MTS Criterion™ Series 60 Test System Operation 100-275-893 A be certain.
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Table of Contents Table of Contents Technical Support How to Get Technical Support.........................................................................................................................7 Before You Contact MTS.................................................................................................................................7 If You Contact MTS by Phone.........................................................................................................................
Table of Contents Load Frame Overview....................................................................................................................................36 Test Table...........................................................................................................................................38 Test Area Guard and Steps (Optional)...............................................................................................38 Hardware Control Panels...............................
Table of Contents Analysis Procedure...........................................................................................................................106 Troubleshooting Troubleshooting............................................................................................................................................130 Maintenance Routine Maintenance Overview Checklist...................................................................................................
Table of Contents 6
Technical Support How to Get Technical Support Start with your manuals The manuals supplied by MTS provide most of the information you need to use and maintain your equipment. If your equipment includes software, look for online help and README files that contain additional product information. Technical support methods MTS provides a full range of support services after your system is installed. If you have any questions about a system or product, contact Technical Support in one of the following ways.
Technical Support When you have more than one MTS system, the system job number identifies your system. You can find your job number in your order paperwork. Example system number: US1.
Technical Support — Messaging applications If You Contact MTS by Phone A Call Center agent registers your call before connecting you with a technical support specialist. The agent asks you for your: • Site number • Email address • Name • Company name • Company address • Phone number where you can be reached If your issue has a case number, please provide that number. A new issue will be assigned a unique case number.
Technical Support • Record the name of the person who helped you. • Write down any specific instructions. After you call MTS logs and tracks all calls to ensure that you receive assistance for your problem or request. If you have questions about the status of your problem or have additional information to report, please contact Technical Support again and provide your original case number.
Preface Before You Begin Safety first! Before you use your MTS product or system, read and understand the safety information provided with your system. Improper installation, operation, or maintenance can result in hazardous conditions that can cause severe personal injury or death, or damage to your equipment and specimen. Again, read and understand the safety information provided with your system before you continue. It is very important that you remain aware of hazards that apply to your system.
Preface Warning: Warning notices indicate the presence of a hazard with a medium level of risk which, if ignored, can result in death, severe personal injury, or substantial property damage. Caution: Caution notices indicate the presence of a hazard with a low level of risk which, if ignored, could cause moderate or minor personal injury or equipment damage, or could endanger test integrity.
Preface Electronic manual conventions This manual is available as an electronic document in the Portable Document File (PDF) format. It can be viewed on any computer that has Adobe Acrobat Reader installed. Hypertext links The electronic document has many hypertext links displayed in a blue font. All blue words in the body text, along with all contents entries and index page numbers, are hypertext links. When you click a hypertext link, the application jumps to the corresponding topic.
Safety Topics: • • • • • • • • Overview............................................................................................................................................16 Personnel Qualifications....................................................................................................................17 Hazards.............................................................................................................................................17 Energy Isolation/Lockout/Tagout....
Safety Overview Safety Information Overview MTS systems are designed to generate single-axis or multi-axial motions and forces simultaneously in a controlled environment and impart these motions and forces into a specimen that is secured to the system.
Safety Personnel Qualifications Personnel Qualifications Warning: System installation, maintenance, setup, and operation require specialized training. Installation, maintenance, setup, and operation of the system by unqualified personnel can expose them, and others, to hazards that can cause death or personal injury and damage to equipment. Do not allow unqualified personnel to perform any of the system installation, maintenance, setup, or operating procedures.
Safety Hazard Warning Icons The following hazard warning icons indicate hazards that can result in personal injury or equipment damage when using the MTS Criterion Series 60 systems. They are typically placed on or near the area of concern. They are intended to alert the user to possible hazardous conditions or hazardous situations. Hazard Warning Icons Icon Description Do not start, operate, or service the machine until you read and understand the operator's manual.
Safety Icon Description Hand crush or pinch point hazard. Stay alert and be aware of possible moving parts. Keep clear of areas noted with this icon. The Waste Electrical and Electronic Equipment (WEEE) symbol means that the controller and its electronic parts must not be disposed of as unsorted municipal waste. Proper disposal is required by approved electronic waste collection agencies.
Safety • You should identify a single control point in your primary electrical supply where complete electrical isolation can be accomplished. Also, consider that each uninterruptible power supply (UPS) is potentially an independent (secondary) electrical power source. To determine methods for isolating each UPS as an electrical supply source, see your vendor-supplied UPS documentation.
Safety Warning: Working environments that are not designed with appropriate ventilation, lighting, heating and cooling or non-ergonomic equipment, furniture, and equipment/furniture placements can result in operator fatigue and stress. Operator fatigue and stress can result in operator errors which can result in injury to personnel or damage to the equipment and/or specimen.
Safety Equipment Weight and Lift Points Heavy Equipment Hazards Warning: The system components are heavy, and may need to be moved for maintenance, installation, or decommissioning. If moved, system components require lift equipment capable of handling their weight. If the lift equipment fails when system components are moved, the result can be death or serious injury to personnel, and damage to equipment. Only qualified personnel should lift, move, or transport equipment.
