(Series 3/GTC) 9510-051 Nil Strength Air Ram Does Not Move As Expected - Troubleshooting

(Series 3/GTC) 9510-051 Nil Strength Air Ram Does Not Move As Expected - Troubleshooting

(Series 3/GTC) 9510-051 Nil Strength Air Ram Does Not Move As Expected - Troubleshooting

Article Type:
 Applicable Equipment:
Troubleshooting
 9510-051 Nil Strength

Error Description:

The nil strength air ram cylinder does not operate correctly. Either no movement is observed or incorrect movement of the nil strength air ram is observed.

Possible Error Causes:

Incorrect movement of the nil strength air ram can be a result of a lack of air pressure, incomplete connections through the pneumatic lines, reversed connections of the vacuum tank boss plugs to the nil strength air ram cylinder, or a lack of electrical command signal.

Warning and Cautionary Statements:

Read and understand all warning statements before proceeding:

Warning: The following may involve exposure to high voltages and could result in serious injury or death.  All high voltage measurements and troubleshooting must be performed by experienced, qualified personnel using the appropriate Personal Protective Equipment and following all local codes and facility regulations.  
Warning: Some sections of this manual may require the Load Unit and Hydraulic Pump be de-energized and locked out and tagged out according to all local and facility regulations. Failure to do so could lead to serious injury or death
Warning:  Body parts must never be within the boundary of any moving components with the hydraulic or pneumatic (air ram) system energized. Failure to obey this instruction can result in serious injury or death.    
Warning: Hot surfaces may be present which could result in severe burns.  Wear suitable Personal Protective Equipment to avoid injury from accidental contact with hot surfaces.  
Warning: The Gleeble is capable of generating strong electromagnetic fields. Individuals with pacemakers or other medical equipment should not use or work on the Gleeble. Failure to obey can result in serious injury or death.
Caution: Improper measurements or mishandling of measurement equipment could result in damage to equipment. This work must be performed by experienced, qualified personnel.
Caution:  Adequate hearing protection must be worn at all times when working near the active hydraulic pump 
Caution:  Observing test samples at elevated temperature could lead to vision damage. Proper vision protection must be used when observing samples at high temperature.

Caution: The reader should fully understand all instructions listed in this article. If any points are unclear or the reader is uncomfortable performing any listed steps they should contact DSI before proceeding with any of the listed actions. 

Tools Required for Troubleshooting:

  1. Multimeter (DC Voltage, Ohms)
  2. Gleeble 3500 - 3800 Wiring Diagram: 3000W15 RevK or equivalent.
  3. MAN021: 3500/3800 Nil Strength Calibration Procedure (DSI Option# 9510-051)

Troubleshooting Flow Chart:






Troubleshooting Steps:


Place Gleeble System Into Run Mode:

The Gleeble system must be placed into run mode in order to properly operate the nil strength air ram. Please note that this step is only applicable for GTC equipped systems and does not apply to series 3 systems.
  1. Power on Gleeble system.


  1. Select "Accept Configuration" from configuration screen.


  1. Reset panic safety by pressing the blue reset button.



Warning:  Body parts must never be within the boundary of any moving components with the hydraulic or pneumatic (air ram) system energized. Failure to obey this instruction can result in serious injury or death.
  1. Press the NilAirRam button.


  1. The Nil Air Ram should move in the tension direction.
If placing the Gleeble into run mode resolved the issue, no further troubleshooting is necessary
If no movement is observed please proceed to Ensure All Pneumatic Connections Are Secure.
If the nil strength air ram moved in the wrong direction please proceed to Nil Strength Air Ram Does Not Move As Expected


Ensure All Pneumatic Connections Are Secure:

The nil strength air ram is a pneumatically actuated device. As such it is important that all the required pneumatic connections are installed and secured for the device to operate properly:

  1. Press the emergency stop button on the console to remove any potential pneumatic pressure.


  1. Verify the following pneumatic connections are correct and secure:
    1. Gleeble system to compressed air source.


    1. Nil strength air ram regulator to Gleeble compressed air manifold.


    1. Nil strength air ram regulator to vacuum tank boss plug feed through.


    1. Vacuum tank boss plug feed through to nil strength air ram cylinder.


  1. Clear the panic safety by releasing the emergency stop button and pressing the blue reset button.



Warning:  Body parts must never be within the boundary of any moving components with the hydraulic or pneumatic (air ram) system energized. Failure to obey this instruction can result in serious injury or death.   

  1. Press the NilAirRam button.


  1. The Nil Air Ram should move in the Tension direction.
If ensuring the Gleeble pneumatic connections are secure resolved the issue, no further troubleshooting is necessary.
If no movement is observed please proceed to Ensure Compressed Air Supply Is Charged And Open To Gleeble System.
If the nil strength air ram moved in the wrong direction please proceed to Nil Strength Air Ram Does Not Move As Expected..

