ReNew Technical Reference 100-178-163 A l
Copyright information Trademark information © 2007 MTS Systems Corporation. All rights reserved. MTS and TestWorks are registered trademarks of MTS Systems Corporation. ReNew is a trademark of MTS Systems Corporation. Contact information Publication information 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 http://www.
Contents Preface 5 About This Manual Conventions 6 7 Contacting MTS 10 What to Expect When You Call 11 Introduction 13 Description 14 Specifications 17 Installation 19 Installing cables 26 Operation 33 Handset Control 33 Maintenance 39 Troubleshooting Guide 41 Appendix 43 Additional Digital I/O Information 43 Configuration Drawings 45 ReNew Technical Reference Contents 3
Contents ReNew Technical Reference
Preface Safety first! Before you attempt to use your MTS product or system, read and understand all safety information. MTS systems and equipment are to be installed by MTS personnel or authorized representatives only. Unforeseen hazards may result if product use is inconsistent with the method(s) described and presented in the manual. It is very important that you remain aware of hazards that apply to your system.
About This Manual About This Manual Purpose Summary This manual provides detailed information about the ReNew™ and SMA Upgrade Systems - from MTS Systems Corporation. This manual gives you the necessary information for each system for maximum operating conditions and efficiency. Each chapter has been designed to walk you through a section at a time so you can use the ReNew or SMA System to its fullest advantage.
About This Manual Conventions The following sections describe some of the safety conventions that are used in your MTS manual. Hazard conventions Hazard notices are included throughout this manual and contain safety information that is specific to the task 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 the directions that are given.
About This Manual Warning notices WARNING Warning notices indicate the presence of a hazard which can cause severe personal injury, death, or substantial property damage if the warning is ignored. For example: Hazardous fumes can accumulate in the test chamber as a result of testing. Breathing hazardous fumes can cause nausea, fainting, or death. Ensure that the chamber is properly ventilated before you open the chamber door or put your head or hands into the chamber.
About This Manual Safety Symbols These symbols are present on the exterior of the testing system. Item Description Caution or Warning - refer to manual for description of hazard. High Force Moving Parts - can cause severe injury or equipment damage. Stay clear of moving parts while using machine. Wear Eye Protection - stay clear and use eye protection while test is in progress.
Contacting MTS Contacting MTS MTS provides a full range of support services after your system is installed. If you have any questions about a system or product, contact MTS in one of the following ways: Note Address If you need technical support, review the following pages for information about what to expect when you contact us. MTS Systems Corporation 14000 Technology Drive Eden Prairie, Minnesota USA 55344-2290 Address technical support questions to the Technical Support Department. Telephone U.S.
Contacting MTS What to Expect When You Call Note Before you call Know your site number and system number Some of the following information specifically discusses what to expect when you call the MTS HELPLine. The process for international technical assistance will differ. MTS can help you more efficiently if you have the following information available when you call. You will be asked for your site number and system number.
Contacting MTS Know relevant computer information Know relevant software information Be prepared to troubleshoot While on the phone Write down relevant information After you call 12 Preface If you are experiencing a computer problem, have the following information available: • Manufacturer’s name and model number • Amount of system memory • Network information (type and version level) If you are experiencing a software problem, have the following information available: • Operating software i
Introduction The ReNew®and ReNew SMA®Upgrade System product series are the latest generation of system upgrade products for material testing equipment from MTS Systems Corporation. Our ReNew System works in conjunction with an MTS testing frame or comparable frame and offers the most up-to-date enhancement features in the material testing industry.
Description Description General description System performance and customer responsibility The ReNew products allow the user to utilize the latest control electronics and software with otherwise obsolete material testing machines. In many cases, the mechanical systems within a testing machine consisting of ballscrews, belts, gears, motors, etc. have a much longer service life than the electronics that control them.
Description Controller functions All ReNew systems are controlled by MTS's latest precision frame controller. The controller performs the following functions: 1. Data acquisition for both analog and quadrature inputs 2. Programmable data acquisition rate 3. Digital servo control of frame speed and position 4. Interface between TestWorks software and the frame 5. Detects the activation of limit switches 6. Handset interface 7.
