Series 293 Hydraulic Service Manifold Product Information Model 293.11A, Model 293.11B, Model 293.12A, and Model 293.12B 015-081-000 F 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..........................................................................................................9 Problem Submittal Form in MTS Manuals.............
Table of Contents Wear proper clothing...........................................................................................................29 Remove flammable fluids....................................................................................................29 Check bolt ratings and torques...........................................................................................29 Practice good housekeeping........................................................................................
Table of Contents Checking the Accumulators...........................................................................................................
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.
Introduction Topics: • • • • • • • • • • • About the Hydraulic Service Manifold (HSM)....................................................................................16 Series 293.1X HSM Component Identification..................................................................................17 HSM Fluid Flow.................................................................................................................................20 HSM Filtering.....................................................
Introduction About the Hydraulic Service Manifold (HSM) The hydraulic service manifold (HSM), also called the actuator manifold, is a hydraulic component that controls hydraulic pressure to one work station. The HSM controls are independent of the hydraulic power unit’s controls. The basic function of the HSM is to provide line pressure regulation.
Introduction Series 293.1X HSM Component Identification Series 293.
Introduction Component Identification Item Name Description A Front View Viewing angle B Top View Viewing angle C Side View Viewing angle 1 Control Manifold Distributes hydraulic fluid to and from a single hydraulic channel.
Introduction Item Name Description an actuator and servovalve. The control manifold also contains a low pressure solenoid valve, a high-pressure solenoid valve, a main valve, a slow turn-on accumulator, and a pressure gage to control a single hydraulic channel. 2 Pressure Gage Indicates system hydraulic pressure. 3 Slow Turn-On Accumulator Fills to extend the pressure rise time and slowing the rate at which the main control valve operates.
Introduction HSM Fluid Flow Hydraulic fluid from the HPU enters the HSM at the pressure in port. It passes through an inlet check valve and a filter. After filtration, part of the fluid is channeled to the pilot pressure circuit. The rest of the fluid passes through a control manifold, fills the pressure accumulator, passes through the control manifold, and exits the HSM to an actuator/servovalve through the pressure out port. Return fluid from the actuator enters the return in port.
Introduction About HSM Pilot Pressure The HSM is equipped with a hydraulic circuit which provides separately filtered fluid at HPU pressure to operate the pilot stage of multistage servovalves. This portion of the HSM operates automatically and requires only routine filter maintenance. Note: Turning pressure on and off, or changing between low and high output pressure, does not affect the pilot pressure output. Pilot pressure is always present, as long as pressure is available from the HPU.
Introduction HSM Rapid Pressure Reduction The control manifold dumps hydraulic pressure rapidly when the high and low solenoid valves are de-energized simultaneously to turn off the fluid flow and port the output pressure line to the return line. The control circuit is connected to the drain line and pressure in the control circuit drops rapidly, allowing downstream pressure and a control spring to close the main control valve. HPU pressure is disconnected from the pressure output.
Introduction Series 293.1X HSM Specifications Model Differences Model Control Voltage Pilot Pressure 293.11A 24 V DC No 293.12A 24 V DC Yes 293.11B 115 V AC No 293.12B 115 V AC Yes Model 293.1X HSM Specifications Parameter Specification Environmental Temperature 4.4°C–50°C (40°F–122°F) Humidity 0%–80% relative, noncondensing Dimensions The height varies according to the accumulator installed. Height 749 mm (29.5 in) Length 356 mm (14.0 in) Width 368 mm (14.
Introduction Parameter Specification Number of channels 1 to 4 Filtration Main supply 10 μ main supply Pilot pressure supply 3 μ pilot pressure supply Operating Pressure Variable Low Pressure 1-21 MPa (150-3000 psi) High Pressure 21 MPa (3000 psi) Nominal Flow 190 L/min (50 gpm) Slow On/Off Ramp Time 5.0-9.0 seconds Maximum Solenoid Current 1.5 A at 24 V DC or 0.3 A at 115 V AC Accumulators Pressure 0.94 L (0.25 gal) standard, up to 3.8 L (1 gal) optional Return 0.45 L (0.
Safety Topics: • General Safety Practices: Hydraulic Power Units and Hydraulic Service Manifolds.........................