Safety • Unauthorized customer modifications to the equipment • Operator experience and specialization • Test specimens Because of these variables (and the possibility of others), your system can operate under unforeseen circumstances that can result in an operating environment with unknown hazards. Improper installation, operation, or maintenance of your system can result in hazardous conditions that can cause death, personal injury, or damage to the equipment or to the specimen.
Safety Have first aid available Accidents can happen even when you are careful. Arrange your operator schedules so that a properly trained person is always close by to render first aid. In addition, ensure that local emergency contact information is posted clearly and in sight of the system operator. Know potential crush and pinch points Be aware of potential crush and pinch points on your system and keep personnel and equipment clear of these areas.
Safety Remove flammable fluids Remove flammable fluids from their containers or from components before you install the container or component. If desired, you can replace the flammable fluid with a non-flammable fluid to maintain the proper proportion of weight and balance. Know compressed gas hazards Your system may contain accumulators that require a high-pressure gas precharge (pressures that exceed 138 bar [2000 psi]).
Safety On rare occasions, a fastener can fail even when it is correctly installed. Failure usually occurs during torquing, but it can occur several days later. Failure of a fastener can result in a high velocity projectile. Therefore, it is a good practice to avoid stationing personnel in line with or below assemblies that contain large or long fasteners. Practice good housekeeping Keep the floors in the work area clean.
Safety Use appropriately sized fuses Whenever you replace fuses for the system or supply, ensure that you use a fuse that is appropriately sized and correctly installed. Undersized or oversized fuses can result in cables that overheat and fuses that explode. Either instance creates a fire hazard. Provide adequate lighting Ensure adequate lighting to minimize the chance of operation errors, equipment damage, and personal injury.
Safety the appropriate measures and equipment required to handle and use the chemical safely. Ensure that the chemical is disposed of appropriately. Know servohydraulic system interlocks Interlock devices should always be used and properly adjusted. Interlock devices are designed to minimize the chance of accidental damage to the test specimen or the equipment. Test all interlock devices for proper operation immediately before a test.
Safety Know the causes of unexpected actuator motions The high force and velocity capabilities of MTS actuators can be destructive and dangerous (especially if actuator motion is unexpected). The most likely causes of unexpected actuator response are operator error and equipment failure due to damage or abuse (such as broken, cut, or crushed cables and hoses; shorted wires; overstressed feedback devices; and damaged components within the servocontrol loop).
System Introduction Topics: • • • • • • About This Manual.............................................................................................................................32 About Other MTS Documentation.....................................................................................................32 System Overview...............................................................................................................................33 Integrated Operations Platform Overview.........
System Introduction About This Manual This manual is for operators of MTS Criterion Series 60 Systems.
System Introduction System Overview Station Components Item Name Description 1 Computer The system computer provides the human/machine interface. MTS TW software resides on this computer. 2 MTS TW Software MTS TW software enables you to run material tests and generate reports. 3 Controller The controller provides the necessary interface between the PC and the load frame.
System Introduction Integrated Operations Platform Overview The Integrated Operations Platform (IOP) consolidates the computer, system electronics and controls, and hydraulic power supply into a single compact, mobile unit. The side door on the right side opens to a slide-out drawer that can optionally contain a printer or provide storage for fixtures. Warning: Inside the IOP is an outlet switch for the computer and monitor. Plugging in a device could damage the device or the IOP.
System Introduction Item Name Description 1 Monitor The monitor is connected to the human/machine interface computer. 2 Computer The system computer provides the human/machine interface. MTS TW software resides on this computer. 3 Pump Assembly Hydraulic power for the load frame is provided by the pump assembly housed in the integrated operations platform. 4 Controller The controller provides the necessary interface between the PC and the load frame.
System Introduction MTS Criterion Series 60 Systems Computer Front Panel Ports and Indicators Number Port / Indicator Description 1 Dual USB Ports You can import or export .proj test files into or out of the computer using the USB interface. 2 PS/2 Port Use this port to connect the PS/2 keyboard to the computer. 3 Key Lock Locks the front panel door. A key is required to open the door. 4 LED Indicators The LED indicators show computer system status. They do not indicate the load frame status.
System Introduction Important: Observe all hazard and warning stickers shown on the front of the frame. Caution: During a test, the lower crosshead remains stationary, and the actuator moves the upper crosshead and table in an upward direction to provide load to the specimen. The lower crosshead is only for adjusting the tension and compression spaces to insert specimens. Applying load on the specimen by adjusting the crosshead position can cause equipment damage.
System Introduction Item Name Description 1 Upper Crosshead Connected to the test table by the columns. The upper crosshead, table, and columns move together. 2 Crosshead Lift Screw Provides movement to the upper crosshead and table. 3 Lower Crosshead Remains still for tension and compression tests, while load or force is applied to the specimen by downward movement of the upper crosshead and table. 4 Test Table Connected to the upper crosshead by four columns.
System Introduction Optional Test Area Guard and Steps Hardware Control Panels Load Unit Control Module The load unit control (LUC) module allows you to move the lower crosshead to the proper height for installing specimens for both tension and compression tests. The LUC module also contains the Machine Active indicator, Emergency Stop button, and user interactive switches for opening and closing grip wedges used for a tension test. The LUC module is enabled by pressing the Enable button on the handset.
