MTS Landmark™ Floor Standing Load Units Product Information Models 370.10, 370.25, 370.50 100-184-093 F be certain.
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Contents Technical Support 7 How to Get Technical Support.................................................................................................................7 Before You Contact MTS.........................................................................................................................7 If You Contact MTS by Phone.................................................................................................................9 Problem Submittal Form in MTS Manuals..............
Unlock the Crosshead.............................................................................................................................53 Anchoring the Load Unit........................................................................................................................55 Operation 57 Special Transducer Considerations........................................................................................................58 Control Module................................................
Prerequisites.............................................................................................................................101 Check the Precharge Pressure..................................................................................................101 Change the Precharge Pressure................................................................................................103 Decrease Pressure..............................................................................................
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.
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.
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 • Name • Company name • Company address • Phone number where you can be reached If your issue has a notification number, please provide that number. A new issue will be assigned a unique notification number.
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 notification 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.
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.
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.......................................................................................................................16 • Safety Practices Before Operating the System.....................................................................................16 • Safety Practices While Operating the System ......................................................................................20 • Load Unit Hazard Labels................................................
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 Locate lockout/tagout points Know where the lockout/tagout point is for each 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.
Safety Ensure Correct Cable Connection If a system cable has been disconnected, ensure that you establish the correct cable-to-connector relationship during reconnection. Incorrect cable connections can result in improper servo loop phasing or an open servo loop condition, either of which can cause unstable or unexpected and potentially dangerous system motions. Verify the correct cable-to-connector relationship by observing the cable and connector labeling and the system wiring schematics.
Safety to the dangers of escaping compressed gas and particulates that are expelled from the chamber or around the seals. Do not assume that cover plates and ports are installed in all the critical locations. Consult MTS when in doubt about the safety or reliability of any system-related procedure or modification that involves devices that contain any type of compressed gas.
Safety Do not exceed the Maximum Supply Pressure For hydraulic systems and components, make sure that hydraulic supply pressure is limited to the maximum pressure defined by the system operating limits. Read and review “System Operating Limits” for the system. Do not disable safety devices Your system may have active or passive safety devices installed to prevent system operation if the device indicates an unsafe condition. Do not disable such devices as it may result in unexpected system motion.
Safety Specimen temperature changes During cyclic testing, the specimen temperature can become hot enough to cause burns. Wear personal protection equipment (gloves) when handling specimens.
Safety or crush anything in the path of the equipment and cause serious injury. Stay clear of any potential crush points. Most test systems can produce sudden, high-force motion. Never assume that your reactions are fast enough to allow you to escape injury when a system fails. 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).
Safety Hazard Labels Rest of World (part number 100-164-565) Icon Description Failure to follow operating instructions can cause death or serious injury. Read and understand the operator’s manual before using this machine. Moving parts can crush and cut. Keep hands clear while operating machine. Pushing or striking load frame may cause it to tip over. Read the operator’s manual for moving instructions.
Safety Icon Description Flying debris and loud noise hazard. Wear ear and eye protection. Hydraulic pressure beyond rated working pressure can rupture components, cause severe personal injury, and damage equipment. Do not exceed 21 MPa (3000 psi) rated working pressure. Hazard Label for HSM Needle Valve Adjustment Icon Description The HSM needle valve is factory adjusted and should not be adjusted in the field except by MTS Field Service Engineers.
Safety Hazard Label for HSM Needle Valve Adjustment Icon Description The HSM needle valve is factory adjusted and should not be adjusted in the field except by MTS Field Service Engineers.
Introduction Topics: • Overview................................................................................................................................................28 • EU Declarations.....................................................................................................................................29 • Component Description.........................................................................................................................30 • Functional Description...
Introduction Overview The load unit is the primary structure for most materials testing. It is a stand-alone testing unit. The load unit consists of the load frame plus additional parts, such as hydraulic crosshead lifts and control modules. Load units come in different sizes and shapes. The following illustration shows typical load units with common accessories. The load units are designed to perform tension and compression tests, fatigue and fracture mechanics tests, as well as other tests.
Introduction What you need to know MTS Systems Corporation assumes that you know how to use your controller. For information about performing any controller-related step in this manual's procedure, see the appropriate manual. You are expected to know how to perform the following procedures: • Turn hydraulic pressure on and off. • Select a control mode. • Adjust the actuator position. • Zero a sensor signal. • Zero a sensor output. • Use your grips and fixtures. • Define a simple test.
Introduction extensometers, furnaces, ovens and environmental chambers, and so forth) conforms to the requirements of Machinery Directive 2006/42/EC and other applicable EC Directives. This will require the customer to affix the CE Marking on the system assembly and to complete the EC Declaration of Conformity before putting the machinery into service.
Introduction Component Descriptions Item Component Description A B Front View Back View 1 Crosshead Moves up and down the column to accommodate different sized specimens and fixtures. The crosshead is stiff and light weight; it is one end of the force train. 2 Crosshead locks Clamps the crosshead to the columns. The locks are typically hydraulically powered. 3 Crosshead lifts Raise and lower the crosshead hydraulically to accommodate different specimen sizes.
