DCPD Measurement System Product Information 100-279-690 B be certain.
© 2014 MTS Systems Corporation. All rights reserved. Original Instructions (English): 100-279-690 B Trademark Information MTS, be certain., Bionix, ElastomerExpress, FlatTrac, FlexTest, Just In Case, LevelPlus, MTS Criterion, MTS EM Extend, MTS Insight, MTS Landmark, RPC, ServoSensor, SWIFT, Temposonics, TestWare, TestWorks are registered trademarks of MTS Systems Corporation within the United States.
Table of Contents Table of Contents Technical Support How to Get Technical Support.........................................................................................................5 Before You Contact MTS.................................................................................................................5 If You Contact MTS by Phone..........................................................................................................7 Problem Submittal Form in MTS Manuals.............
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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: • • • General Safety Practices...................................................................................................................14 Hazard Placard Placement................................................................................................................14 No User Serviceable Parts Within.....................................................................................................
Safety General Safety Practices If you have system related responsibilities (that is, if you are an operator, service engineer, or maintenance person), you should study this manual carefully before you attempt to perform any test system procedure. You should receive training on this system or a similar system to ensure a thorough knowledge of your equipment and the safety issues that are associated with its use.
Safety No User Serviceable Parts Within Part #572402-07 No user serviceable parts within.
Introduction Topics: • DCPD Measurement System Introduction........................................................................................
Introduction DCPD Measurement System Introduction The direct current potential drop (DCPD) crack measurement system is paired with an MTS closed-loop servohydraulic controller. The closed-loop controller provides specimen loading, and data acquisition and storage. A typical materials test applies a load or force on a specimen to grow the crack. In fatigue crack growth tests, the load is a dynamic load simulating a material in a rotating or dynamic environment such as an aircraft engine.
Introduction Item Label Description 7 Control Cable connector to controller DIO. 8 I/O Power switch: I = on, O = off. 9 Grounds Chassis and earth ground connections. 10 Input Power Standard AC power plug. 11 Channel n Connector pairs: orange are analog outputs to the controller; green and yellow and connections to the preamp. A typical DCPD system supports a single reference specimen and a single active specimen.
Introduction Specifications Parameter Specification Input voltage 100-240VAC, 50-60Hz, 5-2Amp Temperature 5ºC to 40ºC (41ºF to 104ºF) Humidity 5% to 85%, non-condensing Altitude 2000 m (6562 ft) maximum Space Requirements For proper ventilation, allow 51 mm (2 in) clearance on all sides of the chassis. The rear of the chassis requires a minimum clearance of 15.24 cm (6 in) for cable connections.
Installation Topics: • • • • • Installation.........................................................................................................................................22 Connect the Cables...........................................................................................................................22 Set Up the Controller.........................................................................................................................26 Controller Configuration for DCPD......
Installation Installation This chapter explains how to set up and install the hardware for the DCPD Measurement System and Test Controller, configure the FlexTest software for a DCPD Measurement System, and set up a foil specimen test. For information about controller setup or TestSuite Software operation, refer to the appropriate manual. Cable Installation Guidelines The following guidelines assume a single reference specimen and a single active specimen.
Installation Caution: There is dangerous voltage inside the enclosure. Connecting cables with power applied can cause damage to the device. Ensure that the power is turned off before connecting cables.
Installation Item Description 4 Active Specimen1 5 Connection to electrical main power 6 Electrical and earth grounds 7 Terminal Block 1. Connect the remote current control cable. a) Connect the DCPD remote current control cable to the white connection labeled Remote on the back of the DCPD Measurement System. b) Connect the other end of the DCPD Remote Current Control cable to the connection labeled D/A Output on the back of the controller. c) Set the Remote/Local switch to Remote.
Installation 6. Connect Channel 2. a) Connect the orange cable to the orange Channel 2 connection on the back of the DCPD Measurement System. b) Attach the other end to the Channel 2 DUC on the back of the controller. On a FlexTest 40 Controller, this connection is labeled J1B. 7. Note: The Preamp has two sets of connections. On one side are the RJ11 (output) connections. On the other side are the channel (input) connections.
Installation c) Connect the shield cable to the signal ground connection on the back of the DCPD Measurement System. d) Connect the other ends of the cables to the terminal block. 1. Screw the two heavy conductor cables into the two large terminal block connections. 2. Screw the four small cables into the four small terminal block connections. e) Connect the cables from the terminal block to the preamp. 1. Connect the green cable to the green connection on the terminal block. 2.
Installation Note: After making changes to the .hwi file, re-run the system loader. 3. Configure Station Builder. a) Open Station Builder. If prompted to enter a password, use the appropriate password. If theSelect Project window opens, select the appropriate project. The Open Configuration window will open. b) Open the appropriate test config. file. For example, "Landmark Frame B1.cfg". The Station Builder window will open. 4. Assign and configure the Current Output Command.