System Introduction Warning: Unintended force can be applied to body parts, mounted specimens, grips and fixtures, or other objects in the crosshead's path. Unintended force can injure personnel and equipment. Before you move the crosshead, ensure that the crosshead path is clear and that you understand how to control crosshead motion using system controls.
System Introduction Load Unit Control Module Description Number Control/Indicator Description 1 Machine Active Indicator Illuminates when the LUC module has power. To apply power to the LUC module, you must enable the handset. 2 Lower Crosshead Up Button Jog button. Press this button to move the lower crosshead up. 3 Lower Crosshead Down Button Jog button. Press this button to move the lower crosshead down. 4 Upper Grip Control Switch (Shown in closed position.
System Introduction Number Control/Indicator Description 3. On the computer, reset the interlock in the TW application. 4. On the handset, press the Enable button. 5. Turn the grip control knob to open. Hydraulic Control Panel The hydraulic control panel is located on the Integrated Operations Platform (IOP). Hydraulic Control Panel on IOP Hydraulic Control Panel Description Number Control/Indicator Description 1 Emergency Stop Button Stops all system movement.
System Introduction Number Control/Indicator Description 2. 3. 4. 5. On the IOP, press the white Start Pump button. On the computer, reset the interlock in the TW application. On the handset, press the Enable button. Turn the grip control knob to open. 2 Power Supply Switch Press the switch to On (I) to turn on power and Off (O) to turn off power. 3 Power Indicator When illuminated, hydraulic power is on. 4 Start Pump Button Starts the hydraulic pump motor.
System Introduction Handset The handset has a lock control that enables (when enabled, the green light is illuminated) or disables the handset and the LUC module. The LUC module controls lower crosshead movement and upper and lower grip controls.
System Introduction MTS Criterion Series 60 Systems Handset Description Number Control / Screen / LED Description 1 Page Shows the next four lines of text in the display. 2 Active When illuminated, indicates the machine is active and can move. 3 F1 and F2 The F1 and F2 programmable function keys are designated as digital inputs to which you can assign test functions. Test functions can include start test, pause test, hold positions, and so forth.
System Introduction Number Control / Screen / LED Description 8 Actuator Return Returns the upper crosshead and table to the original position (zero point). 9 Start Starts the test action. Testing software must be active. 10 Actuator Down Moves the upper crosshead and table in the downward direction while depressed. The handset must be enabled. 11 Actuator Up Moves the upper crosshead and table in the upward direction while depressed. The handset must be enabled.
System Introduction • • • Positioning the actuator Setting up meters Installing an extensometer Test Activities • • • • Selecting a test Running the test Entering variable values Readying the load frame for the next test Review, Analysis, and Reporting Activities • • • • • • • • • Comparing test runs Excluding test runs Adding and ordering data fields Displaying additional statistical data Configuring charts Switching views Adjusting variables and recalculating results Saving display configurations Gen
System Introduction Positioning the Actuator You can position the table/upper crosshead using the controls outlined in red below. The lower crosshead can only be positioned using the load unit control (LUC) module. Setting up Meters Right-click to show the Meter Type menu. Installing an Extensometer TWX requires that the extensometer have its setup, calibration, and verification parameters stored in a TEDS file.
System Introduction Selecting a Test Selecting a test can be done from the main screen as shown below, or from the File menu. Running the test The buttons in the Test Controls panel allow you to run a test. Use the green arrow (run the test) button to start a test.
System Introduction Entering Variable Values The test designer may have added prompt dialogs for variable values. If so, they appear automatically as the test is run. Readying the Load Frame for the Next Test Click the home button to return the actuator to the 0.000 mm position. Comparing Test Runs Select the Compare checkbox next to a test run to see the test run in the graph.
System Introduction Excluding Test Runs If there is a problem with a test run, you can exclude it from calculations and statistical results by tagging the test run. Adding and Ordering Data Fields Right-click anywhere in the results panel to show the Set Result Variables window. This window allows you to add fields to the results panel. Once they are added, you can use the Set Variable Order window to arrange the variables that are shown in the results panel.
System Introduction Displaying Additional Statistical Data The statistical data shown in the Statistics Panel can be configured using the Configure Statistics window. Right-click in the Statistics Panel to show the Configure Statistics window.
System Introduction Configuring Charts Right-click a chart to configure it.
System Introduction Switching Views You can show up to four views at a time. If more than four views have been created, you can switch between them by right-clicking a view and selecting Switch to View.
System Introduction Adjusting Variables and Recalculating Results You can adjust variables even after a test is run. To do so, enter the corrected value, and then press Enter to recalculate results. This can be helpful in correcting errors or performing "what if" analysis. If you wish to revert to the original value, simply click the Reset button. Saving Display Configurations Once you have the display configured the way you like it, you can save it so that you switch between displays.
System Introduction Generating a Report You can generate an individual report for each test run, or you can produce a single report for all test runs as shown here.
System Introduction MTS Criterion™ Series 60 | 57
Key Concepts Topics: • • • • • • • • • • About This Chapter............................................................................................................................60 Understanding Your MTS Software...................................................................................................60 Understanding MTS Applications and File Types..............................................................................61 Understanding the Control Loop....................................