Description The ReNew SMA When a material testing system to be upgraded has a functioning servomotor and amplifier, the ReNew SMA can be used. The term SMA stands for “Sans-Motor Amplifier”, literally meaning that the servomotor and amplifier are not included in this model. The ReNew SMA product is most often used for upgrading Instron 4400 and 5500 frames, provided that the existing motor and amplifier are functional. The sensor signals (load, strain, etc.) can be routed directly to the ReNew SMA box.
Specifications Specifications Environmental specifications (indoor use only) Temperature 5 - 40°C (41 -104 °F) Relative humidity 20 - 80%, non-condensing from 5 - 31°C (41 - 88°F) Altitude Up to 2,000 m (6,500 ft.) Individual ReNew model specifications ReNew Elite Physical Height 540 mm (21.3 in) Width 280 mm (11.0) Depth 630 mm (2.8 mm) Weight 23 kg (50 lb) Power Requirements (ReNew 10 & 20) Voltage* 120 VAC Frequency 47 - 63 Hz Power 1.
Specifications ReNew SMA and ReNew SMA-DA Physical Height 460 mm (18.1 in) Width 180 mm (7.1) Depth 432 mm (17.0 mm) Weight 15 kg (33 lb) Power Requirements Voltage* 120 or 220 - 230 VAC, single phase Frequency 47 - 63 Hz Power 100 VA * 18 Introduction This specification allows for a variation of up to ± 10% from the values stated.
Installation Location and ventilation All ReNew boxes can be placed on the floor next to or behind a floor-standing machine, or beneath a tabletop machine. The box should be positioned so that the circuit breaker located on the back panel can be accessed if necessary. Ventilation holes are present in the top and bottom of the ReNew enclosure. Do not block either of these openings during use.
Appliance inlet configurations The ReNew Elite has an IEC 60320 C20 appliance inlet. The conductor configuration is shown below: The ReNew SMA has an IEC 60320 C14 appliance inlet.
External earth connection The ReNew systems have an additional ground connection on the rear of the enclosure. This must be connected to a low-impedance ground for proper EMC performance. It is also recommended that this lug be used to connect the frame to the ReNew box. Use the supplied cable. Perform a continuity check between the load frame and the ground conductor of the power cord before connection to the supply.
This switch must be located no more than 1 meter from the test space and must be rigidly attached to the machine. Use the included double-sided foam tape to attach the switch to the machine. Clean surfaces with Isopropyl alcohol before applying the tape. Sheet-metal screws can also be used. The ReNew SMA system does not have an e-stop connection, as it does not interface with the power circuits of the existing load frame.
ReNew Elite system connections Cable Description MTS # 1 CABLE-USB V2.
ReNew SMA system connections Cable Description MTS # 1 CABLE-USB V2.0 CABLE,A-B,3 METER/10 FOOT 100-096-419 2 CABLE ASSY,SMA RENEW 44/55 100-091-756 3 CABLE ASSY,ELITE L/C RENEW 100-091-797 3 CABLE ASSY,SMA RENEW 44/55 L/C 100-091-762 4 CABLE ASSY,RENEW GROUND 100-091-106 5 BOX ASSEMBLY-REMOTE POWER SWITCH 100-165-688 On Instron 4400 frames, the control cable (#2 above) plugs into the existing handset connector.
Cable Description MTS # 3 CABLE ASSY,SMA RENEW 44/55 L/C 100-091-762 4 CABLE ASSY,RENEW GROUND 100-091-106 For these applications the existing motor, amplifier, controls, and signal conditioning must be functional. The analog input cable (#2 above) is connected to the appropriate sensor signal conditioner outputs inside the Instron electronics rack. The ReNew SMA does not control the movement of the frame, it is used only for data acquisition.
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. Basic controller connectors J1—USB. This is the connection to the computer. J2—Handset. This is intended for a handset. J3—Interlock.
J8—DC Conditioner 2. Could be strain based extensometer, second load cell, or high level analog output sensor. Typically Strain 2 in TestWorks 4. J9—DC Conditioner 1. Could be strain based extensometer, second load cell, or high level analog output sensor. Typically Strain 1 in TestWorks 4. J10—Mongoose AC Pwr Cntrl. This input control AC power for Elite and SMA chassis. J11—Digital I/O Input. this I/O is used to enable low and high clutches using D I/ O 3. J12—DC Cond 3 QFCC/Sable.