Introduction Item Component Description 4 Control panel The Emergency Stop button is standard; the other controls are optional. Grip controls Clamp and unclamp the hydraulically controlled grips during specimen installation and removal. Also provide a pressure adjustment to control grip clamping force and a rate adjustment that controls how fast the grips secure the specimen. Crosshead lifts control Controls the crosshead lifts to raise and lower the crosshead hydraulically.
Introduction Item Component Description 13 Lift points Allows the load unit to be moved by lifting the entire load unit. For load units with the actuator integral to the base, hoist rings are provided in the crosshead. For load units with the actuator integral to the crosshead, slings should be used under the crosshead on each side of the actuator. Functional Description The load unit is a stand-alone testing structure.
Introduction 69 MPa (10,000 psi) to accommodate a variety of grips manufactured by MTS Systems Corporation. A front panel control allows the grip pressure to be adjusted within the factory setting. A rate control sets how fast the grips open and close. Actuator velocity limiting switch This switch/indicator is used to control actuator speed. The switch is spring loaded left/right with a center neutral position.
Introduction Series 661 Force Transducer The force transducer commonly used with the Model 370 Load Unit is a Series 661 Force Transducer. There is no manual for the force transducer. The following table provides the specifications for the force transducers. Parameter Specification Maximum excitation voltage 15 V DC Bridge resistance 350 ¾ Maximum crosstalk 1.0% of full scale torsional to load Hysteresis 0.08% of full scale (250 N–2.5 kN) 0.05% of full scale (5 kN–50 kN) 0.
Introduction Dimensions The following dimensions are rounded off to the nearest millimeter. Series 661 Force Transducer Dimensions Model A 1 B C D E 2 661.20-01 154 mm (6.06 in) 57 mm (2.24 in) 10 mm (0.39 in) 95 mm (3.74 in) 89 mm (3.5 in) 661.22-01 114 mm (4.48 in) 92 mm 3.62 in) 1 mm (0.03 in) 203 mm (7.99 in) 74 mm (2.91 in) 661.23-01 152 mm (5.98 in) 140 mm (5.51 in) 203 mm (7.99 in) 86 mm (3.
Installation Topics: • About Installation...................................................................................................................................38 • Unpacking Horizontal Configuration......................................................................................................38 • Lifting and Moving the Load Unit...........................................................................................................42 • Connecting Cables..........................
Installation About Installation This section provides information on load unit installation. After installation is complete, it is recommended that you verify operation before putting the load unit into service and start running tests. Unpacking Horizontal Configuration Note: Illustrations show a typical load unit. Some load units can be packaged control panel down. However, regardless of orientation, the following instructions can be used.
Installation Unpack the Load Unit (Horizontal Configuration) 1. Cut the packing straps and remove any bolts as needed. Make sure the lifting eyebolts are tight. 2. Inspect the load unit for shipping damage. Look for the following: • Scratches in the load unit or lift cylinder columns • Damaged electrical connections • Damaged hydraulic connections • Dents and other structural damage • Torn, kinked, or breaking hoses Report any damage found to both the carrier and MTS. In the U.S.
Installation Lift the Load Unit Upright Item Description 1 Crane Travel 2 30° Maximum 4. Move the load unit to its final position. Before you move the load unit, ensure that: • The floor where the load unit will sit can bear its weight. • The path to where the load unit will sit is clear and uncluttered. • The area where the load unit will sit is clean and well lit, with all hoses and cables moved out of harm’s way. • The eyebolts are tight. • The crosshead is manually locked.
Installation • If your load unit has isolation pads, and the load unit does not sit level, install stock metal shims between the pads and the floor. • If your load unit has airmounts, inflate each airmount in 5 mm (0.20 in) increments to level the load unit. • Check the airmounts’ pressures often to ensure that they do not exceed 0.55 MPa (80 psi). • Check the airmounts’ inflated heights to ensure that they are all between 83 and 88 mm (3.25 and 3.5 in).
Installation 6. Remove the chains. 7. Contact MTS Systems Corporation to arrange for installation services. In the U.S. and Canada, call the MTS Call Center at 1-800-328-2255. Elsewhere, contact your local MTS office. Lifting and Moving the Load Unit This section describes how to lift and move the Series 370 Load Unit. Overview You will need a fork lift or overhead crane capable of lifting the load unit.
Installation Approximate Weights of Load Units Model Base Mount Crosshead Mount Approximate Weight Approximate Weight 370.10 631 kg (1390 lb) 815 kg (1795 lb) 370.25 871 kg (1920 lb) 1091 kg (2405 lb) 370.50 1563 kg (3445 lb) 1756 kg (3870 lb) Lift and Move the Load Unit 1. Unpack the load unit. a) Remove the load unit from the shipping container (if used). b) Remove any protective wrapping. c) Use a clean cloth to wipe dust or debris deposited during shipment. 2.
