Analytical scales *
[ ] Density determination kit *
Manufacturer: ............................
Model: ......................
............................
Model: ......................
Manufacturer:
sundry ...................................................................................................................................................
Copyright 2010, Zwick GmbH & Co. KG D-89079 Ulm
* Only Zwick calibration certificate possible

Addresser:
Company/Institute ....................................................................................................................................
Road/Postbox
....................................................................................................................................
Postal (ZIP) code, place

..............................................................................................................................................
Department ..................................
Name .....................................................................................
Telephone
Fax: .....................................................................................
..................................
Date: ..................................
Please fill in the above form completely and clearly. We will then be able to handle your enquiry quickly and efficiently.
This page is designed to fit a DIN long window envelope.
04.15 / 10978_1 / V5.2
Zwick technical documentation

Instruction manual
Appendix
Password
6 Password
NOTE
The following is Information for the testing system user:
We have provided a superordinate, non-changeable password for your safety. This
password must be kept in a safe place. Remove this page from your user manual and
keep it together with your paperwork.
The superordinate password is:
730510
300
5.2016 1027640
Appendix
Index
7 Index
C
Calibration............................................................. 297
Checklist
Checking the functions......................................295
Test conditions.................................................. 295
H
Hotline...........................................................294, 296
M
Manufacturer
data................................................................... 296
Your company................................................... 296
Z
ZwickService......................................................... 294
5.2016
301
Appendix
Index
5.2016
302
General index
General index
A
Additional national and operational regulations...... 31
Attention
Data loss........................................................... 135
Electromagnetic fields.........................................95
External influences..............................................91
Incorrect test data............................................. 236
Observe clearances............................................ 91
Observe the center of gravity..............................90
Transport damage...............................................90
B
Before switching on.................................................42
C
Calibration.....................................................206, 297
Caution
Risk of injury..................................... 224, 227, 230
Checking and preventive measures
Safety manual..................................................... 35
Checklist
Checking the functions......................................295
Test conditions.................................................. 295
Cleaning
Anodized surfaces.................................... 210, 253
Painted surfaces....................................... 210, 253
Plexiglas/polycarbonate panes................. 210, 253
Cleaning recommendations.................................... 47
D
Danger of explosion.......................................... 88, 91
Danger of hot surfaces
due to swiveled-out piston!................................. 40
Bubble spirit level........................................98, 182
High travel speed..............................170, 171, 174
Declaration of Conformity............................. 283, 284
Die
Cleaning............................................................184
Disposal.................................................................. 97
E
EC Declaration of Conformity....................... 283, 284
Electronic rating plate............................................. 55
Electronics
Switch on.......................................................... 109
EMC
Guidelines..................................................... 89, 95
Extrusion barrel
Cleaning............................................................184
5.2016
F
Function description
.......................................................................... 226
H
Hotline...........................................................294, 296
I
Installation site........................................................ 91
M
Mains cable.............................................................45
Maintenance work...................................................44
Manufacturer
data................................................................... 296
Your company................................................... 296
Material cycle.......................................................... 97
N
National regulations................................................ 31
O
Operating................................................................ 43
Operator personnel................................................. 38
Overview
.......................................................................... 226
P
Packaging............................................................... 97
Personnel..........................................................38, 39
Piston
Cleaning............................................................184
Function description..........................................226
Overview........................................................... 226
Preventing waste.................................................... 47
R
Recycling.................................................................97
Residual risks..........................................................35
Responsibility for personnel....................................38
Risk of burns
Cleaning............................................................183
Dismantling........................................................114
due to hot test material!.................................... 124
from hot parts of the testing system..........107, 124
if contact is made with the die plug!.........185, 215,
222, 225, 228, 231, 238, 239, 246
Servicing.......... 215, 222, 225, 228, 231, 233, 238,
239, 244, 246
When cleaning the die plug.............................. 242
Risk of damage
Incorrect die height........................................... 145
Switching off the testing system........ 110, 112, 180
Risk of fire............................................................. 183
303
General index
Risk of injury
Active medical implants.............................. 88, 124
Chemical reactions........................................... 125
due to inadvertent switching on........................ 202
Due to sharp blade edges!................................233
Due to unexpected startup of blade..................187
Functions of the safety devices........................ 124
Safety measures.........................89, 107, 125, 202
Warning...............................................................88
S
Safety labels
On the testing system................................... 36, 37
Safety measures..................................................... 42
Safety-related equipment........................................ 32
Serial number plate
Large...................................................................56
Service work
Environmental protection.................................... 47
Servicing............................................................... 205
Separating pane........................................249, 253
Spindle.............................................. 210, 211, 253
T
Testing system
Cleaning..............................................................97
Safety labels................................................. 36, 37
W
Warning
Risk of injury..................................................... 102
Work
On electrical equipment...................................... 45
On pneumatic equipment....................................46
Workplace............................................................... 40
Z
ZwickService......................................................... 294
304
5.2016
General figure index