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.
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.
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 43.
J6 and J7 Monitor Two Monitor connectors are provided. There are several possible uses for analog monitor outputs: external data acquisition, tuning, troubleshooting, etc. 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.
Installation ReNew Technical Reference
Handset Control Operation 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.
Handset Control Safety Symbols (inside) These symbols are present “inside” the testing system enclosure. Item Description Caution or Warning - refer to manual for description of hazard. Hazardous Voltage - contact with live components may cause shock or burn. Disconnect system from main power before servicing. Moving parts may crush or cut. Do not operate the system with covers removed. Disconnect system from main power before servicing. Safety ground connection. Caution. Hot surface.
Handset Control Travel limit switches (Physical limits) CAUTION The manner in which limit switch adjustments are made varies from system to system depending on the manufacturer. Be sure you understand how to set the limits on your existing load frame. Your MTS representative will be able to show you how to set the limits. Always adjust the limits whenever you change grips or fixtures. Damage to equipment or personal injury may result. Always adjust the limits whenever you change grips or fixtures.
Handset Control ReNew Technical Reference Operation 37
Handset Control 38 Operation ReNew Technical Reference
Maintenance WARNING Disconnect the power cord from the wall outlet before cleaning or lubricating any part of the test frame. Regular maintenance is needed to prolong the life of your frame and keep it performing optimally. Monthly machine/ frame maintenance 1. Check the inside of the frame for the following: A. The fan is free of all material and spins easily with no noise. B. The filters on the vent and fan are free from dust. C. There is no grease on the ball screw pulleys and/or belts. D.
Semiannual maintenance 1. Remove system covers and vacuum or blow out any dust or debris from inside the test frame. 2. Grease ball screws at the crosshead fittings—use # 2 hardness white lithium grease available from MTS (Lubriplate no. 1200-2 multipurpose grease). 3. Verify speed and position accuracy of the frame. See the TestWorks software manual for further details. Note General cleaning 40 Maintenance MTS offers annual maintenance and calibration plans.
Troubleshooting Guide Use this chapter to identify mechanical and electronic problems with your ReNew and ReNew SMA Systems. To contact the MTS HELPLine and/or an MTS Applications Engineer, see “Contacting MTS” on page 10. Crosshead will not move • Load frame is not powered up (Limit switches on the crosshead are not lit up red and/or the handset LCD is not on). • One or both of the physical limits are tripped. • Line voltage is too low or too high.
Crosshead will not stop • Servo is improperly connected. • Improper machine parameters. Contact an MTS Applications Engineer for further assistance. • Controller error. Contact an MTS Applications Engineer for further assistance. • Proximity limit switch on the crosshead is obstructed. • Limit switch is defective. Contact an MTS Applications Engineer for further assistance. • Frame controller limit switch circuitry is malfunctioning. Contact an MTS Applications Engineer for further assistance.
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 Vdc. The maximum input voltage is 28.0 Vdc. 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.
Configuration Drawings The following Insight Renew Board Jumpers & Fuses configuration chart is intended to provide initial jumper settings for each major frame type. The installation FSE should note any system specific differences in the "Deviation" column. The notes will expedite any future board replacement.
Configuration Drawings ReNew Technical Reference
Insight Renew Board Jumpers & Fuses Schematic DWG: 700-003-357 Designator Description Dwg Sheet Mong - Elite & SMA X1 X2 X3 X4 X5 X6 X7 X8 X9 X13 X14 X15 X16 X17 X18 X19 X20 X21 X22 X27 X28 X29 X30 X31 X32 X33 X34 Install to Enable J13 (Schematic J1) Mong Front L/C Input. *1 Install to Enable J13 (Schematic J1) Mong Front L/C Input. *1 Install to Connect Chassis GND on J3 L/C Connector to Insight PCB Chassis GND Install 1-2 for normal crosshead upper limit function.
100-178-163 MWC Reision A
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 http://www.mts.
