PRINTER MUST BE SERIAL (Dot Matrix) TO RUN FROM 4400 CONSOLE

Must have the following settings on Printer: 

BAUD RATE= (1200)

DATA BITS= (7)

STOP BIT= (1)

PARITY= (EVEN)

Note:Must use the RS232 Out Connecter on back of the 4400 console to plug the Printer into.

Instron software verification documentation, accreditations and certificates can be viewed and downloaded here

The order that you turn them on is not important. However, the machine must be ready when the Merlin SW is launched. The machine is ready when the display, located to the right of the load cell connector, reads "1" or a "."

You have four options: 

1. Purchase a System Support Agreement. This provides you with priority in the call queue, remote access to our engineering staff, discounts and additional services for one full year. 
2. Sign-on to our Consultation Service line. This Fee based support provides you with priority in the call queue for those times that you just specific help. 
3. Limited Free Technical Support on a call back basis. 
4. Schedule a Field Service Engineer to visit your site.

Load Cell Connections:

15 Pin Load Cell Plugs (DC Load Cells) Pin 3 -ve Output Pin 9 +ve Output Pin 1+ve Excitation Pin 5 -ve Excitation Pin 2 and 4 ID. Code Resistor or wire link

25 Pin Load Cell Plugs (DC Load Cells) Pin 18 -ve Output Pin 19 +ve Output Pin 4 and 5 Code Resistor or wire link

Extensometer Connections

AC Extensometers

25 Pin Extensometer Plugs Pin 14 -ve Output Pin 15 +ve Output Pin 1+ve Excitation Pin 2 -ve Excitation Pin 4 and 5 ID. Code Resistor or wire link

DC Extensometers. 25 Pin Extensometer Plugs Pin 18 -ve Output Pin 19 +ve Output Pin 8 and 20 Wire link (4400 and 5500 machine only) Pin 21 and 23 Wire link Pin 4 and 5 ID. Code Resistor or wire link May also need to link pin 18 to pin 3(AGnd). Note: Where it says ID code resistor you can usually just put a jumper between those two points.

CHECK VOLTAGES 

(NOTE) these are located at the top right of the CPU Board that is attached to the door that swings open on the console. 

(X30) +5 VOLTS 

(X31) GROUND 

(NOTE) These are located at the Bottom of the CPU Board. 

(X42) –15 VOLTS 

(X43) +15 VOLTS 

Note:If voltages are off contact Instron Support for help. 

(Note)If Voltages are Good. On the CPU Board there are 2 RAM Chips, Ram 0 and Ram 1. One of them will have the word Dallas on it. They are close to the smaller board that piggy- backs on the Board. 

A) Turn power off on frame, Swap Chips. 

B) Turn power back on, after a few seconds turn the power back off. 

C)Swap backs Chips, Turn power on. 

D) If watch dog error goes away you are all set.

1. For 5800 systems: +/-0.4% of reading down to 1/100 of load cell capacity +/-0.5% of reading down to 1/500 of load cell capacity 
2. For 5500 systems: +/-0.4% of reading down to 1/100 of load cell capacity +/-0.5% of reading down to 1/250 of load cell capacity 
3. For 4500/8500/8800 systems: +/-0.5% of reading down to 1/250 of load cell capacity (4500) +/-0.5% of reading down to 1/100 of load cell capacity (8500/8800) 
4. For 4200/4300/4400 systems: +/-0.5% of reading down to 1/50 of load cell capacity (through IEEE) +/-1.0% of reading down to 1/100 of load cell capacity (through IEEE) +/-0.5% of reading down to 1/10 of load cell capacity (through display) +/-1.0% of reading down to 1/50 of load cell capacity (through display) 
5. For an 1100,1120 or 2150 system +/-0.25% of the range in use or +/-0.5% of the indicated load, whichever is greater.
6. For 1130 & 3211 systems: +/-0.5%of the range in use. 

Note: In all cases the absolute error remains constant below specified minimum limit of capacity. Instron's traceable standards were calibrated according to ASTM E74 or ISO 376 specifications at Instron's Force Calibration Laboratory accredited by NVLAP or another accedited laboratory mutually recognised by the International Laboratory Accreditation Co-operation (ILAC) and the International Accreditation Forum (IAF).

As long as the motor light is not lit up on the console you can press (S1-0) enter.
It is important that you realize that this will clear your console to the factory defaults.
It will say "Loss" in the display.
You will need to enter a new speed, and calibrate your Load Cell.

