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Copyright information Trademark information Publication information © 2006 - 2010 MTS Systems Corporation. All rights reserved. MTS and TestWorks are registered trademarks of MTS Systems Corporation; MTS Insight is a trademark of MTS Systems Corporation within the United States. These trademarks may be protected in other countries.
Contents Technical Support 5 How to Get Technical Support Before You Contact MTS 5 6 If You Contact MTS by Phone 7 Problem Submittal Form in MTS Manuals 8 Preface 9 Before You Begin Conventions 9 10 Documentation Conventions 10 Introduction 13 About This Manual Description 13 14 Specifications 17 General Specifications Model Specifications Dimensions 17 18 22 Crosshead Detail 23 Baseplate Detail 24 Safety 27 General Safety Practices 27 Safety Practices Before System Operation 28
Controller Connections 40 Connecting the Main Power 40 Transformer Requirements for MTS Insight 150, 200 and 300 Machines Installing Cables 44 46 Controller Connectors 46 Operation 53 Main Power Switch (I/O) and E-Stop 54 Travel Limit Switches (Physical Limits) Crush Zone Hazards 55 57 Fixture Mounting 58 Load Cell Mounting Handset Control 59 63 Maintenance 65 Routine Maintenance Overview Checklist 66 Appendix 69 Additional Digital I/O Information 69 Electromechanical Load Unit Maintena
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. If you cannot find answers to your technical questions from these sources, you can use the Internet, e-mail, telephone, or fax to contact MTS for assistance. Technical support methods www.mts.
Before You Contact MTS MTS can help you more efficiently if you have the following information available when you contact us for support. Know your site number and system number The site number contains your company number and identifies your equipment type (such as material testing or simulation). The number is typically written on a label on your equipment before the system leaves MTS. If you do not know your MTS site number, contact your sales engineer.
Know relevant software information For software application problems, have the following information available: • The software application’s name, version number, build number, and (if available) software patch number. This information can typically be found in the About selection in the Help menu.
Write down relevant information After you call In case Technical Support must call you: • Verify the notification number. • Record the name of the person who helped you. • Write down any specific instructions. 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 notification number.
Preface Before You Begin Safety first! Other MTS manuals Before you use your MTS product or system, read and understand the Safety manual and any other 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.
Conventions Conventions Documentation Conventions The following paragraphs describe some of the conventions that are used in your MTS manuals. Hazard conventions Hazard notices may be embedded in this manual. These notices contain safety information that is specific to the activity to be performed. Hazard notices immediately precede the step or procedure that may lead to an associated hazard. Read all hazard notices carefully and follow all directions and recommendations.
Conventions 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.
Conventions 12 Preface MTS Insight™ Material Testing System
Introduction About This Manual Purpose This manual provides detailed information about the MTS Insight Material Testing Systems. The information includes an overview of all the models available, installation, operation, and maintenance. The MTS Insight product series is the latest generation of electromechanical material testing equipment from MTS. The purpose of this manual is to help you understand your testing system, its capabilities, and operating requirements.
Description Description Every MTS Insight material testing system is comprised of a load frame, electronic frame controller, and TestWorks software. The following figure shows the external features of the various MTS Insight load frames. Low Capacity Mid-Capacity Multihead High-Capacity The personal computer is also an integral part of the system. It runs TestWorks software which provides full machine control, data acquisition and management, and advanced data analysis and presentation.
Description Frame controller The frame controller is responsible for the following: • Provides main data and signal processing power • Detects the activation of limit switches • Provides the interface between the software (computer) and the frame • Provides digital servo control—for speed and position accuracy • Responsible for self-ID load cell and frame • Handset interface • Programmable, 1000 Hz maximum, data acquisition rate • Management of frame power MTS Insight™ Material Testing Sys
Description Software TestWorks 4 is a versatile software program offering you a host of features that will make the material testing process fast and easy to use. The software has various method templates available. The method templates in the General Testing Package provide a starting point in configuring test methods that conform with your testing needs. The General Testing Package is separated into 4 specific testing categories.
Specifications Specifications This section provides general specifications for the MTS Insight Material Testing System frames and illustrations of the crosshead and baseplate threaded hole patterns for mounting fixtures. Note At the time of this printing, some specifications have not been tested and calculated specifications are provided in the following tables. Consequently, specifications are subject to change without notice. Contact MTS for verification if critical specifications.