Safety manual
Picture 1 Safety labels .................................................................................................................. 36
Picture 2 Testing system workplace .............................................................................................. 40
Technical manual
Picture 1 Electronic rating plate .................................................................................................... 55
Picture 2 Serial number plate, large .............................................................................................. 56
Picture 3 Overview of Aflow with optional pre-compaction ........................................................... 57
Picture 4 Aflow dimensions ........................................................................................................... 58
Picture 5 Interfaces ....................................................................................................................... 61
Picture 6 Piston, with a radius of R0.4 .......................................................................................... 66
Picture 7 Overview of automatic extrudate cutter ......................................................................... 70
Picture 8 Overview of die plug ...................................................................................................... 72
Picture 9 Overview of the separating pane ................................................................................... 74
Picture 10 Overview of pneumatic cleaning and pre-compaction ................................................. 76
Picture 11 Test granulate .............................................................................................................. 78
Installation manual
Picture 1 Scope of delivery ........................................................................................................... 92
Picture 2 Remove screws ............................................................................................................. 94
Picture 3 Lifting positions .............................................................................................................. 96
Picture 4 Mount the die holder .................................................................................................... 100
Picture 5 Mounting the specimen chute ...................................................................................... 101
Picture 6 Connections ................................................................................................................. 102
Picture 7 Die and extrusion barrel ............................................................................................... 108
Picture 8 Mains switch at the rear ............................................................................................... 109
Picture 9 Electronics ................................................................................................................... 109
Picture 10 Back side of testing system ....................................................................................... 113
5.2016
305
User manual
Picture 1 Operational controls ..................................................................................................... 126
Picture 2 Operating field buttons ................................................................................................. 127
Picture 3 Electronics ................................................................................................................... 128
Picture 4 First mask .................................................................................................................... 131
Picture 5 Possible mask calls ..................................................................................................... 131
Picture 6 PC Operation ............................................................................................................... 132
Picture 7 Mask <Main menu> ..................................................................................................... 134
Picture 8 Travel-time diagram of a test ....................................................................................... 142
Picture 9 Operational controls for cleaning and compaction unit ................................................ 177
Picture 10 Mechanical operation ................................................................................................. 178
Picture 11 Mains switch at the rear ............................................................................................. 179
Picture 12 Close die plug ............................................................................................................ 186
Picture 13 Swivel options for the cleaning and compaction unit ................................................. 188
Picture 14 Swiveled-in probe head and piston ............................................................................ 190
Picture 15 Cleaning with the cleaning and compaction unit ........................................................ 192

Picture 1 Overview of Aflow with optional pre-compaction ......................................................... 208
Picture 2 Pull out the device electronics ..................................................................................... 214
Picture 3 Battery in the device electronics .................................................................................. 214
Picture 4 Overview of pneumatic weight lifting unit ..................................................................... 223
Picture 5 Overview of pneumatic weight lifting unit with cleaning function ................................. 226
Picture 6 Overview of pneumatic weight lifting unit with pegging ............................................... 229
Picture 7 Overview of automatic extrudate cutter ....................................................................... 232
Picture 8 Blade for the automatic extrudate cutter ...................................................................... 234
Picture 9 Overview of die plug .................................................................................................... 241
Picture 10 Replace the plug view in lifted up (extended) position ............................................ 243
Picture 11 Screws for adjusting the die plug ............................................................................... 245
Picture 12 Overview of the separating pane ............................................................................... 248