Key Concepts About This Chapter This chapter, as well as the information in the Safety chapter, contains information you should know before you attempt to run tests with your MTS Criterion Series 60 System. This information applies to the typical system used as an example in this manual. For information that applies to other system configurations or tests, see: • • The "Best Practices for Other System Configurations and Tests" chapter in this manual.
Key Concepts Item Description 1 All MTS TestSuite Applications 2 MTS TW Express It is important to understand that to run tests on your station, the only MTS TestSuite software you need is the MTS TW Express application (or TWX for short). Note: The MTS TW Elite application can be configured for operators. In that configuration, it has the same capabilities as the MTS TW Express application.
Key Concepts File Type Description Test Template Files Test Template files are command files created with TW Elite for performing tests. Test Template files contain only test definition information. MTS TestSuite Test Template Icon Test Procedure Files Test Procedures files are similar to Test Template files, but include a container that stores test data and results.
Key Concepts Item Description 1 Feedback 2 Controlling Element 3 Controlled Element 4 Command The controlling element is the computer, the MTS Insight controller, and the MTS TW application. The controlling element produces a control signal (Command) that represents the direction and amount of extension you desire to apply to the crosshead. The controlled element comprises the motor, the crosshead, and the specimen itself.
Key Concepts 1. You input an actuator up command by clicking the Up arrow in the Actuator Controls panel in the TWX application. 2. The MTS Insight controller generates a signal that represents the direction and amount of extension the actuator needs to travel to accommodate your command. 3. The MTS Insight controller generates this command and sends it to the servovalve.
Key Concepts Lower Crosshead The lower crosshead is independent of the table and upper crosshead assembly and moves in response to the electric motor positioned to the right of the frame. To control the movement of the lower crosshead, use the up and down buttons on the LUC module.
Key Concepts Important: The LUC module is enabled by pressing the handset Enable button, and the controls move only the lower crosshead, while the handset controls move only the table, columns, and upper crosshead assembly. Understanding How the Grips Move Warning: The grips on Series 60 load frames extend during clamping. Holding the specimen with your hand too near the grip while clamping can result in crushed fingers. Always use a tool (pliers, tongs, channel lock, etc.
Key Concepts Grips Extend While Clamping! Item Description 1 Upper Grip in Open Position 2 Grips Extend While Clamping Tension Test Overview When performing a tension test, the specimen is held by the appropriate grip fixtures in the tension space, which is the space between the upper crosshead and lower crosshead. The test signals the actuator to move the upper crosshead and table upward, while the lower crosshead remains stationary.
Key Concepts Warning: A hazardous zone exists within and around the load frame perimeter, including the actuators, crosshead, columns, lifts, specimen fixtures, and any equipment that can move or any equipment that is in the path of actuator movement. Movement of any equipment, even under normal test conditions, can be sudden, and with high force. Death or severe injury can occur when any part of your body is crushed by moving equipment.
Key Concepts and the sensors measure the load applied, the displacement, and the specimen compression. The controller transfers the data to the testing software, and the software provides the results and reports per test configuration. If you have the appropriate fixtures, bending/flexural or shearing tests can be done in the compression space.
Key Concepts Using the E-Stop Control If something unusual occurs that requires immediate action, use an Emergency Stop (E-Stop) control to: • • Stop whatever setup operation or test you have in progress, and Remove hydraulic pressure from the station. While using your system, always keep in mind where the E-Stop control is and what it does.
Key Concepts Resetting Interlocks To resolve an interlock condition, simply click the Reset button on the Controller panel. Using the Status Window to Identify Error Conditions Show the Status window by clicking the small arrow in the lower right corner of the Status panel. It can be very helpful in determining what is causing an interlock condition. Using the Application Log to Identify Error Conditions The MTS TestSuite TW application is equipped with a log to help you identify error conditions.
Key Concepts Note: The Application Log is found in the lower right corner of the main TW screen. You may need to expand the bottom panel to see it.
Running the Example Tension Test Topics: • • • • • • • • • • • • • • • • Overview............................................................................................................................................74 Safety Orientation..............................................................................................................................74 Turn On the Station.........................................................................................................................
Running the Example Tension Test Overview This chapter describes how to run the MTS Example STH Tension (Simplified) test and analyze test data. The instructions and screen images pertain to running this test on the typical system described in the System Introduction . The MTS Example STH Tension (Simplified) test is provided with your system and includes data for five test runs for you to learn about the analysis functions. Note: The MTS Example STH Tension (Simplified) test does not use strain feedback.
Running the Example Tension Test Warning: Crush zones exist above and below the lower crosshead. Body parts can be crushed by the moving crosshead or actuator. Keep all body parts clear of the crush zones when moving the crosshead or actuator. 2. Emergency Stop controls. Use the Emergency Stop buttons to stop a test immediately. Turn the Emergency Stop control clockwise to reset the interlock. 3. The enclosure.
Running the Example Tension Test An interlock on the door prevents running a test with the door open. 4. Equipment and software. See System Introduction. Turn On the Station 1. Turn on the computer. Turn the computer power switch to the on position. It is located behind the keyed access door on the front of the integrated operations platform (IOP).