Specifications Model Specifications Low Capacity MTS Insight 1 MTS Insight 2 MTS Insight 2 High Speed MTS Insight 5 MTS Insight 5 Column Configuration Single Single Double Single Double Force Capacity 1 kN (225 lbf) 2 kN (450 lbf) 2 kN (450 lbf) 5 kN (1125 lbf) 5 kN (1125 lbf) Standard Length 750 mm (29.5 in) 750 mm (29.5 in) NA 750 mm (29.5 in) 1100 mm (43 in) Extended Length 1004 mm (39.5 in) 1004 mm (39.5 in) 1400 mm (55 in) 1004 mm (39.
Specifications Mid-Capacity MTS Insight 30 MTS Insight 30 Double Double Double Double Double 10 kN (2250 lbf) 30 kN (6750 lbf) 30 kN (6750 lbf) 50 kN (11250 lbf) 50 kN (11250 lbf) Standard Length 1100 mm (43 in) 1100 mm (43 in) NA 1100 mm (43 in) 1050 mm (41 in) Extended Length 1400 mm (55 in) 1400 mm (54.75 in) 1350 mm (53 in) 1400 mm (54.
Specifications High-Capacity MTS Insight Model MTS Insight 100 Column Configuration MTS Insight 150 MTS Insight 200 MTS Insight 300 Double Double Double Double 100 kN (22500 lbf) 150 kN (33750 lbf) 200 kN (45000 lbf) 300 kN (67500 lbf) Standard Length 1200 mm (47.3 in) 1200 mm (47.3 in) 1200 mm (47.3 in) 1150 mm (45.
Specifications MTS Insight 50 W Multihead Crosshead Return Speed 500 mm/min. (20 in./min.) Vertical Test Space (crosshead travel) 1016 mm (40 in.) Horizontal Test Space (between baseplate adapter centerlines) 155.5 mm (6.125 in.) Position Resolution 0.001 mm (0.00004 in.) Position Accuracy 0.01 mm (0.0004 in) Speed Accuracy % of set speed ±0.
Specifications Dimensions Extended Length 1394 mm (55 in) 103 mm (4.1 in) Extended Length 1900 mm (74.75 in) 641 mm (25.2 in) Extended Length 1913 mm (75.75 in) 699 mm (27.5 in) 155 mm (6.1 in) 269 mm (10.6 in) 155 mm (6.1 in) Standard 1613 mm (64 in) Standard 1600 mm (63 in) 134 mm (5.3 in) 100 mm (3.9 in) 102 mm (4 in) 76 mm (3 in) Standard 1140 mm (45 in) 155 mm (6.1 in) 125 mm (4.
Specifications Crosshead Detail The crosshead has a single hole drilled through for mounting loadcells, alignment fixtures, grips, and so forth.
Specifications Baseplate Detail The baseplate has various patterns of threaded holes for mounting fixtures.
Specifications 50 kN W Multihead MTS Insight™ Material Testing System Introduction 25
Specifications Model Baseplate Thickness mm 26 Introduction in. 1 kN 19 0.7 2 kN 19 0.7 2 kN EL HS 25 1.0 5 kN 25 1.0 10 kN 25 1.0 30 kN 25 1.0 50 kN 25 1.0 50 kN W 50 2.0 50 kN W Multihead 50 2.0 100 kN 140 5.5 150 kN 152 6.0 200 kN 152 6.0 300 kN 178 7.
Safety General Safety Practices This section provides information about safety issues that pertain to electromechanical systems in general. These issues include statements to the intended use and foreseeable misuse of the system, the hazard zone, definition for the graphical hazard labeling that is affixed to your product, and other (more general) safety information that relates to the high-performance characteristics of MTS electromechanical systems.
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. In addition, you should gain an understanding of system functions by studying the other manuals supplied with your test system. Contact MTS for information about the content and dates of training classes that are offered.
Locate Lockout/tagout points Know where the lockout/tagout point is for all of the supply energies associated with your system. This includes the hydraulic, pneumatic, electric, and water supplies (as appropriate) for your system to ensure that the system is isolated from these energies when required. Know facility safe procedures Most facilities have internal procedures and rules regarding safe practices within the facility.
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 Practices While the System Is in Operation Wear appropriate personal protection Wear eye protection when you work with electromechanical testing machines, breakable specimens, or when anything characteristic to the specimen could break apart. Wear ear protection when you work near electric motors, pumps, or other devices that generate high noise levels. Some systems can create sound pressure levels that exceed 70 dbA during operation.
Stay alert Avoid long periods of work without adequate rest. In addition, avoid long periods of repetitious, unvarying, or monotonous work because these conditions can contribute to accidents and hazardous situations. If you are too familiar with the work environment, it is easy to overlook potential hazards that exist in that environment.