Picture 1 Access online help ....................................................................................................... 261
Picture 2 Screen elements .......................................................................................................... 265
Picture 3 Screen layouts display ................................................................................................. 265
Picture 4 Series layout ................................................................................................................ 266
Picture 5 Curve graph ................................................................................................................. 268
Picture 6 Test configuration wizard ............................................................................................. 269
Picture 7 Calling-up context menus ............................................................................................ 270
306
5.2016
Picture 13 Overview of pneumatic cleaning and pre-compaction ............................................... 250
03.12 / 14263 / V5.1
Transport- und Auspackanleitung

Transport and unpacking instructions
Instructions de transport et dballage
D
ic kai sl
Zwat er
M
Te
ting
03.12 / 14263 / V5.1
17
Transport- und Auspackanleitung

Transport and unpacking instructions
Instructions de transport et dballage
E
Ma
ckai sl
Z witer
Te
st
ni g

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Zwick

Zwick GmbH & Co. KG

Zwick GmbH & Co. KG

+49 (0)7305 10-0

Acceptance report for machines, systems,

Acceptance report for machines, systems, and devices

Zwick GmbH & Co. KG

KINGFA SCI. & TECH. (Europe) GmbH

The machine/system/device named above was

Copyright 2016, Zwick GmbH & Co. KG, D-89079 Ulm

Zwick/Roell department and signature

Name and address of the customer

Acceptance report for machines, systems,

Copyright 2016, Zwick GmbH & Co. KG, D-89079 Ulm

General table of contents

General table of contents

Legal notice ....................................................................................................................... 13

About this user manual .................................................................................................... 14

Warranty and liability ........................................................................................................ 24

Testing system .................................................................................................................. 30

Additional national and operational regulations ........................................................... 31

Safety-related equipment ................................................................................................. 32

Intended use ...................................................................................................................... 33

Improper use ..................................................................................................................... 34

Residual risks ................................................................................................................... 35

Safety labels on the testing system ................................................................................ 36

Before switching on ......................................................................................................... 42

Maintenance work ............................................................................................................. 44

Working on electrical equipment .................................................................................... 45

Working on pneumatic equipment .................................................................................. 46

Cleaning and disposal ...................................................................................................... 47

Copyright 2016, Zwick GmbH & Co. KG, D-89079 Ulm

Testing system .................................................................................................................. 57

Automatic extrudate cutter .............................................................................................. 70

Die plug .............................................................................................................................. 72

Separating pane ................................................................................................................ 74

Cleaning and compaction unit ........................................................................................ 76

Test granulate .................................................................................................................... 78

General table of contents

Initial commissioning ..................................................................................................... 107

Dismantling ...................................................................................................................... 111

Introduction ..................................................................................................................... 123

General safety notes ...................................................................................................... 124

Operational controls ....................................................................................................... 126

Operating ......................................................................................................................... 178

Service and maintenance manual

General safety notes ...................................................................................................... 202

Documentation for maintenance and servicing ........................................................... 204

Servicing .......................................................................................................................... 205

Calibration ....................................................................................................................... 206

Service recommendations ............................................................................................. 207

Testing system ................................................................................................................ 208

Troubleshooting .............................................................................................................. 222

Pneumatic weight lifting unit ......................................................................................... 223

Pneumatic weight lifting unit with cleaning function .................................................. 226

Pneumatic weight lifting unit with peg positions ........................................................ 229

Automatic extrudate cutter ............................................................................................ 232

Die plug ............................................................................................................................ 241

Separating pane .............................................................................................................. 248

Cleaning and compaction unit ...................................................................................... 250

Cleaning and disposal .................................................................................................... 252

Overview of all service intervals ................................................................................... 253

Special test programs