Ensure Compressed Air Supply Is Charged And Open To Gleeble System:

If using a local compressed air supply (within the Gleeble Lab), it must be verified that the air source is open to the Gleeble and charged. 
  1. Press the emergency stop button on the console to remove any potential pneumatic pressure in the Gleeble.


  2. Verify the compressed air supply is connected and open to the Gleeble System.
  3. Verify the compressed air source is charged to roughly 80PSI. 
  4. Clear the panic safety by releasing the emergency stop button and pressing the blue reset button.




  1. Press the NilAirRam button.
Warning:  Body parts must never be within the boundary of any moving components with the hydraulic or pneumatic (air ram) system energized. Failure to obey this instruction can result in serious injury or death.   



  1. The nil strength air ram should move in the tension direction.
If investigating the compressed air supply resolved the issue, no further troubleshooting is necessary 
If no movement is observed please proceed to Nil Strength Air Ram Does Not Move.
If the nil strength air ram moved in the wrong direction please proceed to Nil Strength Air Ram Does Not Move As Expected.


Nil Strength Air Ram Does Not Move As Expected:

If the nil strength air ram is moving opposite to the expected direction, it is possible that the pneumatic hoses that run to from the air ram cylinder to the vacuum feed through simply need to be swapped:

Warning:  Body parts must never be within the boundary of any moving components with the hydraulic or pneumatic (air ram) system energized. Failure to obey this instruction can result in serious injury or death.   

  1. On the console toggle the nil strength air ram compression/tension button to off (tension mode).
  2. Press the NilAirRam button.


    1. The nil strength air ram should move in the tension direction.
  1. Toggle the nil strength air ram compression/tension button to on (compression mode).
  2. Press the NilAirRam button.


    1. The nil strength air ram should move in the compression direction.
  1. If the nil strength air ram moves opposite to the direction described, swap the locations of the pneumatic lines that feed the air ram cylinder at the vacuum feed through.

If the air ram moved as expected, no further troubleshooting is necessary
If the nil strength air ram does not move at all please proceed to Nil Strength Air Ram Does Not Move.

Nil Strength Air Ram Does Not Move:

If the nil strength air ram is not moving at all when commanded, it should be verified that the nil strength air ram regulator has been set in accordance with the instructions provided by DSI:

Warning:  Body parts must never be within the boundary of any moving components with the hydraulic or pneumatic (air ram) system energized. Failure to obey this instruction can result in serious injury or death.   

  1. Set nil strength air ram regulator per DSI manual #21 (DSI Part number: MAN021). This manual will be included with the nil strength kit. If you are unable to locate this manual please contact DSI for a replacement manual. 


If adjusting the regulator in accordance with manual #21 resolved the issue, no additional troubleshooting is required.
If adjust the regulator has failed, please proceed to Check Power at AM-3016 in Pocket Jaw NEMA Box.

Check Power At 3016 I/O In Pocket Jaw NEMA Box:

If  the nil strength air ram is still not moving as expected, it is possible that there is an electrical problem. The 3016 I/0 board located in the pocket jaw NEMA box should be investigated to ensure it is functioning as expected. 

  1. Clear any panic safety by releasing the emergency stop button and pressing the blue reset button.


  1. Using a multimeter set to measure DC voltage check for 24Vdc at DIO4-24 on the 3016 green combicon connector while referencing ground. Use electrical drawing 3000W15 as a reference and to confirm the measurement location on your specific wiring revision.
    1. If voltage is not present at DIO4-24 contact DSI for service.


Warning:  Body parts must never be within the boundary of any moving components with the hydraulic or pneumatic (air ram) system energized. Failure to obey this instruction can result in serious injury or death.   
  1. Verify 24Vdc output voltage at DIO4-15:
    1. On the console set NilAirRam to On, set NilAirCom to off (tension).


    1. Check for LED indicator light at IO5 as shown:

    1. Using a multimeter set to measure DC voltage check for 24Vdc at DIO4-15 on the 3016 green combicon connector while referencing ground. Use electrical drawing 3000W15 as a reference and to confirm the measurement location on your specific wiring revision.

      1. If voltage is not present verify the channels barrel fuse is intact.





      1. If the fuse is faulty replace the fuse, otherwise replace the DIO4-5 red relay.
  1. Verify 24Vdc output voltage at DIO4-17:
    1. On the Console set NilAirRam to On, set NilAirCom to On (compression).


    1. Check for LED indicator light at IO6 as shown:

    1. Using a multimeter set to measure DC voltage check for 24Vdc at DIO4-17 on the 3016 green combicon connector while referencing ground. Use electrical drawing 3000W15 as a reference and to confirm the measurement location on your specific wiring revision.


      1. If voltage is not present verify the channels barrel fuse is intact.



      1. If fuse is faulty replace the fuse, otherwise replace the DIO4-6 red relay.

If the electrical checks of the 3016 IO board have resolved the issue, no further troubleshooting is required
If the electrical checks of the 3016 IO board have failed, please contact DSI for service..