Read and understand manuals Projectile hazard WEEE 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. Customers in the EC region who desire to return an end-oflife controller and its electronic parts are encouraged to contact your local MTS Systems Sales/Service Offices for instructions.
Safety
Installation This section provides guidelines for moving and installing your MTS Insight material testing system. Unless otherwise specified, it is your responsibility to off-load, unpack, and move the equipment to the final location on your premises. This includes insurance and safety responsibility. Before moving the machine from the receiving area to its final location, be sure to check the dimensions of all doors and passages through which the machine will travel.
Moving Single-Column Frames Moving Single-Column Frames Pallet jacks rated at or above the weight of the machine should be used; refer to the tables in the Specifications section for frame weights. CAUTION When tipping the frame, push or pull only at the top. Do not push the frame at the sides. Pushing on the side of the frame can damage the sheet metal. It is recommended that the frame be moved by at least two people: one to tip the frame and one to position the pallet jack.
Moving Single-Column Frames With one person holding onto the frame and one person operating the pallet jack, move the frame to its final position. Tip the frame as you did when you put it on the pallet jack and pull the pallet jack out from under the frame. Carefully lower the frame back to its normal upright position. WARNING The MTS Insight frames are heavy. Moving the frame using improper procedures can injure personnel (for example strained muscles and back injuries) or damage the frame.
Moving Double-Column Frames Moving Double-Column Frames Double-column MTS Insight load frames should only be moved using a forklift rated at or above the weight of the machine; refer to the tables in the Specifications section for frame weights. CAUTION Improper lifting can damage the frame. When lifting and moving the frame, follow these guidelines to minimize the chance of equipment damage: • Do not lift by the top plate that joins the ends of the ball screws and side covers.
Machine Location and Ventilation Machine Location and Ventilation To ensure proper ventilation, locate the load frame approximately 300 mm (12 inches) from adjacent walls and equipment. Allow approximately 1 m (3 feet) behind the equipment for service access. Do not block the vent holes in the bottom of the machine. For comfortable working conditions and proper equipment operation, heat dissipation of the equipment must be considered in providing adequate heating or air conditioning in the laboratory area.
Controller Connections Controller Connections Connecting the Main Power 1 kN through 50 kN MTS Insight frames rated 50 kN or less are supplied with a transformer that reduces the voltage for frame operation; see the following illustration. CAUTION Do not connect the frame directly to the main AC line voltage. Connecting the frame directly to the main AC line voltage will cause equipment damage.
Controller Connections Additional power for 50 kN W Multihead For 50 kN W Multihead frame, the National Instruments power supply also needs to be connect to main power.
Controller Connections 100 kN through 300 kN Important Local electrical codes supersede any information found in this manual. Electrical connections must be made by qualified personnel and is their responsibility for using the proper power disconnect along with the correct size and type of wire and conduit that conforms to all their local electrical codes when connecting the machine and transformer to the buildings main power.
Controller Connections MTS Insight 100 Following shows connections to MTS Insight 100 load frames. Customer wiring connections MTS Insight 150, 200 and 300 Following shows connections to MTS Insight 150, 200, and 300 load frames.
Controller Connections Transformer Requirements for MTS Insight 150, 200 and 300 Machines Important Remember to verify local codes, voltages and frequencies before ordering transformer. Following are the minimum requirements for transformers for the MTS Insight 150, 200, and 300 load frames. Additional considerations Typical power in selected areas • Isolation Type Transformer (Electrical isolation between input and output). • 3-phase input and output.
Controller Connections Machine specific requirements Insight 150 Insight 200 Insight 300 • Nominal output power 12 kVA. • Nominal output phase current 15 A maximum. • Peak output phase current 30 A maximum for 1.25 seconds • Nominal output power 16 kVA. • Nominal output phase current 20 A maximum. • Peak output phase current 40 A maximum for 1.25 seconds • Nominal output power 24 kVA. • Nominal output phase current 30 A maximum. • Peak output phase current 60 A maximum for 1.
Controller Connections Installing Cables Exercise care when connecting cables. Ensure that you are using the correct cables and that all connections are secure. When you are finished, double-check to ensure that all components are connected properly. CAUTION Turn the power off before connecting cables. Connecting cables with power applied can cause damage to the equipment. Controller Connectors J1 USB 46 Installation This is a standard USB 2.
Controller Connections J2 Handset This is intended to interface to the handset. Specifics for this connector are: • 12 V output power with 200 mA current limit • RS422 driver (differential) • RS422 receiver (differential) • Interlock input. Handset shorts between INTLK+ and INTLK- when it is connected.
