Model 293.22 Hydraulic Service Manifold Product Manual 015-081-100 E be certain.
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Table of Contents Table of Contents Technical Support How to Get Technical Support.........................................................................................................5 Before You Contact MTS.................................................................................................................5 If You Contact MTS by Phone..........................................................................................................7 Problem Submittal Form in MTS Manuals.............
Table of Contents Remove flammable fluids....................................................................................................27 Check bolt ratings and torques...........................................................................................27 Practice good housekeeping...............................................................................................28 Protect hoses and cables................................................................................................
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.
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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. Model 293.
Introduction Topics: • • • • • • • • • • About the Hydraulic Service Manifold (HSM)....................................................................................14 Model 293.22 HSM Component Identification...................................................................................15 HSM Fluid Flow.................................................................................................................................19 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 Model 293.22 HSM Component Identification Model 293.22 Hydraulic Service Manifold Model 293.
Introduction Component Identification Single Channel 16 | Model 293.
Introduction Component Identification Multiple Channel Item Name Description A Front View Viewing angle B Side View Viewing angle Model 293.
Introduction Item Name Description C Front View of the Control Manifold Viewing angle 1 Return Accumulator Reduces pressure and flow fluctuations resulting from changing system demands. 2 Pilot Pressure Accumulator (optional) Reduces pressure and flow fluctuations at the pilot pressure port. 3 Pressure Accumulator Reduces pressure and flow fluctuations resulting from changing system demands. 4 Pressure Gage Indicates system hydraulic pressure.
Introduction Item Name Description 13 Pilot Filter Indicator1 A pop-up indicator is activated when the pilot pressure filter element becomes dirty. 14 Distribution Manifold Distributes hydraulic fluid from the main manifold to up to four control manifolds. 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.
Introduction When high-pressure solenoid SOL2 energizes, pressure in the control circuit rises and is applied to the main control valve, causing it to open completely and remain open. The HSM is now in high pressure mode. De-energizing SOL2 allows pressure to bleed off. The main control valve closes until the low-pressure setting is reached. The HSM is now in low-pressure mode. De-energizing the low-pressure solenoid disconnects HPS pressure from the control circuit.
Introduction As it passes through the orifice into the control circuit, the initial pressure is decreased substantially. As the control circuit fills, the slow turn-on accumulator begins to fill, extending the pressure rise time and slowing the rate at which the main control valve operates. Control circuit bleed-off through the low-pressure control also increases the time required for the main control valve to balance.
Introduction Multi-Channel Hydraulic Schematic Note: The Drain Out must be connected to the HPU reservoir or drain circuit. 22 | Model 293.
Safety Topics: • General Safety Practices: Hydraulic Power Units and Hydraulic Service Manifolds.........................24 Model 293.
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........................................................................................................................34 Model 293.22 HSM Hydraulic Connections.......................................................................................34 Model 293.22 HSM Electrical Connections.......................................................................................36 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: Connect the Drain Out line hose to the HPU reservoir or the drain circuit on the hardline before you apply hydraulic pressure. Note: Remove a fluid cap port plug only when a hose is ready for connection. Retain these plugs for use during service.
Installation Model 293.22 HSM Electrical Connections The Model 293.22 HSM is equipped with a control manifold that permits selection of various hydraulic pressures. Control cable connections must be made between the high and low solenoids of the HSM and system controller. The following figure shows the locations of the high/low solenoids in both a multichannel and single-channel HSM.
Installation • The Model 293.22B contains 115 VAC control power. The 3-pin DIN connector for the high/low solenoids is shown below. 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.
Operation Topics: • • • • HSM Control......................................................................................................................................40 HSM Pilot Pressure Considerations..................................................................................................40 Model 293.22 HSM Controls and Indicators......................................................................................41 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 Model 293.22 HSM Controls and Indicators Controls and Indicators Item Description 1 Pressure Gage 2 Control Manifold Multi Channel 3 Low Pressure Adjustment 4 Top View 5 Side View Model 293.
Operation Item Description 6 Pilot Filter Indicator2 A pop-up indicator is activated when the pilot pressure filter element becomes dirty. 7 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 8. Turn off the system. Model 293.
Maintenance Topics: • • • • Hydromechanical System Precautions..............................................................................................46 Model 293.22 HSM Main Filter Cleaning...........................................................................................46 Model 293.22 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: The rapid expansion of pressurized gas can propel objects and generate concussive forces. The spray of pressurized fluid can be hot and piercing. With pressure supplies turned off, residual pressure in the system can cause machinery to move. Pressurized gas and pressurized fluid can result in injury or death. Unless required for a procedure, turn off hydraulic, pneumatic, and water supply to the system before performing maintenance. Isolate the system from the supply sources.
Maintenance 12. Stand the container in the ultrasonic unit tank and submerge the element in the container for at least five minutes. Allow additional time if the element is exceptionally dirty. 13. Remove the element from the container. Apply compressed air to the element to remove fluid and dirt. 14. Empty, rinse, and refill the container with cleaning solution. 15. Repeat Step 12 and Step 13. Inspect the element.
Maintenance 6. Wipe the filter base dry with a clean, lint-free cloth and visually check the main seal and back-up ring for damage. If necessary, replace them with new seals from the pilot filter kit. 7. Check the filter bowl for signs of contamination (particles adhering to the inside of the bowl). If contamination is present, check the system for wear or loss of seal integrity. Warning: Re-using a dirty filter can introduce contamination.
Maintenance Accumulator Precharge Return 0.35 MPa (50 psi)4 Pilot pressure 7 MPa (1000 psi) Slow turn-on 1.4 MPa (200 psi) Record both the pressure and the room temperature in a log book. Use these readings as a basis for changing the interval between pressure checks. Initially, check the precharge after two weeks or 100 operating hours: • If there is a change of ±1.4 MPa (±200 psi) or more in the pressure line accumulator, check the precharge every week or 50 operating hours.
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