Model 293.32 Hydraulic Service Manifold Product Information 015-081-200 F be certain.
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Table of Contents Table of Contents Technical Support How to Get Technical Support.........................................................................................................7 Before You Contact MTS.................................................................................................................7 If You Contact MTS by Phone..........................................................................................................9 Problem Submittal Form in MTS Manuals.............
Table of Contents Keep bystanders safely away.............................................................................................29 Wear proper clothing...........................................................................................................29 Remove flammable fluids....................................................................................................29 Check bolt ratings and torques.....................................................................................
Table of Contents Model 293.32 HSM Pilot Filter Replacement.................................................................................48 Checking the Accumulators...........................................................................................................
Table of Contents 6
Technical Support How to Get Technical Support Start with your manuals The manuals supplied by MTS provide most of the information you need to use and maintain your equipment. If your equipment includes software, look for online help and README files that contain additional product information. Technical support methods MTS provides a full range of support services after your system is installed. If you have any questions about a system or product, contact Technical Support in one of the following ways.
Technical Support When you have more than one MTS system, the system job number identifies your system. You can find your job number in your order paperwork. Example system number: US1.
Technical Support — Messaging applications If You Contact MTS by Phone A Call Center agent registers your call before connecting you with a technical support specialist. The agent asks you for your: • Site number • Email address • Name • Company name • Company address • Phone number where you can be reached If your issue has a case number, please provide that number. A new issue will be assigned a unique case number.
Technical Support • Record the name of the person who helped you. • Write down any specific instructions. After you call MTS logs and tracks all calls to ensure that you receive assistance for your problem or request. If you have questions about the status of your problem or have additional information to report, please contact Technical Support again and provide your original case number.
Preface Before You Begin Safety first! Before you use your MTS product or system, read and understand the safety information provided with your system. Improper installation, operation, or maintenance can result in hazardous conditions that can cause severe personal injury or death, or damage to your equipment and specimen. Again, read and understand the safety information provided with your system before you continue. It is very important that you remain aware of hazards that apply to your system.
Preface Warning: Warning notices indicate the presence of a hazard with a medium level of risk which, if ignored, can result in death, severe personal injury, or substantial property damage. Caution: Caution notices indicate the presence of a hazard with a low level of risk which, if ignored, could cause moderate or minor personal injury or equipment damage, or could endanger test integrity.
Preface Electronic manual conventions This manual is available as an electronic document in the Portable Document File (PDF) format. It can be viewed on any computer that has Adobe Acrobat Reader installed. Hypertext links The electronic document has many hypertext links displayed in a blue font. All blue words in the body text, along with all contents entries and index page numbers, are hypertext links. When you click a hypertext link, the application jumps to the corresponding topic. Model 293.
Introduction Topics: • • • • • • • • • • • • About the Hydraulic Service Manifold (HSM)....................................................................................16 293.32 HSM Component Identification..............................................................................................17 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 293.32 HSM Component Identification Side View Model 293.
Introduction Top View Component Description 1 Main manifold Distributes hydraulic fluid between the HPU and the control manifold. It also has fittings for accumulators and filters. 2 Control manifold Distributes hydraulic fluid to and from a single hydraulic channel. A hydraulic channel is usually associated with an actuator and a servovalve. The control manifold also contains a low-pressure solenoid valve, a high-pressure solenoid valve, a main valve, a slow turn-on valve, and a pressure gage.
Introduction 12 Component Description Pilot filter indicator Indicates when the pilot filter requires replacement. 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 drops, downstream pressure and a control spring fully close the main control valve. The HSM returns to the pressure-off mode. About HSM Pilot Pressure The HSM is equipped with a hydraulic circuit which provides separately filtered fluid at HPU pressure to operate the pilot stage of multistage servovalves. This portion of the HSM operates automatically and requires only routine filter maintenance.
Introduction HSM Rapid Pressure Reduction The control manifold dumps hydraulic pressure rapidly when the high and low solenoid valves are de-energized simultaneously to turn off the fluid flow and port the output pressure line to the return line. The control circuit is connected to the drain line and pressure in the control circuit drops rapidly, allowing downstream pressure and a control spring to close the main control valve. HPU pressure is disconnected from the pressure output.