Controller Connections J3 Interlock This is intended to connect to a test area enclosure switch that opens when the door is opened. If not used, a jumper plug (p/n 049-635-901) must be installed. If you are building a cable, maximum length is 30.48 m (100 ft) with 24 gauge wire. Switch should be wired normally closed, such that when the switch opens, an interlock is generated. J4 Encoder This connector is intended for an encoder based extensometer. Specifics for this connector: are • Power: +5 V +/- 0.
Controller Connections J5 Digital I/O Digital I/O signals include three optically isolated inputs, three optically isolated outputs, and 12V power. Functions of each digital input or output are software selectable. A typical example might be connecting an external switch; see “Additional Digital I/O Information” on page 69.
Controller Connections J6 and J7 Monitor Two Monitor connectors are provided. There are several possible uses for analog monitor outputs: external data acquisition, tuning, troubleshooting, and so forth. For tuning, it is desirable to monitor command and feedback, or command and error, simultaneously while changing the controller parameters. Therefore, two monitor outputs are provided. Specifics for these connectors are: • Analog +/-10.
Controller Connections Crosshead load cell connector Load cell connector (shown on an Insight 50) A connector (D-15) for the load cell is provided under the crosshead on one of the columns.
Controller Connections 52 Installation MTS Insight™ Material Testing System
Operation This section describes the actions performed during normal, day-to-day operation of the MTS Insight frame. For information on using the MTS Insight frame in actual testing, refer to the TestWorks software manual. Contents Main Power Switch (I/O) and E-Stop Travel Limit Switches (Physical Limits) Crush Zone Hazards Fixture Mounting 55 57 58 Load Cell Mounting Handset Control 54 59 63 CAUTION Do not operate the MTS Insight test frame without the side covers and bellows in place.
Main Power Switch (I/O) and E-Stop Main Power Switch (I/O) and E-Stop The main power switch for the machine is on the base of the frame. The frame is also equipped with an Emergency Stop button. The Emergency Stop will cut the power to the motor and should be used for emergency purposes only. To shut down the motor power and stop the test program, press the Emergency Stop button. Twist the switch clockwise to release it.
Travel Limit Switches (Physical Limits) Travel Limit Switches (Physical Limits) The limit switches are located on the crosshead. They are normally closed and are activated when the limit switch contacts the adjustable limit rod. The adjustable limit rod can be positioned anywhere along the range of travel to prevent the crosshead from traveling beyond that point. Note Always adjust the limits whenever you change grips or fixtures.
Travel Limit Switches (Physical Limits) When a physical limit is reached there are three ways to get the crosshead moving again: 56 Operation • First press Motor Reset in TestWorks 4. Then use the crosshead capabilities of your software (virtual handset). Move the crosshead away from the limit until the switch closes and the crosshead can move in both directions again. See the TestWorks software manual for further details.
Crush Zone Hazards Crush Zone Hazards It is important to stay clear of any potential crush zones when the system is operating. Know where the crush zones are in your system and protect yourself and others from those crush zones with appropriate safety devices. The following paragraphs describe crush zones and precautions to take while working around crush zones.
Fixture Mounting Fixture Mounting MTS offers a wide variety of fixtures. Mounting these fixtures typically involves installing the fixture or load cell onto a mounting (clevis pin) adapter and securing it with a mounting dowel (pin). To further secure a fixture, some configurations also include locking collars. A typical mounting configuration is shown in the following illustration.
Load Cell Mounting Load Cell Mounting Mounting load cells typically involves securing the load cell to the frame via a threaded bolt along with associated hardware (in most cases a flat washer, adapter sleeve, and plate assembly). The following illustrations show the standard mounting configurations. Following the illustrations is a table that provides frame size, bolt thread size, and recommended torque value.
Load Cell Mounting Cap screw Washer Sleeve Plate assembly or Load cell 30 kN, 50 kN, and 50 kN W Sleeve Cap screw Cap screw (12) Washer Plate assembly Load cell plate Load cell or 50 kN W Multihead 60 Operation MTS Insight™ Material Testing System
Load Cell Mounting Threaded stud Cap screw Supernut with jackbolts Sleeve Washer Sleeve Plate assembly Load cell 100 kN through 300 kN Plate assembly Load cell (Configuration depends on system requirements.
Load Cell Mounting Load Frame Size Load Cell Bolt Torque Specifications Bolt Thread Lube and Torque to: Wrench 1 kN and 2 kN M6 x 1 mm 4 N•m (3 lbf-ft) M5 hex key (MTS p/n 100-146-009) 2 kN EL HS, 5 kN, and 10 kN M6 x 1 mm 4 N•m (3 lbf-ft) M5 hex key (MTS p/n 100-146-009) 2 kN EL HS, 5 kN, and 10 kN M12 x 1.