Installation Lock the Crosshead Item Description 1 190 N · m (140 lbf · ft) Lock the Crosshead Item Description 1 Hydraulically Locked Crossheads 2 Manually Locked Crossheads 3 Manual locks not available on Models 370.25 and 370.50. 4. Before you move the load unit, check the following: • The floor where the load unit will sit can bear its weight. • The path to where the load unit will sit is clear and uncluttered.
Installation Lift Point Locations Item Description 1 M20 X 2.50 mm Holes for Swivel Hoist Rings (supplied for lifting) 2 Slings Warning: Airmounts can be overinflated and then explode. You can be seriously hurt if an airmount explodes, sending fragments flying. Only inflate airmounts that have the full weight of the load unit resting on them. Never inflate an airmount above 0.41 MPa (60 psi). Check airmount pressures with an accurate pressure gage.
Installation The load unit can be moved on its pallet with a fork lift, or with its lifting hoist rings (actuator integral to the base), or with slings (actuator integral to the crosshead) using an overhead lifting device. Lift the load unit only as high as necessary.
Installation Warning: Airmounts can be overinflated and then explode. You can be seriously hurt if an airmount explodes, sending fragments flying. Only inflate airmounts that have the full weight of the load unit resting on them. Never inflate an airmount above 0.55 MPa (80 psi). Check airmount pressures with an accurate pressure gage. Each airmount's inflated height—measured from the floor to the bottom of the load unit’s leg—should be 83–89 mm (3.25–3.5 in). 6.
Installation Item Description 2 Isolation Pads 3 Load Unit 4 57 - 63 mm (2.25–2.5 in) 83 - 89 mm (3.25–3.5 in) 5 0.41 MPa (60 psi) 0.55 MPa (80 psi) 6 Install shims to level. 7. Remove the slings/chains. 8. Secure the load unit. The load unit must be secured to an adequate platform before it can be operated. The base of tabletop load units have a threaded hole in each corner (M16 X 2.00 mm). a) If necessary, drill four mounting holes for the load unit. The load unit hole pattern is shown below.
Installation Mounting Hardware Item Description 1 Jam Nut 2 Isolation Pad 3 Washer 4 Threaded Stud 5 Spring 6 Self Locking Nut 9. Contact MTS Systems Corporation to arrange for installation services. In the U.S. and Canada, call the MTS Call Center at 1-800-328-2255. Elsewhere, contact your local MTS office.
Installation Connecting Cables Your controller manual should have cabling information about the connections described in this section. Most controller manuals provide the signal pinouts of the connector, assembly numbers for standard MTS cables, and cable specifications for cables you may build. Prerequisite You must have either a cable assembly drawing of your test system, or you must know the system controller well enough to determine each type of cable connection.
Installation Note: Location of the load frame low flow solenoid shown in the figure is typical. Actual location can vary depending on manifold configuration.
Installation Connect the Low Flow Power Supply Item Description 1 Main Power In 2 To Low Flow Solenoid 3 To Load Frame Rear Panel 4 Door Interlock Jumper Connect Hydraulics This procedure describes how to connect the load unit to the hydraulic power source. The load unit may be connected directly to the hydraulic power unit (also called HPU), to hydraulic plumbing in the workplace, or through a hydraulic service manifold.
Installation Caution: Hydraulic fluid must be properly filtered. Failure to maintain clean hydraulic fluid will lead to poor system performance and expensive repairs. MTS supplied HPUs incorporate the necessary filtration. If the source of hydraulic fluid pressure is customer supplied, it is the customer's responsibility to ensure proper filtration. Important: The internal hydraulic connections from the actuator manifold and accessories (such as the hydraulic lifts and locks) should already be made. 1.
Installation Note: This procedure only applies to load units equipped with hydraulic crosshead positioning and locks. Caution: The crosshead can slowly drift down the columns if the locks are turned off and when hydraulic pressure is turned off. The crosshead can damage any test fixtures, grips, and specimen in its path. Unlock the crosshead only to reposition it. Always lock the crosshead after you have repositioned it and never leave the crosshead unlocked. 1. Turn on hydraulic pressure. 2.
Installation Loosen the Manual Crosshead Locking Bolts Item Description 1 136 N·m (100 lbf·ft) 2 271 N·m (200 lbf·ft) 3 271 N·m (200 lbf·ft) Loosen the Manual Crosshead Locking Bolts Item Description 1 190 N·m (140 lbf·ft) 3. Cycle the lock control to unclamp, and then reclamp, the crosshead. 4. Use the lock control to unclamp the crosshead. Wait 30 seconds for the pressure in the crosshead locks to drop to zero. 5. Use the lift control to position the crosshead where you want it. 6.
Operation Topics: • Special Transducer Considerations.......................................................................................................58 • Control Module.......................................................................................................................................58 • 370 Load Unit: Crush Point Hazards.....................................................................................................59 • Specimen Installation.............................