Running the Example Tension Test 2. Turn on the station after the computer has fully booted. Turn on the controller, the IOP, and the load frame, by turning the switch on the front of the IOP to the 1 position. The green light will illuminate. 3. Open the TW Express software. Click the TW icon on the desktop. 4. Open the Example test.
Running the Example Tension Test Select MTS Templates > TW - Static - Hydraulic > MTS STH Tension (Simplified). Important: If you wish to use an extensometer, select an extensometer-enabled test like MTS STH ASTM A370 Tension (Extensometer - Actuator). 5. Turn on the pump. Press the Start Pump button on the front panel of the IOP. Clear Interlocks Your MTS Criterion test system performs many self-checks when it is powered up. If a safety condition is violated, the system sets an interlock.
Running the Example Tension Test Select the arrow in the lower right corner of the Status panel. Tripped interlocks are indicated with red boxes. 2. If necessary, correct any interlock conditions. Some examples of interlock clearing actions are resetting the Emergency Stop button, turning the pump on, closing the enclosure door, and so forth. 3. Reset the interlocks. Click the Clear Interlocks button in the Controller panel.
Running the Example Tension Test Recover from a Tripped Limit To prevent actuator and lower crosshead damage, your MTS Criterion test system monitors the position of these components. The system has limit switches that trip before actuator or crosshead movement can cause damage. If, during normal operation, you encounter a tripped limit, use one of the two methods below to restore the system to operation. 1. Use the actuator controls in TW. a) Reset the Interlock.
Running the Example Tension Test Important: The Handset Enable button must show a green LED to enable use of the handset or load unit controller. You will not be able to move the actuator from the handset or the lower crosshead from the load unit controller until you light the green Handset Enable LED on the handset. b) Use the Actuator Up or Actuator down button to move the actuator out of the interlock condition.
Running the Example Tension Test Press the Handset Enable button on the handset. 2. If necessary, lower the lower crosshead. This provides clearance for the actuator. Use the Lower Crosshead Down button. Lower the crosshead only enough to provide clearance for the actuator, as you will adjust the lower crosshead for specimen installation in the next section. Note: If you reach the bottom of the crosshead travel, the interlock will set.
Running the Example Tension Test a) Use the actuator down button on the handset to lower the actuator. It moves slowly so you will need to look closely to see if the upper crosshead and table are moving. When the actuator reaches the bottom of its travel, the interlock will set. b) Clear the interlock by pressing the handset enable button twice. 4. Raise the actuator slightly. This helps ensure that the interlock does not inadvertently trip. Set Up the Load Meter for Specimen Installation 1.
Running the Example Tension Test Right-click the Load meter and select Meter Type > Running Maximum/Minimum. You will use this meter to monitor the maximum and minimum forces imparted on the specimen during installation to ensure that the specimen is undamaged at the conclusion of specimen installation. 3. Zero the load meter. Right-click the Load meter area and select zero signal. The meter will show a value near zero.
Running the Example Tension Test Warning: The grips on Series 60 load frames extend during clamping. Holding the specimen with your hand too near the grip while clamping can result in crushed fingers. Always use a tool (pliers, tongs, channel lock, etc.) to hold the specimen during specimen installation. Never hold the specimen with your hand when clamping the grips. 1. Ensure that both grips are unclamped. Move the upper and lower grip control switches to the unclamped position. 2.
Running the Example Tension Test If necessary, enable the handset, and then use the Lower Crosshead Up and Lower Crosshead Down buttons to position the crosshead. If a travel endpoint is reached, press the Handset Enable button on the handset twice to reset the interlock. 3. Check for proper specimen clearance and adjust as necessary.
Running the Example Tension Test Ensure that the specimen: • • • Is properly positioned in the v groove. (The seam of the rebar should be in the crotch of the v groove.) Has good contact across the entire face of the grip. Is not bottomed out (end of specimen touching) the grip. b) Move the upper grip control to its center position to ready it for the test. 2. Fine-tune the position of the lower crosshead.
Running the Example Tension Test b) Verify that the specimen: • • • Is properly positioned in the v groove. (The seam of the rebar should be in the crotch of the v groove.) Has good contact across the entire face of the grip. Is not bottomed out in (end of specimen touching) the grip. c) Move the lower grip control to its center position to ready it for the test.
Running the Example Tension Test Optional: Installing an Extensometer For illustrative purposes, the MTS STH ASTM A370 Tension (Extensometer – Actuator) test is used here to demonstrate extensometer setup. Skip any of the following steps that have already been completed earlier or by another technician. 1. For safety, turn the pump off. 2. Connect the extensometer to the extensometer cable.
Running the Example Tension Test 3. Plug in the extensometer cable. a) The J9 port is located inside the lower panel on the left side of the IOP. Open the panel door by pushing the release, and then rotating the lever clockwise. b) Route the cable through the hole in the rear of the cabinet.
Running the Example Tension Test c) Plug the rectangular end of the extensometer cable into the J9 port. 4. From the TW main window, select Controller > TEDS Devices. The TEDS Devices window appears. 5. Select Strain1 and click Assign.
Running the Example Tension Test 6. Select the TEDS file for the extensometer you are using. 7. If necessary, verify the device. You may be asked to verify the TEDS device. If so, click Verify. You may need to take action if the TEDS device cannot be verified. If necessary, contact MTS for assistance. 8. Ensure that the extensometer meter is active.