Handset Control Handset Control The handset has an encoder and buttons to help you during specimen installation and test execution. The handset also has an alphanumeric display and LEDs to provide feedback. 14 1 LOAD 1 - 0.0021 kN DISP 1 - 0.
Handset Control Handset functions The handset is intended to be used in a system for specimen loading or setup. In some applications, it can be used to completely run a test. Handset Controls and Indicators # Control/Indicator Description 1 Page Displays the next four lines of text in the display. 2 Active Indicator. When lit, indicates the system is active (power applied). 3 F1 and F2 Programmable functions that are set up in the software as digital inputs.
Maintenance Routine Maintenance Overview Checklist General cleaning 67 Monthly maintenance 67 Semiannual maintenance Other service MTS Insight™ Material Testing System 66 67 67 Maintenance 65
Routine Maintenance Overview Checklist Routine Maintenance Overview Checklist Recommended service to be performed at each running time interval noted Calendar Time using 8 hour Running Time rate per day Daily Weekly Annually Running Time-Hours 8 40 2000 Shunt Cal Check X Clean Work Area/Machine Surface X * Verify Limits and E-Stop X Inspect Cable/Connections X PC Maintenance Back-up TestWorks files (*.reg/.
Routine Maintenance Overview Checklist There are no customer serviceable components on the MTS Insight frames. Maintenance consists of keeping the frame and work area clean, general inspection, checking interlocks, and scheduled frame calibration. WARNING Disconnect the power cord from the wall outlet before cleaning or inspecting any part of the test frame. Inadvertent electrical component contamination with detergents or cleaning fluids can cause circuits to short resulting in equipment damage.
Routine Maintenance Overview Checklist 68 Maintenance MTS Insight™ Material Testing System
Additional Digital I/O Information Appendix Additional Digital I/O Information The digital inputs have an MOCD223 optical isolator with 2.7 Kohm, ½ Watt series resistor. To reliable turn on they need 1 mA of current. This means the minimum input high voltage is 4.0 V DC. The maximum input voltage is 28.0 V DC. The device should be off for input voltages less than 1.0 V. The digital outputs are implemented by an AQV252G PhotoMOS relay with a 0.75 Amp poly fuse in series.
Additional Digital I/O Information A typical example might be connecting an external switch.
Electromechanical Load Unit Maintenance and Service Logs Contents 8 Hours/Daily 72 40 Hours/Weekly 2000 Hours 74 2000 Hours 75 2000 Hours 76 Model 505.07/.
8 Hours/Daily 8 Hours/Daily 8 Hours/Daily Service Interval Recommendation Date Shunt Calibration Check Clean Work area/ Machine Surface Performed by Performed by 72 Notes Electromechanical Load Unit Maintenance and Model 505.07/.
40 Hours/Weekly 40 Hours/Weekly 40 Hours/Weekly Service Interval Recommendation Date Verify Limits and E-Stop Inspect Cable/Connections Performed by Performed by Model 505.07/.
2000 Hours 2000 Hours 2000 Hours/Annual Service Interval Recommendation PC Maintenance Date System Inspection Back-up TestWorks Files (*.reg/ .cal files) HD Defragmentation Inspect/Clean Controller Inspect Drive Belts for Excessive Wear Inspect Cable Connections Performed by Performed by Performed by Performed by Performed by 74 Electromechanical Load Unit Maintenance and Notes Model 505.07/.
2000 Hours 2000 Hours 2000 Hours/Annual Service Interval Recommendation System Checks Date Check E-Stop Check Upper Limit Check Lower Limit Check Load Cal/ Shunt Cal Performed by Performed by Performed by Performed by Model 505.07/.
2000 Hours 2000 Hours 2000 Hours/Annual Service Interval Recommendation Lubrication Date Frame and Work Area Crosshead/ Ball Screw (#2 white lithium grease) Bearings In Base Plate (#2 white lithium grease) Drive Train Bearings (if applicable) Clean/Replace Air Filter Clean Guide Clean Off Columns with Frame and WD40 (D/G/S Work Area Series Frames) Performed by Performed by Performed by Performed by Performed by 76 Electromechanical Load Unit Maintenance and Performed by Notes Model 505.
m MTS Systems Corporation 14000 Technology Drive Eden Prairie, Minnesota 55344-2290 USA Toll Free Phone: 800-328-2255 (within the 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.