Introduction Model 293.32 HSM Dimensions Bottom View Item Description 1 403.35 mm (15.88 in) 2 377.82 mm (14.875 in) 3 393.70 mm (15.50 in) 4 339.85 mm (13.38 in) 5 101.60 mm (4 in) Model 293.32 HSM Specifications Model 293.32 HSM Specifications Parameter Specification Environmental Temperature 4.4°C–50°C (40°F–122°F) 22 | Model 293.
Introduction Parameter Specification Humidity 0%–80% relative, noncondensing Dimensions The height varies according to the accumulator installed. Height 1092 mm (43 in) Width 406 mm (16.0 in) Depth 508 mm (20 in) Weight 180 kg (400 lb) Standard; 455 kg (1000lb) Maximum Accumulators Pressure 3.8 L (1 gal) Standard, 19 L (5 gal) Maximum Return 1 L (0.25 gal) Standard, 7.6 L (2 gal) Maximum Pilot Pressure 0.5 L (0.12 gal) Standard, 1 L (.
Introduction Parameter Specification Pilot Pressure and Return -06 (SAE 37º flare) Drain In -06 (SAE 37º flare) Drain Out -08 (SAE 37º flare) Hydrostatic Bearings -06 (SAE 37º flare) 24 | Model 293.
Safety Topics: • General Safety Practices: Hydraulic Power Units and Hydraulic Service Manifolds.........................26 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........................................................................................................................36 Model 293.32 HSM Hydraulic Connections.......................................................................................36 Model 293.32 HSM Electrical Connections.......................................................................................38 System Checks.....................................................................
Installation HSM Site Preparation Consider the following items for site preparation: • The HSM must be installed in an area that is protected from extreme temperature and humidity. An environment with a non-corrosive atmosphere is recommended. • The HSM must be located as close as possible to the servovalve(s) it supplies. The maximum allowable distance must take the specific system dynamic flow transient requirements and turn-on/turn-off transient requirements into account.
Installation Note: Ensure that you 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 Item Description 8 -06 Drain in (3) 9 -06 Pilot Pressure out 10 06 Hydrostatic bearing 1 11 -32 Pressure out to actuator 12 -32 Return in from actuator Model 293.32 HSM Electrical Connections The Model 293.32 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 the system controller.
Installation Item Description 5 Low Pressure Adjustment 6 Low Pressure Solenoid 7 High Pressure Solenoid Depending on the model, the high/low solenoids may be powered by either 115 VAC or 24 VDC. The following figure shows the pin assignments of each connector. • The Model 293.32A contains 24 VDC control power. The 3-pin connector for the high/low solenoids is shown below. • The Model 293.32B contains 115 VAC control power. The 3-pin DIN connector for the high/low solenoids is shown below.
Installation 8. Check the setting of the low and high pressure output levels. Check the ramp time between low and high pressure levels. 9. Turn off hydraulic and electrical power. 10. Check the HPU fluid level. 40 | Model 293.
Operation Topics: • • • • HSM Control......................................................................................................................................42 HSM Pilot Pressure Considerations..................................................................................................42 Model 293.32 HSM Controls and Indicators......................................................................................43 Setting Low Pressure......................................................
Operation HSM Control Solenoid control valves located on the HSM control manifold are controlled by the system controller; they cannot be controlled locally. Low-pressure, high pressure, or pressure-off conditions are operated from the system controller (which can be controller software, a control panel, or a remote module). The manifold design requires the HSM to be switched to low pressure from the off condition. This makes the sequence to obtain a high-hydraulic pressure output, from off to low to high.
Operation Model 293.32 HSM Controls and Indicators Controls and Indicators Item Description 1 Main Filter 2 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. 3 Pilot Filter Indicator1 A visual indicator is activated when the pilot pressure filter element becomes dirty.
Operation Setting Low Pressure The pressure delivered in high-pressure mode is determined by the HPU output pressure. Refer to the operation section of the appropriate HPU manual for instructions on setting this level. In low-pressure mode, the pressure delivered is determined by the setting of the low-pressure adjustment in the HSM. Refer to the appropriate section for the location of the low-pressure adjustment. The setting can be changed by using the following procedure. 1. Turn the HPU to low pressure.
Maintenance Topics: • • • • Hydromechanical System Precautions..............................................................................................46 Model 293.32 HSM Main Filter Cleaning...........................................................................................46 Model 293.32 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 5. 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 service kit. 6. 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)3 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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