Running the Example Tension Test Move the extensometer legs and verify that there is a corresponding reading change in the extensometer meter. 9. Attach the extensometer to the specimen. 10. Make sure that the extensometer is completely closed.
Running the Example Tension Test 11. Zero the extensometer meter. Right-click the extensometer meter and select Zero Signal. 12. Turn the pump back on. Set Up Meters for the Test 1. Verify that the forces that were imparted on the specimen during specimen installation are acceptable.
Running the Example Tension Test For example, the rebar specimen used in this example test could tolerate installation forces up to 60 kN before permanent deformation would result. Because the Running Maximum/Minimum meter reads only .554 kN tension and 1.123 kN compression at the conclusion of specimen installation, it is safe to say that the specimen has not been damaged. 2. Change the load meter to timed type. Right-click on the Load meter and select Meter Type > Timed.
Running the Example Tension Test Right-click the Actuator meter and select Zero Signal. The meter will read near 0.00 mm. You will be able to return to this 0.00 mm position easily at the conclusion of the test by clicking the Return To Position button in the Actuator Controls panel. If Required, Resolve Resource Errors Resource errors occur if the resources in the software do not match the resources for the station. TWX indicates resource errors with a white “x” encircled in red. 1.
Running the Example Tension Test 3. Correct the mismatch between software and station resources. If necessary, contact MTS for technical assistance.
Running the Example Tension Test Running the Test 1. Set the Area variable for round geometry. Select Define > Variables, and then select the Area variable. In the Properties panel, enter Round for the Option parameter and click Apply. 2. Run the test. a) Click the green arrow (Run the Test) button. Note: If the controls are locked, you need to disable the handset by pressing the Handset Enable button on the handset. b) Enter parameters when prompted.
Running the Example Tension Test Be sure to use an accurate and precise caliper when measuring, as these readings significantly affect your results. 3. (If you are using an extensometer): When prompted, remove the extensometer. The extensometer should be removed before plastic deformation begins. The removal point variable value depends on the material you are testing. Typical values are 102% of original length for metals or 105% of original length for plastics. 4. Complete the test.
Running the Example Tension Test Removing the Specimen Warning: Using the handset allows crosshead movement while the operator is near the crush zone. Being near the load frame allows more precise control over crosshead movement, but also puts you closer to the crush zone. Always keep all body parts clear of the crush zone when moving the crosshead. 1. If the specimen broke: a) Enable the handset.
Running the Example Tension Test b) Remove the specimen from the lower grip. 1. Grasp the lower specimen half with a tool. 2. Move the Lower Grip Control switch to the open position.
Running the Example Tension Test 3. Remove the specimen half. c) Remove the specimen from the upper grip. Use the same method as previously described. 2. If the specimen did not break: a) Enable the handset. b) Grasp the specimen with a tool.
Running the Example Tension Test c) Open the upper and lower grips and remove the specimen. Ready the Load Frame for the Next Test 1. Turn off the handset control.
Running the Example Tension Test Press the Handset Enable button on the handset. 2. Return the actuator to the 0.00 mm position. a) Click the Return to Home button in the Actuator Controls panel. Analyze the Results For details on data analysis features, see Reviewing Analyzing and Reporting Data (p. 106).
Reviewing, Analyzing, and Reporting Data Topics: • Reviewing Analyzing and Reporting Data.......................................................................................
Reviewing, Analyzing, and Reporting Data Reviewing Analyzing and Reporting Data Review Tab Overview After a test run finishes, test results are automatically shown on the Review tab of the main display. You can use controls in the Review tab to: • • • • • Configure displays to view data for individual or multiple test runs. Compare test runs to one another. Perform “what if” scenarios by adjusting variable values and recalculating results. Generate reports. Export raw data.
Reviewing, Analyzing, and Reporting Data 2. Open the example test. a) Select File > Open Test > MTS STH Example Tension (Simplified) and click Open. b) Select the Review tab. The review screen appears populated with tests runs. The six test runs shown are provided by MTS for training purposes.
Reviewing, Analyzing, and Reporting Data 3. Compare all test runs.
Reviewing, Analyzing, and Reporting Data Upon opening the Review tab, only the selected test run is graphed. Compare all test runs on the same graph by selecting the Compare check box next to each test run. Graphs for each test run are plotted in the Load versus Extension panel. 4. Exclude invalid test runs. In this example, Test Runs 1, 4, and 5 had problems associated with them. a) Exclude those three test runs from the statistical data by selecting the Tagged check box next to each test run.
Reviewing, Analyzing, and Reporting Data 5. Set up autotag. Another way to eliminate problem test runs is to set up autotag. Autotag uses rules to exclude errant test runs from the statistical results panel and reports. a) Open the autotag window by right-clicking anywhere in the leftmost panel and selecting Configure Autotag Rules. b) Set up a rule.
Reviewing, Analyzing, and Reporting Data 1. Add a rule. Click the green + sign in the upper right corner of the Configure Autotag Rules window. 2. Enter a variable. Click the Variables tab, and then select PeakLoad from the list. PeakLoad appears in the Calculation panel. 3. Enter a function and a value. In the Calculation panel, enter <60 kN immediately following PeakLoad and click Close. 4. Enter an error message. Enter PeakLoad is less than 60000 in the Error Message text box. 5. Click Close.