Most communication errors can be solved by powering down all equipment, including machine frame, control tower and computer. They should then be powered back on in the following sequence: machine frame, control tower and computer. This should result in communication being re-established. If not, check all cables and connections and perform the restart that was described above. If this does not fix your problem, then please call Instron Tech Support at 1-800-473-7838. Please make sure that you have all relevant serial and model numbers at hand when calling.

Perform the following: 1. Attempt to reset the 5500 machine (turn off for 10 seconds, turn on). 2. Look at the LED display on the display (located to the right of the load cell connector.) If the display is a "1" click "retry" to establish a communication link. If the display is a 2, check the cable between the computer and the frame and reboot the computer. 3. Confirm if new hardware (sound card, network card, modem, etc.), has been added since the machine last worked properly? If so, check for resource conflicts with the assistance of your IS department. The default settings for the the Instron communication board are IRQ 10, DMA 6, I/O 380h. If the problem persists, please use our Service Support Form (refer to the [question number] located at the end of each question and provide your model and serial number). Service and Technical Support Form

This may be the result of clutter on the hard drive. Run ScanDisk and delete any temp files. This should resolve the problem. If the problem persists, please use our Service Support Form (refer to the [question number] located at the end of each question and provide your model and serial number). Service and Technical Support Form

A power glitch can occasionally cause this condition. Power down, wait 10 seconds, and power back up. If the condition remains, a possible hardware failure has occurred. Contact Instron Service. Please use our Service Support Form (refer to the [question number] located at the end of each question and provide your model and serial number). Service and Technical Support Form

If you enable load or strain control in the Series IX software and don't have the proper PROM version or the ADVANCED FUNCTIONS PANEL, you will get this message. To run in load or strain control while using a 4500 frame you will need to upgrade your PROM's to the latest version and install the ADVANCED FUNCTIONS PANEL into your 4500 tower. Contact Technical Support at 1-800-473-7838 for availability and pricing. NOTE: If you have the advanced functions panel, updated proms and using a Dell PC running Windows NT but continue to receive this message, you will need to upgrade your software to V8.27 or higher.

This is a possible hardware failure. Contact Instron Service. Please use our Service Support Form (refer to the [question number] located at the end of each question and provide your model and serial number). Service and Technical Support Form

The following could be the problem: 

1. The frame to console cable could be loose. With the power turned off to the machine, make sure that the cable is securely attached with the securing screws on the connector to both the frame and the console. 
2. There is a motor door on some table models; make sure that the access door to the motor is securely closed. If unsure if your system has a motor access door or its location, consult the load frame manual for your system. 
3. The Emergency Stop Switch may be activated. This can be released by turning the Red Emergency Stop button clockwise. Power down, wait 10 seconds, and power back up. 
4. The mechanical travel limit may be activated. Release the locking screw on the limit stop to allow the limit rod to relax, and then re-tighten. Power down, wait 10 seconds, and power back up. 

There may be a possible hardware failure. Contact Instron Service. Please use our Service Support Form (refer to the [question number] located at the end of each question and provide your model and serial number). Service and Technical Support Form

You should check the following: 

1. Ensure the machine has been enabled by depressing the frame icon on the Merlin Console (Consult your operator manual) and the green "Frame Ready" LED is illuminated on the control panel. 
2. Ensure the emergency stop switch is not depressed. Consult your system operator manual for proper setting. 
3. Check the travel limit on side of the column is not activated. Consult your system operator manual for proper setting. 
4. Ensure the test speed is not set to zero. If the problem persists, please use our Service Support Form (refer to the [question number] located at the end of each question and provide your model and serial number). Service and Technical Support Form

The upper or lower crosshead travel limit has been tripped. Release the limit stop or drive the crosshead in the opposite direction. Once the limit has been released, the travel indicator will turn itself off.

Adapter Cables for Instron Load Cells (Electrical Compatibility) 

Load Cells 4200/4300 4400 4500 5500 8500 

2518-800 (Series) 0 2525-001

2525-001
2525-800 (Series) 2525-002 0 2525-002 

2525-002
2518-100/600 (Series) 0 2525-001 0 2525-001 0 

2511-100/200 (Series) 2503-045 2525-001 2503-045 2525-001 N/A

2511-300/400 (Series) 2503-045 2503-045 & 2501-045 & 2503-045& N/A (2525-001) 

(2501-045) (2525-001)

2512-100 (Series) 0 2525-001 0 2525-001 N/A 

2512-200 (Series) 0 

NOTE: “0” Used as is, No Adapter cable required