Operation Special Transducer Considerations Special considerations must be followed when using low force transducers in a high force system. Small force transducers are commonly used in larger systems. You need to be aware that the load unit can produce forces that exceed the rating of the low force transducer. Caution: Low force transducers in a high force system can be exposed to excessive forces. Applying forces that exceed the rated capacity of the force transducer can damage the transducer.
Operation Series 370 Load Unit Controls Item Control Description 1 Upper Hydraulic Grip Controls Item 1 controls clamping and unclamping the optional upper hydraulic grip. Item 1A adjusts the upper grip clamping rate. Item 1B is the upper grip pressure gage. 2 Lower Hydraulic Grip Controls Item 2 controls clamping and unclamping the optional lower hydraulic grip. Item 2A adjusts the lower grip clamping rate. Item 2B is the lower grip pressure gage.
Operation Crush Point Area Item Description 1 Crush Point Area Location A crush point exists between the platen and crosshead on load units where the actuator piston rod and specimen move. Precautions Keep clear of any mechanical linkage that moves within a closed area. If the linkage should move (when the system starts or due to mechanical failure), very high forces can be present that could pinch, cut, or crush anything in the path of linkage movement.
Operation Note: When changing hydraulic grips, make sure you cap or plug the hydraulic hoses when removed to prevent oil spillage. Oil spillage can create an environmental concern and slippery surface that can cause personal injury. Promptly clean up any oil that might have spilled when hoses were removed. You must also have the controller set up to control the actuator movement, and you must have a test program defined. Warning: The crosshead is very heavy.
Operation 2. Set the crosshead position. The crosshead position depends on the length of the specimen being tested, the starting position of the actuator, and the size of the fixtures or grips being used. 3. Install the specimen. Specimen installation varies according to the type of grip being used. For installation instructions, see the appropriate grip manual.
Operation Position the Crosshead Hydraulically 1. Important: This step pressurizes the lift actuators. The crosshead might have shifted position while hydraulic pressure was turned off. Briefly turn the crosshead positioning control to the lift crosshead position to apply a slight upward pressure to the crosshead. Then return the lift control to the stop position. 2. Use the crosshead lock/unlock control to unlock the crosshead. Wait 5 seconds for the pressure in the crosshead locks to drop to zero. 3.
Operation The following procedure describes using an overhead crane to position the crosshead. You can use any device that can lift the weight of the load unit. Crosshead Weights Model 370.02 Model 370.10 Model 370.25 Model 370.50 84–114kg (186–252 lb) 57 kg (125 lb) 102 kg (225 lb) 193 kg (425 lb) 1. Center the overhead crane directly over the load unit. 2. Wrap lifting slings around the crosshead. Remove any slack in the lifting chains or slings while keeping tension to a minimum. 3.
Operation Crosshead Locking Bolt Torque Item Description 1 190 N·m (140 lbf·ft) 2 271 N·m (200 lbf·ft) 6. Raise or lower the crosshead using the overhead crane. 7. Manually clamp the crosshead to lock the crosshead into position.
Operation Manually Clamp the Crosshead Warning: The crosshead is very heavy. A dropping crosshead can crush hands, damage grips, and smash specimens. Observe the following precautions to reduce the possibility of unexpected crosshead movement: Ensure that the crosshead is locked. The overhead crane and lifting chains must be able to support the weight of the crosshead. Center the crane directly over the load unit. Remove any slack in the lifting chains before unlocking the crosshead.
Operation Note: Use the same sequence when you loosen the bolts. Crosshead Clamping Bolt Torque Values The following table includes values for crosshead clamping bolt torques for each step in the manual clamping procedure. Torque Values 3 Load Unit Step 1 Step 2 Step 3 Step 4 370.02 20 N·m (15 lbf·ft) 171 N·m (126 lbf·ft) 190 N·m (140 lbf·ft) 190 N·m (140 lbf·ft) 370.10 20 N·m (15 lbf·ft) 171 N·m (126 lbf·ft) 190 N·m (140 lbf·ft) 190 N·m (140 lbf·ft) 370.
Operation Warning: The crosshead is very heavy. A dropping crosshead can crush hands, damage grips, and smash specimens. Be careful when working in a crush zone. To reduce the hazards in this procedure, observe the following: Set and enable displacement interlocks to limit the actuator’s movement. Ensure that the crosshead is locked. Ensure that the columns are clean and dry. Keep your hands out of the crush zone except when performing the steps needed to complete this procedure. 5.
Operation Caution: Grips are designed to operate within a range of hydraulic pressure. Too much pressure can damage both the grips and the specimen. Do not adjust grip pressure higher than the grip rating. To determine the correct hydraulic pressure to apply to your grips before adjusting the Pressure control, see your grip manual. 5. Adjust the pressure control for the desired hydraulic pressure. 6. If you exceed the desired pressure setting, adjust the Pressure control counterclockwise 1/2 turn.