Safety General Safety Practices: Hydraulic Power Units and Hydraulic Service Manifolds The hydraulic power unit (HPU) provides high pressure hydraulic fluid to system components for system operation. The hydraulic service manifold (HSM) controls distribution of that hydraulic fluid pressure. This section provides general information about safety issues that pertain to system hydraulic supply and distribution components.
Safety • Facility variables (facility variables include the structure, atmosphere, and utilities) • 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.
Safety Read all manuals Study the contents of this manual and the other manuals provided with your system before attempting to perform any system function for the first time. Procedures that seem relatively simple or intuitively obvious may require a complete understanding of system operation to avoid unsafe or dangerous situations. Locate and read hazard placards/labels Find, read, and follow the hazard placard instructions located on the equipment.
Safety Be aware of component movement with hydraulics off The actuator rod can also drift down when hydraulics are turned off hitting anything in its path. This uncommanded movement is because of oil movement between the pressure/return ports and oil blow by across the piston hub. Be aware that this can happen and clear the area around the actuator rod when hydraulics are turned off. Know electrical hazards When the system electrical power is turned on, minimize the potential for electrical shock hazards.
Safety Practice good housekeeping Keep the floors in the work area clean. Hydraulic fluid that is spilled on any type of floor can result in a dangerous, slippery surface. Do not leave tools, fixtures, or other items not specific to the test, lying about on the floor, system, or decking. Protect hoses and cables Protect electrical cables from spilled hydraulic fluid and from excessive temperatures that can cause the cables to harden and eventually fail.
Safety Provide adequate lighting Ensure adequate lighting to minimize the chance of operation errors, equipment damage, and personal injury. You need to see what you are doing. Provide means to access out-of-reach components Make sure you can access system components that might be out of reach while standing on the floor. For example, ladders or scaffolding might be required to reach load cell connectors on tall load units.
Safety Do not disturb sensors Do not bump, wiggle, adjust, disconnect, or otherwise disturb a sensor (such as an accelerometer or extensometer) or its connecting cable when hydraulic pressure is applied. Ensure secure cables Do not change any cable connections when electrical power or hydraulic pressure is applied. If you attempt to change a cable connection while the system is in operation, an open control loop condition can result.
Safety Do not use RF transmitters Keep radio frequency (RF) transmitters away from the workstation computers, remote terminals, and electronics consoles. Intense RF fields can cause erratic operation of the more sensitive circuits in the system. Know compressed gas hazards Some environmental chambers use liquid nitrogen or some inert gas to achieve a required test atmosphere. Typically these gasses are supplied in pressurized tanks.
Installation Topics: • • • • HSM Site Preparation........................................................................................................................36 Series 293.1X HSM Hydraulic Connections......................................................................................36 Series 293.1X HSM Electrical Connections......................................................................................38 System Checks.....................................................................
Installation HSM Site Preparation Consider the following items for site preparation: • The HSM must be installed in an area that is protected from extreme temperature and humidity. An environment with a non-corrosive atmosphere is recommended. • The HSM must be located as close as possible to the servovalve(s) it supplies. The maximum allowable distance must take the specific system dynamic flow transient requirements and turn-on/turn-off transient requirements into account.
Installation Note: Remove a fluid cap port plug only when a hose is ready for connection. Retain these plugs for use during service. Note: Connect the drain-out line hose to the HPU reservoir or the drain circuit on the hardline before you apply hydraulic pressure.
Installation Item Description 7 Top View 8 Return Out -16 9 Pressure In -16 10 Filter Drain -06 (maintenance only) 11 Drain Out -06 to HPU 12 Hydrostatic Bearings Controlled Pressure -04 13 Pressure -16 14 Return -16 15 Pilot Return -06 16 Drain -06 Note: The filter drain is provided for maintenance of the filter. The drain port is at the same hydraulic pressure as the HPU. Ensure that hydraulic pressure to the HSM is turned off before using this drain port. Series 293.
Installation Control Manifold Front View Item Description 1 Low Pressure Solenoid 2 High Pressure Solenoid 3 Hydrostatic Bearings Supplied Pressure 4 Pressure 5 Hydrostatic Bearings Controlled Pressure 6 Return 7 Pilot return 8 Drain 9 Pilot Pressure Depending on the model, the high/low solenoids may be powered by either 115 VAC or 24 VDC. The following figure shows the pin assignments of each connector. • The Model 293.22A contains 24 VDC control power.
