testControl II – the Innovative Electronics

Powerful, innovative measurement and control technology.

testControl II measurement and control electronics provide the ideal basis for precise, reproducible test results. In addition to setting new standards in safety technology, efficiency and quality, testControl II is laying down a benchmark for drive technology.

Advantages and features

High measuring accuracy and reproducibility

Maximum accuracy
The smallest force changes on the specimen are quickly and accurately recorded and displayed. The A/D converter guarantees high measured-value accuracy over a wide measurement range with sampling rates of 400 kHz and 24 bit resolution.

High data transmission rate
Each travel and force peak is acquired with high resolution and recorded synchronously at 500 Hz on all measuring channels. Optionally, the measured value acquisition rate can be expanded to 2,000 Hz. The high data transmission rate enables fast measurement with the highest degree of reproducibility. This is highly advantageous for quick tests, short, brittle fracture events and in tear-growth, adhesion and peel tests.

Time-Synchronous Signal Processing
Time-synchronous acquisition of measured values from all sensors connected to plug-in slots takes place at the fast system-frequency, as does data transmission to ZwickRoell testing software. This ensures high test-result reproducibility regardless of the sensors in use or the test sequence; for example force and travel signal synchronicity is maintained, even with strongly differing test speeds.

Machine Compliance Correction
High-quality drive technology plus online correction of machine compliance enable very high travel-measurement and positioning accuracy. The ZwickRoell testing software automatically determines the optimum curve, ensuring maximum possible accuracy for travel measurement and positioning via the crosshead displacement transducer.

Real-time correction via the corrected channel directly in the testControl II electronics, regardless of test speed and duration!
Control and positioning directly to the corrected channel.
Ideal for tests for which direct-measurement extensometers cannot be used.

Eco mode
The testControl II machine electronics automatically switch to eco mode when not in use, saving energy.

System monitoring
testControl II system monitoring provides the user/laboratory manager with detailed information on the current status and level of utilization of the testing equipment. This enables further increases in testing equipment availability and greatly simplifies maintenance planning and spares/replacement procurement.

Powerful Drives and Drive Controllers

Fast, adaptive drive controller
The high drive control frequency of 1,000 Hz delivers fast, precise force and strain control. Benefits include enabling components to be loaded very quickly and accurately with a predetermined force.

Strain Rate Control
The AllroundLine drive technology’s excellent constant-velocity characteristics and interaction with the sensor technology and adaptive control make it ideal for demanding strain-rate control (e.g. ISO 6892-1, Method A1).

Controller Setup
Special controller set-up for testing situations with demanding control requirements. For example, if the force sensor is located on the fixed crosshead in force-controlled tests, the controller can simply be switched in the software.

Powerful Drives
Powerful drives allow cyclic tests to be performed at maximum speed up to nominal load - with no waiting time between tests. AllroundLine and ProLine use maintenance-free AC drives.

Flexibility through modularity

Flexibility Through Modularity
testControl II offers six flexible time-synchronized slots. These make it possible to use multiple sensors at the same time, and can be monitored and protected irrespective of use.

For example, an extensometer and a transverse strain extensometer can be used in addition to the load cell.
If the testing system is equipped with several load cells or additional sensors, these can all remain plugged in. All plugged-in sensors are automatically protected against overloads.

Innovative Interfaces
The innovative EtherCat^® interface is incorporated as standard. The time-synchronized real-time Ethernet field bus system ensures future-proof integration of sensors and power units.

Gigabit Ethernet Interface
The Gigabit Ethernet interface (a proven industry standard) for the testing machine computer enables very high data throughput.

Use in dynamic testing

testControl II measurement and control electronics represent a universal controller for various drives used in materials testing.

The version developed for servo-hydraulic testing machines allows control of hydraulic linear or torsion testing actuators, used free-standing or in a testing machine.

The controller can be used for static, quasi-static, oscillating and dynamic tests on materials, components and complete structures.

The double axis controller is used for combined tension and torsion axis actuators.

testControll II Xtension

Plug & play - quick and easy to use with standardized operation in ZwickRoell Roel testing software.
Fast switching between various testing situations with different sensor systems, while your sensors remain connected.
Money-saving mobile use on different testing machines.
All testControl II Xtension channels can be used for any calculations.
testControl II Xtension's sensors can be used for force / strain control.
Easy retrofitting whenever you need extra sensors.
With the second testControl II Xtension even applications with an unusually large number of sensors are possible.

Ergonomic remote control with display

You can control the testing system with the remote control:

Start or stop a test
Approach the initial position LE
open or close automatically controlled specimen grips
specify self-defined functions

You can drive the crosshead of the testing system via the rocker switch.

Technical overview

Technical data	Uniaxial / Biaxial
Control frequency	10 kHz
Measured value acquisition, mathematical	10 kHz, 24 bit
Integrated safety concept	2-channel specification for maximum safety
	Interface for interlocked safety doors
	Interface for emergency stop link
Slots	5x module bus¹
	1x PCI Express
PC interface	GigaBit Ethernet
Hydraulic interfaces	2x servo valves²
	1x hydraulic distribution unit
	1x hydraulic power pack
	1x leak oil drain pump
	1x load frame hydraulics (clamping and adjustment)
Additional interfaces	1x SATA for optional hard drives
	3x USB
Electrical connection	85..260 V, 47..63 Hz, 700 W
Dimensions (HxWxD), approx.	510 x 135 x 525 mm
Weight	19 kg

Biaxial: 4 modules slots occupied by axial force, axial displacement, torque, and angle of rotation
Biaxial: 1x servo valve per axis

For use with an AllroundLine or zwickiLIne materials testing machine with testControl II (from 2015)

Type	testControl II Xtension
Item No.	1021870
Number of available slots for measurement and control modules:
Synchronized module bus slots	6
Force measurement	Class 0.5/1, depending on load cell, compliant to DIN EN ISO 7500-1, ASTM E4
Measurement range	Up to 165% of Fmax
Calculated resolution (e.g., load cell in tensile/compression direction)	24	bit
Measured value recording rate	400	kHz
Measured value transmission rate to PC	500 (optional 2000)	Hz
Zero-point correction	Automatic, at start of measurement
Measurement signal runtime correction	Yes
Interfaces	EtherCAT, synchronization module
Required software versions:
testXpert II	V3.7 or higher
tC II electronics	from V7.7
testControl II Xtension	from V7.7 EthBusExp	(Research V1.7)
Ambient temperature	+10 ... +35	°C
Connected load
Electrical connection	100 ... 240 (wide-range input)	V
Tolerance range	± 10	%
Power consumption (full load), approx.	0.44	kVA
Power frequency	50/60	Hz

testControl II display remote control for efficient and ergonomic operation of the testing system

Type	Remote control
Item No.	057984
Power supply	24	V
Maximum current consumption	100	mA
Ambient temperature	+10 ... +45	°C
Dimensions
Length	260	mm
Width	90	mm
Depth	60	mm
Cable length	2.85	m