Operation Handset Controls and Indicators Item Control/Indicator Description 1 Page Displays previous or next text in the display. 2 Active Indicator. When lit, indicates the system is active (power applied). 3 Scroll Highlight Scrolls the highlighted selection down. Selection cycles to the top when the bottom line is highlighted and the switch is pressed. 4 Thumb-Wheel Makes fine actuator adjustment (towards display – up; away from display – down). Only if Handset Enable is active.
Operation Item Control/Indicator Description 7 Connector RJ-45, to Controller. 8 Hydraulic Off Shuts down the HPU. 9 Start Starts the test action. Only if the application test software is active. 10 Interlock Reset Resets active interlock(s) providing the cause for the interlock(s) has been remedied. 11 Thumbwheel Enable Press to enable the thumbwheel to position the actuator. Press again to disable the thumbwheel. The indicator lights when the thumbwheel is active. 12 Fault Indicator.
Operation In conjunction with the controller and specimen installation mode using the handset, the load frame itself has two operation modes: full flow, and actuator velocity limiting restricted flow. A switch on the load frame control panel activates a solenoid which controls a hydraulic circuit within the load frame hydraulic service manifold. In the actuator velocity limiting mode, oil flow to the actuator is directed through an orifice which limits actuator velocity to 10 mm/second or less.
Operation Service Most normal service requirements can be met utilizing the normal three operating modes as listed previously. However, there can be circumstances where operation in full flow mode with the test area enclosure open is required. In these cases, trained service personnel can disconnect the standard enclosure cable, and temporarily replace it with a service connector. This operation is not considered typical use, and should only be used by trained individuals.
Operation Interlock Logic Item Description 1 Door Interlock 2 Solenoid Contacts 3 Test Controller Program Interlock Input. Open = Interlock.
Maintenance Topics: • Routine Maintenance Overview Checklist.............................................................................................76 • Other Maintenance Tasks......................................................................................................................79 • Daily Inspections....................................................................................................................................80 • Clean the Columns..............................
Maintenance 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 Biweekly Running Time-Hours 8 Ensure the actuator platen area is clean. X Check all filter indicators. X 40 80 Annually 500 1000 1,500 2,000 MTS MTS MTS MTS 4 Ensure all hose, cables, and connectors are attached properly. X Ensure that the crosshead, lifts, and supports are in working order.
Maintenance Calendar Time using 8 hour Running Time Rate Per Day Daily Weekly Biweekly Running Time-Hours 8 40 Annually 80 500 1000 1,500 2,000 Ensure that the crosshead columns are clean. MTS MTS MTS MTS MTS Ensure that there are no extreme column abrasions. MTS MTS MTS MTS MTS Ensure that the crosshead speed is appropriate. MTS MTS MTS MTS MTS Test to ensure the crosshead unlock causes a program interlock.
Maintenance Calendar Time using 8 hour Running Time Rate Per Day Daily Weekly Biweekly Running Time-Hours 8 40 80 Annually 500 1000 1,500 2,000 Complete a cursory check of the hydraulic service manifold. MTS MTS MTS MTS Monitor the filter indicators. MTS MTS MTS MTS Ensure that the manifold hose connections are tight. MTS MTS MTS MTS Ensure that the accumulator connections are dry. MTS MTS MTS MTS Ensure that the accumulator connections are tight.
Maintenance Calendar Time using 8 hour Running Time Rate Per Day Daily Weekly Biweekly Running Time-Hours 8 40 80 Annually 500 1000 1,500 2,000 Ensure that the turning parameters are appropriate and the system is stable. MTS MTS MTS MTS Ensure that the E-Stop is in working condition. (If applicable.) MTS MTS MTS MTS Check the visual and audible response to a full stroke waveform. MTS MTS MTS MTS Check the displacement control and valve balance.
Maintenance What to Do When to Do It Clean the load unit columns. When the columns become greasy or dirty. Prevent rust. Depends on the operating environment; more often in humid environments. Maintain airmount pressures. When the load unit sits unevenly. Adjust the hydraulic locks. When the crosshead sticks or moves jerkily on the column. Lubricate the crosshead locking bolts. Whenever they begin to be hard to tighten or sticky when loosened.
Maintenance • Hoses must be routed as to avoid direct heat sources, moving, or abrasive equipment. • Check actuator speed control functionality. If any problems are encountered, they should be repaired before operating the load unit. Clean the Columns The crosshead locks cannot securely clamp the crosshead to dirty or greasy columns. You will need ethanol and lint-free cloths to perform this procedure. Warning: The crosshead can slide down the columns.
Maintenance Prevent Rust Where you operate the load unit determines how often you take rust prevention measures. Humid and corrosive environments require more prevention. Recommended Supplies • Ethanol • Silicone spray • 000 emery cloth • Touch-up paint • Metal primer paint • Lint-free cloths Warning: The crosshead locks cannot securely clamp on damp columns. The crosshead can slip if the columns are still damp with kerosene. You can be hurt and your equipment damaged.