Installation 1. For Display Units, select "V" for Volts. 6. Assign and configure the DUC for DCPD Channel 2. a) In the left navigation pane, go to Auxiliary Outputs. b) Under the Input Hardware Resources tab, select the corresponding channel hardware location. For example, 494.26 DUC S2-J1B c) Assign the channel for the Active specimen to Aux Input 1. 1. In the Display Name field, click the plus button. • Change the Display Name to REF pd. • Change the Internal Name to REF pd.
Installation If prompted to enter a password, use the appropriate password. The Open Configuration window will open. b) Open the test config. file that was configured in the previous steps.. For example, " Landmark_Frame1_DCPD.cfg". The Station Manager window will open. All Station Manager windows that were previously opened will open. c) d) e) f) g) h) i) j) k) Open Station Setup. Under Auxiliary Inputs, choose "ACT pd". In ACT pd window, go to Limits.
Installation Station Builder: Current Command Digital Outputs Off Manual Command- Digital Output On, Reverse Off 30 | DCPD Measurement System
Installation Manual Command- Digital Output On, Reverse On Change Gain in DUC Active and Reference Channel- Typical Voltages DCPD Measurement System | 31
Installation Digital Output On Reverse Off ACT pd and REF pd show measured voltages from the DCPD unit. These are typical starting values. Current Output shown is half of the full-scale command, which is 11 amps. Digital Output Off Reverse Off With these output settings, no current is going to the specimen. Only thermocouple voltages are being measured by the unit. Digital On Reverse On These are typical reversed starting values.
Installation Foil Specimen After the DCPD Measurement System is installed and the Controller is setup, the foil specimens is used to verify the DCPD unit is functioning properly. The following figure shows the cabling connections for the foil specimen. This section assumes the DCPD unit has been connected to the controller and that the controller has been set up for DCPD operation; refer to the Installation section for information. The cables have clips on the ends that are attached to the foil specimen.
Installation The following sequence is a guideline for using the foil specimen in validation system operation. The sequence assumes the DCPD unit has been connected to the controller and that the controller has been set up for DCPD operation. 1. With the DCPD unit power off (I/0 switch on the back panel to 0), ensure the DCPD unit is properly connected to the controller and the controller has been set up for DCPD operation as defined in the Installation section. 2.
Operation Topics: • Operation...........................................................................................................................................
Operation Operation Operation during testing is primarily controlled through software and the Test Controller. Refer to your software and controller documentation for additional information. Manual Controls Item Description 1 Current Set: 10-turn control and Local/Remote selector switch. 2 Gain: X1/X10 selector switch. 3 LPF (low pass filter) 50HZ/300HZ selector switch. This switch should typically be set to 50 HZ. Manual operation is somewhat empirical and depends on specimen size and material.
Operation You should choose settings that provide the best feedback signal for a majority of your signals. It might be necessary to use a smaller gain or current setting if over the course of a test, the specimen resistance increases dramatically. It might also be necessary to use lower currents or gains if the initial resistance of the reference specimen is high compared to the active specimen. All specimens, reference and active, use the same values for current, gain, and LPF.
Maintenance Topics: • • Maintenance......................................................................................................................................40 Clean the Air Filter.............................................................................................................................
Maintenance Maintenance Maintenance of the DCPD consists of keeping the unit clean and occasionally cleaning the filter. The unit can be wiped off with a clean, damp cloth and then wiped dry with a clean, lint-free cloth. Clean the Air Filter The filter is stainless steel mesh and intended to be cleaned rather than replaced. It is recommended to check the filter every 6 months (or less in dirty environments) and clean the filter if necessary. Perform the following procedure to clean the filter.
Troubleshooting Topics: • Troubleshooting.................................................................................................................................
Troubleshooting Troubleshooting Problem Solution No lights on front of unit. Verify the power switch is on (I/0 switch on the back panel to I). Verify any main power circuit breaker is on. Verify the main power cable is OK. Always have red light lit on front The Front of the DCPD unit should show a red light when: of unit. 1) The current is short circuited, but the current is small, i.e. less than one amp. 2) The current is not short circuited between the power leads.
Troubleshooting Problem Solution 3) Verify that the gains in the controller for the appropriate signal are not zero. 4) Verify the continuity of the cable is good, by testing the continuity of pins 4 and 7 on the RJ50. Voltage does not reverse. Verify that the green light is lit on the front of the DCPD unit. (It should always be on when using reversing). If the green light is not lit, see the “Always have red light on front of unit” problem.
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