Reviewing, Analyzing, and Reporting Data Test Runs 1 and 4 are automatically tagged and excluded from the statistical results and reports. However, notice that test run 5 is not autotagged because of the non-numerical values in the data. Always review autotagging results to ensure the results are as expected. 6. Add and order data fields shown in the Results panel. This step demonstrates how to set up the Results panel to your liking. a) Add the Yield Index field to the Results panel. 1.
Reviewing, Analyzing, and Reporting Data b) Move the Yield Index column between the Modulus and Test Run End Reason columns. 1. Select the Define tab, right click anywhere in the panel, and select Set Variable Order.
Reviewing, Analyzing, and Reporting Data 2. In the Variable Type drop-down list, select Result. 3. Use the up and down arrows on the right side of the Set Variable Order window to move Yield Index between the Modulus and Test Run End Reason columns. 4. Click OK when complete. The updated list appears.
Reviewing, Analyzing, and Reporting Data 7. Show additional statistical data and reorder as desired. You can also configure the fields in the statistical results panel to your liking. a) Add Minimum and Maximum values to the statistical results. 1. Right-click anywhere within the Statistical Results panel and select Configure Statistics. 2. Move Minimum and Maximum from the Available to the Selected list using the right arrow. 3. Use the up and down arrows to order the fields as desired. 4.
Reviewing, Analyzing, and Reporting Data 8. Add and configure views. You can show up to four views at a time. You can also add additional views and switch to them as desired. a) Switch to four panel view by clicking the Four Panel View button in the toolbar. b) Add and configure a view to show load vs. extension in inches and pounds force. 1. Right-click the lower right panel. Select Views > Add View > Array-Variable Marker Chart for Multiple Runs.
Reviewing, Analyzing, and Reporting Data 2. Accept the default name for the panel. The chart appears in the four panel view. 3. Right-click the new chart and select Configure Chart. 4. For the Y Array drop down list, select Load.
Reviewing, Analyzing, and Reporting Data 5. 6. 7. 8. Select the X Array check box and select Extension in the corresponding drop-down list. In the Y Axis group Display Unit drop-down list, select lbf (pounds force). In the X Axis group Display Unit drop-down list, select in (inches). Click OK. The configured chart appears. If no traces appear in the chart, you may need to select a test run to show the traces for the compared test runs. c) Switch views.
Reviewing, Analyzing, and Reporting Data Right-click the chart you just created, and select Views > Switch to View > Variable-Column Table for Multiple Runs. The selected view appears. 9. Adjust a variable and recalculate. You can adjust variables after performing test runs to do “what if” analysis or to correct errors (for example, an incorrect value for diameter). a) Select a test run. For this example, select test run 6.
Reviewing, Analyzing, and Reporting Data b) In the Variable Table view, scroll down to Diameter and change the value from 12.700 mm to 12.000 mm. Clicking anywhere else on the screen enters the value and updates any dependent calculated values. c) If desired, reset the Diameter to its original value by clicking the Reset button in the Reset Value field. A confirmation window appears.
Reviewing, Analyzing, and Reporting Data 10. Save the current display configuration once you have the display configured as desired. a) Click the Actions button and select Display > Save Display As. b) Enter a display name and click OK. 11. Switch between display configurations. Once display configurations are saved, you can switch between them. a) Click the Actions button and select Display > Switch to Display. Select the Default Layout.
Reviewing, Analyzing, and Reporting Data b) The Default Layout appears. 12. Generate a report for the selected test runs. a) Select Test Runs 2, 3, and 6, and then click the Generate a report for the selected test run(s) button.
Reviewing, Analyzing, and Reporting Data Note: Hold down the Shift key while clicking to select multiple test runs. An Excel report file is generated for each test run that was selected. 13. Generate a report for all test runs. a) Click the Generate a report that includes all test run(s) button.
Reviewing, Analyzing, and Reporting Data b) A single Excel report file is generated for all test runs (excluding those that were tagged). 14. Copy and paste data into another application. Data from the results or statistics panel can be copied to other applications including Microsoft Word, Excel, and Notepad. a) Select the rows in the results or statistics panel you wish to copy. For this example, select Test Runs 2, 3, and 6, right-click any selected row, and then select Copy.
Reviewing, Analyzing, and Reporting Data Note: Hold down the Shift key while clicking to select multiple rows. b) Open the application into which you want to paste the data. For this example, open Word. c) Position the cursor in the target application, right click, and select Paste. The data appears in the target application. 15. Export raw data for a test run. You can also export raw test data for a test run to a tab-delimited .txt file.
Reviewing, Analyzing, and Reporting Data b) Select the desired options in the Export Raw Data window. For this example, select the default values and then click OK. A message box lets you know that the text file was created.
Reviewing, Analyzing, and Reporting Data c) The file can be found in the following directory: C:\MTS TestSuite\Data Files\. d) You can use Notepad to view the data.
Troubleshooting Topics: • Troubleshooting...............................................................................................................................