Maintenance MTS Landmark™ Floor Standing Load Units Product Information 83
Maintenance Rust Prevention Recommendations Item Description 1 Unpainted surfaces: Spray with silicone, and then wipe with a clean, lint-free cloth. Or, wipe with a clean, lint-free cloth dampened with clean hydraulic fluid. 2 Chrome plated surfaces: For microscratches, wipe with a clean, lint-free cloth dampened with ethanol. For rust discoloration, polish with a very fine emery cloth, and then wipe down. 3 Painted surfaces: For small scratches, use touch-up paint.
Maintenance 2. Check the inflation pressures on each airmount. Bleed any airmount whose pressure is above 0.55 MPa (80 psi). 3. Check the airmounts’ inflated heights. They should be between 57–63 mm (2.25–2.5 in). If the load unit is level and the airmount heights correct, you are done. If not, continue this procedure. Checking Airmount Inflated Heights Item Description 1 5 mm (0.20 in) 2 0.41 MPa (60 psi) 3 57–63 mm (2.25–2.5 in) 4. Check the airmounts’ inflated heights.
Maintenance Checking Airmount Inflated Heights Item Description 1 5 mm (0.20 in) 2 0.55 MPa (80 psi) 3 83–89 mm (3.25–3.5 in) 5. Gradually inflate or deflate each airmount in 5 mm (0.20 in) steps as required to level the load unit. Ensure that airmount pressures do not rise above 0.41 MPa (60 psi) and heights do not rise above 63 mm (3.5 in). Ensure that airmount pressures do not rise above 0.55 MPa (80 psi) and heights do not rise above 89 mm (3.5 in). 6.
Maintenance Warning: Over time, repeated cycling and stress pressures on the cap screws can cause cap screw failure. The cap screw can become a projectile, resulting in equipment damage and personal injury. After 5 years or 5500 duty cycles, contact MTS for replacement of the hydraulic crosshead lock cap screws. 1. Turn on electrical power at the controller. Do not turn on hydraulic pressure yet. 2. If the crosshead is already at a comfortable working level with no specimen installed, proceed to Step 3.
Maintenance Crosshead Fastener Torque Values Item Description 1 136 N·m (100 lbf·ft) 2 271 N·m (200 lbf·ft) 3 271 N·m (200 lbf·ft) 4. Turn off hydraulic pressure. 5. Use the Lock Control to unlock the crosshead position to remove pressure from the hydraulic locks. Wait two minutes for the pressure in the locks to drop to zero before going on to the next step. 6. Tighten each lock’s cap screw until its piston bottoms out. Then loosen and hand-tighten each cap screw.
Maintenance Adjusting the Hydraulic Locks Item Description 1 Tighten 2 Bottom Out Position 3 Loosen, then hand tighten. 7. Loosen each of the hydraulic lock cap screws 1/4 turn. Loosening the Hydraulic Lock Cap Screws Item Description 1 Loosen 1/4 turn. 8. Turn on electrical power at the test controller if you have not already done so. 9. Reset any active interlocks at the test controller. 10. Turn on high hydraulic pressure. 11.
Maintenance 12. Fully loosen the manual crosshead locking bolts. Then turn the Lock Control to the unlock crosshead position. 13. Move the crosshead, locking and unlocking it, to check for smooth operation. Lubricate the Crosshead Locking Bolts Lubricate the locking bolts in a manually locked crosshead whenever they begin to be hard to tighten or sticky when loosened. 1. Position the crosshead to a comfortable working height. 2. Lock the crosshead following the normal crosshead locking procedure. 3.
Maintenance Load Unit Torque 370.10 190 N·m (140 lbf·ft) 370.25 271 N·m (200 lbf·ft) 370.50 271 N·m (200 lbf·ft) 7. Repeat Steps 4 and 5 until all the bolts have been lubricated. Aligning the Force Transducer This section describes how to align a force transducer with the load unit actuator. The load units shown may vary from what you may have. The Model 370.10 and some 370.25 Load Units come with two types of transducer mounting hardware.
Maintenance Preloader Hardware Item Description 1 Identification Plate 2 Stud 3 Hex Nut 4 Washer 5 Adapter Bushing 6 Preloaded Collar 7 Crosshead 8 Transducer (appearance can vary) 9 The identification plate specifies the final torque value. Align the Force Transducer 1.
Maintenance a) If grips are installed, remove them. b) Turn on system electrical power. c) Turn on high hydraulic pressure. 2. Set up the load unit: a) Position the actuator at midstroke. b) Set and enable the test controller’s upper and lower limit detect interlocks to limit the actuator’s movement to 2 mm (0.10 in) in each direction. c) Move the crosshead so that there is about 360 mm (14 in) between the top of the actuator and the bottom of the force transducer. d) Lock the crosshead.
Maintenance Attaching and Zeroing the Indicator Item Description 1 Read along the edge. 2 Zero a) Attach the dial indicator to the actuator. On a low-profile force transducer, adjust the indicator to take the reading along the edge of the loading surface. On a cylindrical style force transducer, adjust the indicator so that its stylus just touches the polished bottom edge of the transducer. b) Zero the indicator. c) Slowly turn the actuator to rotate the indicator 360° around the force transducer.