Installation Pin Assignments for High/Low Solenoid Connectors System Checks Complete the following steps to ensure proper HSM installation. 1. Check the HSM for secure mounting. 2. Check all hydraulic connections according to the system diagrams. Ensure that the connections are secure. 3. Check all electrical cable connections (where applicable) according to the system diagrams. Ensure that the connections are correctly mated and locked. 4. Precharge the accumulators.
Operation Topics: • • • • HSM Control......................................................................................................................................42 HSM Pilot Pressure Considerations..................................................................................................42 Series 293.1X HSM Controls and Indicators.....................................................................................43 Setting Low Pressure......................................................
Operation HSM Control Solenoid control valves located on the HSM control manifold are controlled by the system controller; they cannot be controlled locally. Low-pressure, high pressure, or pressure-off conditions are operated from the system controller (which can be controller software, a control panel, or a remote module). The manifold design requires the HSM to be switched to low pressure from the off condition. This makes the sequence to obtain a high-hydraulic pressure output, from off to low to high.
Operation Series 293.1X HSM Controls and Indicators Model 293.1X HSM Controls and Indicators Item Description 1 Pressure Gage A liquid-filled, constant-read pressure gage is connected directly to the output pressure line. A small orifice protects it against damage from rapid pressure changes. For single-channel operation, the pressure gage is located on the main manifold. For multichannel operation, each control manifold contains a pressure gage.
Operation Item Description 6 Main Filter Indicator1 A pop-up indicator is activated when the main pressure filter element becomes dirty. 7 Pilot Filter Indicator2 A visual indicator is activated when the pilot pressure filter element becomes dirty. Setting Low Pressure The pressure delivered in high-pressure mode is determined by the HPU output pressure. Refer to the operation section of the appropriate HPU manual for instructions on setting this level.
Maintenance Topics: • • • • Hydromechanical System Precautions..............................................................................................46 Model 293.1X HSM Main Filter Replacement...................................................................................46 Model 293.1X HSM Pilot Filter Replacement....................................................................................48 Checking the Accumulators.........................................................................
Maintenance Hydromechanical System Precautions Hydraulic systems have the capacity for rapid and forceful movement. Systems contain equipment that can be hazardous to persons and damaging to equipment, if improperly used. Warning: Do not perform calibration, maintenance, or repair procedures with the hydraulic system operating. This can cause injury to persons or damage to equipment or both (due to unexpected actuator movement). Ensure that you read the following precautions.
Maintenance Warning: Do not replace the filter with residual hydraulic pressure in the system. Residual pressure can cause unexpected, high-pressure fluid discharge and actuator motion. This can result in personal injury or death or damage to equipment. Ensure that the HPU output pressure is zero before you begin the replacement procedure. Item Description 1 Vent Plug 2 Bowl 3 O-ring Seal 4 Filter Element 5 Filter Indicator 6 Filter Head 1.
Maintenance 2. 3. 4. 5. Place a drain pan under the main filter drain port and remove the cap from the port. Remove the vent plug from the filter housing. Allow the fluid to drain for five minutes. With an open-end wrench, rotate the filter housing counterclockwise to remove it. Check the filter housing for contamination (particles adhering to the inside of the bowl). If contamination is present, check the system for wear or loss of seal integrity. Wipe the housing with a lint-free cloth. 6.
Maintenance Warning: Pilot pressure is always present as long as pressure is available from the HPU. Turning HSM pressure on and off, or changing between low and high output pressure, does not affect the pilot pressure output. If residual hydraulic pressure exists, unexpected high-pressure fluid discharge and actuator motion can result when removing the filter. This can cause injury to persons or damage to equipment or both.
Maintenance Checking the Accumulators The accumulators have a pressure charge of compressed gas. The accumulator’s correct precharge pressures are recorded on their labels. The precharge pressure should be checked once a month. Warning: Do not charge the accumulators with gases other than pure (commercial grade, dry) nitrogen gas. Using unacceptable gasses can cause personal injury, damage to equipment, or both. Refer to the accumulator manual for information about charging the accumulator.
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