Troubleshooting Troubleshooting The following table describes some basic troubleshooting issues and possible fixes. Issue Check Cannot clear interlocks, Is an Emergency Stop button no apparent source for pressed? the interlock. Reason Any pressed Emergency Stop will prevent interlocks from being cleared. Check if an E-Stop is pressed in the fault status screen in TW. Is the pump on? The pump must be on to clear interlocks.
Troubleshooting Issue Check Reason too close to each other (piston moving down or crosshead moving up). Check the servo error limit. The servo error represents a position error (command minus feedback). If the servo error is large, it indicates the controller is having problems. This error detector is part of the safety system that can help detect problems with the feedback (cable disconnected, sensor bad). The machine can achieve higher speeds with the actuator moving up than down.
Maintenance Topics: • Routine Maintenance Overview Checklist.......................................................................................
Maintenance Routine Maintenance Overview Checklist Recommended Service Calendar Time Using 8 Hour Running Time Rate Per Day Daily Weekly Annually RUNNING TIME-HOURS 8 40 200 Shunt cal check X Clean work area/machine surface/jaw X Verify limits and Emergency Stop X Inspect cable/connections X PC Maintenance Back up testing software files (*.reg/.
Maintenance Calendar Time Using 8 Hour Running Time Rate Per Day Daily Weekly Annually Cushion plates and wearable plates of the grip (molybdenum disulfide grease) MTS Driven parts of lower crosshead (lubricating grease) MTS Frame, Integrated Operations Platform, and Work Area Clean/replace air filter, suction filter, and high-pressure line filter MTS Clean off frame, Integrated Operations Platform, and work area MTS Change hydraulic oil MTS * There are no customer serviceable components on t
Maintenance Semiannual Maintenance Verify the speed and position accuracy of the frame. This requires standards and other equipment typically not available for routine maintenance. Contact your MTS field service engineer for assistance. Other Service Regular inspection and service of the hydraulic-driven system and crosshead-driven system are needed to prolong the life of your system and keep it performing optimally. This type of service is typically preformed by MTS field service engineers.
Decommissioning Topics: • Decommissioning Procedure...........................................................................................................
Decommissioning Decommissioning Procedure The decommissioning process is performed when the system is going to be moved or taken out of service. Disassembly is required when performing either of these tasks. To decommission the system: 1. Remove the specimen and fixtures. Large grips should be removed if the load frame is going to be tipped over. 2. Move the actuator piston rod down to its lowest position. Retract or open the small piston on both grips to its lowest position. 3.
Decommissioning Warning: Before power is turned off, the cables carry electrical current. Removing the crosshead motor cables without turning off the power can cause personnel injury or death. Ensure that the main power is off and the Electrical Disconnect is locked out before you remove the crosshead motor cable. Remove the cables from the safety enclosure wiring slots carefully when decommissioning the operation box cable if you have a safety enclosure installed for your system. 8.
Index Index A actuator positioning 48, 81 returning to home position 104 analysis procedure data 106 application log 71 autotag rules 110 setting up 110 B base 36 button crosshead down 46 crosshead up 46 emergency stop 41 handset enable 46 home 50 lower crosshead down 41 lower crosshead up 41 page 45 pause 45 start hydraulic pump 43 start test 46 stop 42, 45 stop hydraulic pump 43 stop test 45 C charts adding and configuring 116 configuring 53 cleaning 135 closed loop control 62 compare test runs 108 com
Index Excel report 124 exclude test runs 109 export data 125 extensometer attaching to specimen 93 connecting 89 installing 48 plugging in 90 removing 99 selecting TEDS file 91 verifying activity 92 zeroing 94 hazard (continued) zones 17 home button 50 hydraulic control panel 42 oil leak 131 viscosity 131 power supply 34 pump start 43 stop 43 F I F1 key 45 F2 key 45 failure fault indicator 43 hardware 43 fault 46, 130 feedback loop 63 fields adding 112 adding and ordering 51 moving 113 files project 61
Index lower grip control switch 41 M maintenance monthly 135 semiannual 136 manual overview 32 manuals 7 meters changing 83, 95 expanding area 83 setting up 48 zeroing 84 zeroring 95 module load unit control 39 O oil indicator 43 viscosity 131 P Page button 45 parameters entering 98 paste data 124 Pause button 45 position error 131 power switch 36, 43 power indicator 43 project files 61 PS/2 port 36 pump start 43 stop 43 turning off 89 turning on 78, 94 R raw data exporting 125 recalculate variables 119
Index T table assembly 64 test 38 tag test runs 109 technical support 7 TEDS device verifying 92 file selecting 91 template files 62 tension test 67, 74 test compression 68 example opening 77, 107 guard 38 procedure files 62 table 36, 38 tension 67, 74 test runs comparing 50, 108 excluding 51, 109 selecting 119 selecting multiple 123 tagging 109 tests entering parameters 98 running 49, 98 selecting 49 starting 46 stopping 45 TestSuite software 60 thumb-wheel 45 tripped limit 80 144 troubleshooting 130 TW
MTS Systems Corporation 14000 Technology Drive Eden Prairie, Minnesota 55344-2290 USA Toll Free Phone: 800-328-2255 (within U.S. or Canada) Phone:952-937-4000 (outside the U.S. or Canada) Fax 952-937-4515 E-mail: info@mts.com Internet: www.mts.