Maintenance Load Unit Rating TIR 500 kN (100 kip) 0.051 mm (0.0020 in) d) If the TIR is 0.038 mm (0.0015 in) or less, the force transducer is accurately aligned with the actuator. Go to Step 6. If the TIR is greater than 0.038 mm (0.0015 in), the force transducer needs to be aligned with the actuator. Start over with Step 3. 4. If you have a force transducer that is mounted to the crosshead with a single nut, perform the following substeps.
Maintenance Lubricating the Hex Nut Item Description 1 Tighten. 2 G-n Paste 3 Wooden Blocks 5. If you have a force transducer that is mounted to the crosshead using a preloader collar, perform the following substeps. a) Loosen the six jack bolts or setscrews in 1/4 turn steps to remove most of the tension on the preloader collar, following a standard crisscross torque sequence. b) If your preloader collar has jackbolts, remove and lubricate them one at a time.
Maintenance Preloader Collar Bolts Item Description 1 Remove one at a time 2 G-n Paste 6. Align the force transducer to the crosshead: a) Lightly tap the transducer with the rubber mallet to change its position until you get a TIR of 0.038 mm (0.0015 in) or less. b) Tighten to 5% of the torque recorded on the identification plate. Hex nut—Tighten the nut to 5% of the final torque shown on the identification plate.
Maintenance Bolt Torque Sequence d) Repeat Steps B and C to tighten the force transducer for the following torque progression: 50%, 75%, and 100%. e) Preloader collar only—For uniform tightness, retorque the jackbolts or setscrews to 100% of the final torque shown on the identification plate. Actuator Force Rating Torque Rating 25 kN (5.5 kip) 3.7 N·m (2.7 lbf·ft) 11–500 kN (11–110 kip) 48 N·m (35 lb·ft) 7. Finish the procedure. a) Remove the dial indicator.
Maintenance Accumulator Components Item Description 1 Piston 2 Hydraulic Fluid End Cap 3 Hydraulic Fluid Port 4 Locking pin 5 Screws 6 Accumulator Valve Assembly 7 Accumulator Valve Protective Cover 8 Valve Stem Cap 9 Locknut 10 End Cap 11 Chamber Use the following guidelines to determine when maintenance is required. • Check the precharge pressure at periodic intervals. The length of time between checks depends on how the system is used.
Maintenance 111 Accumulator Temperature Conversion Item Description 1 Degrees Celsius 2 current pressure = original pressure x 3 273 + (current temperature) 4 273 + (original temperature) 5 Degrees Fahrenheit 6 current pressure = original pressure x 7 460 + (current temperature) 8 460 + (original temperature) • If a pressure line accumulator has a pressure level change of ±1.
Maintenance Series 111 Accumulator: Check and Change Precharge Pressure This section covers checking and changing the precharge pressure for the 111 accumulator. Equipment An accumulator charging kit (MTS part number 376986-01). Prerequisites To prepare the accumulator for precharge check: Warning: Accumulators are pressurized devices. Pressurized accumulators and their parts can become lethal projectiles if disassembled and can cause death to persons and/or damage to equipment.
Maintenance Checking the Precharge Pressure Item Description 1 Locknut 2 Valve Stem 3 Close 4 Open 5 Poppet Type Accumulator Valve. To open and close, use locknut. 6 Or 7 Valve Core 8 Core type accumulator valve. To open and close use chuck valve.
Maintenance Item Description 13 Regulator Output Pressure Gage 14 Regulator Shut-Off Valve 15 Regulator Output Pressure Valve 16 Nitrogen Supply Hose 17 Input Check Valve 18 Bleed Valve 19 Extension Hose 20 Gage Protector (factory set to limit pressure to the gage to approximately 1.4 MPa (200 psi) 21 High Pressure Gage—0–21 MPa (0–3000 psi) 22 Low Pressure Gage—0–2.1 MPa (0–300 psi) 23 Chuck Valve 2.
Maintenance Warning: Accumulators have specific pressure ratings. If the precharge pressure is too high, the accumulator can bottom out causing the release of metal particles into the hydraulic fluid. Charging accumulators above their rated level can damage system equipment. Do not charge accumulators to pressures above their rated level. Charge accumulators below their rated fatigue pressure of 21 MPa (3000 psi) for the Model 111.11B and 22 MPa (3200 psi) for the Model 111.12C.
Maintenance Caution: Rapid flow rates with pressure differentials of more than 2.1 MPa (300 psi) across the input check valve can damage the valve seal(s). Avoid rapid and extreme pressure transitions. Do not allow rapid flow rates. Open the regulator shut-off valve only far enough to permit a gradual transfer of gas. 6. Slowly open the regulator shut-off valve until gas is heard escaping from the accumulator charging kit bleed valve.
Maintenance Change the HSM Filter The hydraulic service manifold filter needs to be changed periodically. Component Identification Item Description 1 Dirty Filter Indicator 2 Inlet Filter Caution: Mixing different brands of hydraulic fluid can contaminate your system. Contaminated hydraulic fluid can cause premature wear of the hydraulic components in your system. Do not mix different brands of hydraulic fluid.
Maintenance Filter Part Number Kit Number 10 micron (Beta7.4 = 75) 011-395-936 044-205-201 Change the HSM Filter 1. Ensure that system hydraulic pressure has been reduced to zero before proceeding. To do this, turn off the hydraulic power unit and exercise the actuator until it stops moving. 2. Turn off electrical power at the controller. 3. Place a waste fluid pan beneath the filter housing, which will accumulate any small amount of drainage from the filter housing. 4. Remove the inlet filter bowl.
Maintenance Prerequisites You must have a filter kit that contains the necessary filter element replacement parts. The filter for the Model 252.3x Servovalves is MTS part number 032-844-101. The filter for the revision G Model 252.2x/4x servovalves is MTS part number 100-098-436. MTS does not recommend field replacement of filters in earlier revision servovalves. Replace the Servovalve Filter Element Refer to the following figure during the procedure.
Maintenance Item Description 2 Washers (4) 3 Filter Cover Plate 4 Filter Plug 5 Filter Plug O-Rings 6 Filter O-Ring 7 Filter 8 Filter Housing 9 Filter Cover 10 Model 252.2x/.4x (revision G) Filter Location 11 Model 252.3x Filter Assembly 1. Ensure that system hydraulic pressure has been reduced to zero before proceeding. To do this, turn off the hydraulic power unit and exercise the actuator until it stops moving. Turn off electrical power to the controller.
Maintenance k) Lightly lubricate the filter O-ring with clean hydraulic fluid, install it on the replacement filter, and insert the filter into the housing. l) Lightly lubricate the filter plug O-rings with clean hydraulic fluid, install them on the filter plug, and install the filter plug. m) Secure the filter cover plate to the housing using the four socket head screws and washers removed in Step f. Tighten each socket head screw until it is firmly seated against the filter cover plate.
Maintenance 1. Exercise the actuator. The actuator should be exercised to warm it up. Electrical and mechanical adjustments are more repeatable after the actuator is warmed up. a) Select displacement control for the controller. b) Disable the reset integrator or adjust the Reset control for zero. c) Adjust the actuator for mid-displacement. d) Turn on electrical and hydraulic system power. e) Define a 50%, 0.1 Hz sine wave command and allow the actuator to warm up for approximately one-half hour.
Maintenance g) Using the offset wrench, loosen (but do not remove) the self-locking nut. Mechanical Null Adjustor Pin Item Description 1 Series 252.2X, 252.4X, and 252.5X Servovalves 2 Series 252.
Maintenance Item Description 11 3/32 Inch 12 3/8 Inch h) Turn the adjustor pin until the scribe mark on the adjustor pin is pointing toward the base of the servovalve. i) Tighten the self-locking nut until 1.13 to 1.36 N·m (10 to 12 lb·in) of torque is needed to turn the adjustor pin, ensuring that the scribe mark remains pointing toward the base of the servovalve. j) Remove the torque wrench and offset wrench. 4. Finish the procedure. a) Ensure that the actuator is warmed up. If not, go to Step 1.
Decommissioning Topics: • Decommission the System..................................................................................................................
Decommissioning Decommission the System The decommissioning process is performed when the system is going to be moved or taken out of service. Dis-assembly is required when performing either of these tasks. 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, fully into the cushion. 3.
Decommissioning Warning: Residual hydraulic pressure can produce a high pressure spray. You could be cut by this spray or hydraulic fluid could be forced into your skin. Do not continue with this procedure unless the system has been isolated from hydraulic pressure for at least 20 minutes. Always be cautious when you loosen any hydraulic connection or remove bolts or screws from any hydraulic component. Always allow fluid pressure to dissipate slowly until completely vented before continuing to loosen.
Declarations Topics: • Declaration of Conformity....................................................................................................................120 • Declaration of Incorporation.................................................................................................................
Declarations Declaration of Conformity Original - Page 1 of 3 - DoC Load Unit - December 21, 2009 120 MTS Landmark™ Floor Standing Load Units Product Information
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Declarations Original - Page 3 of 3 - DoC Load Unit - December 21, 2009 122 MTS Landmark™ Floor Standing Load Units Product Information
Declarations Declaration of Incorporation Original - Page 1 of 3 - DoI Load Unit - December 21, 2009 MTS Landmark™ Floor Standing Load Units Product Information 123
Declarations Original - Page 2 of 3 - DoI Load Unit - December 21, 2009 124 MTS Landmark™ Floor Standing Load Units Product Information
Declarations Original - Page 3 of 3 - DoI Load Unit - December 21, 2009 MTS Landmark™ Floor Standing Load Units Product Information 125
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