Series 244 Actuators Product Information Models 244.11, 244.12, 244.20, 244.21, 244.22, 244.23, 244.31, 244.41, 244.51 011-551-304 G be certain.
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Contents Technical Support 5 How to Get Technical Support.................................................................................................................5 Before You Contact MTS.........................................................................................................................5 If You Contact MTS by Phone.................................................................................................................7 Problem Submittal Form in MTS Manuals..............
Installation 45 About Installation...................................................................................................................................46 Load Units..............................................................................................................................................46 Installing a Fixture to the Actuator.........................................................................................................47 Mounting Bolt Specifications...............
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.
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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.
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.
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Introduction Topics: • About the 244 Series Actuator...............................................................................................................14 • What You Need to Know........................................................................................................................14 • Component Identification.......................................................................................................................15 • Functional Description.....................
Introduction About the 244 Series Actuator The Series 244 Actuator is a hydraulically powered device that provides displacement of (or forces into) a specimen or structure for testing. What You Need to Know MTS Systems Corporation assumes that you know how to use your controller. See the appropriate manual for information about performing any controller-related step in this manual’s procedure. You are expected to know how to perform the following procedures: • Turn hydraulic pressure on and off.
Introduction Component Identification Series 244 Actuators Product Information 15
Introduction Series 244 Hydraulic Actuator Major Components Item Component Description 1 Piston rod end The piston rod has a hardened steel insert that provides an internal thread for mounting load cells, swivels, and interface fixtures. The Model 244.51 Actuator has no insert; internal threads are machined directly into the piston rod end. 2 Bearing The high-capacity nonmetallic bearings bond directly to the end caps.
Introduction Item Component Description hydraulic fluid passed by the high-pressure seal back to the system hydraulic power supply. The inner part of the low-pressure/wiper seal provides a hydraulic seal, while the outer part of the seal functions as a scraper ring to minimize external contamination of the seals and bearings. When a high-pressure seal is present, the inner part of the low-pressure seal wipes hydraulic fluid that gets by the high-pressure seal and guides the fluid into the drainback port.
Introduction Functional Diagram Item Description 1 LVDT Core Mount 2 LVDT Core Extension 3 LVDT Coil 4 LVDT Connector 5 Extension Port 6 Retraction Port About Actuator Mounting The actuator can be mounted to a wide variety of fixtures and assemblies: • Component test systems usually have one end of the actuator connected to a custom test frame base and the other end connected to the test specimen.
Introduction • Material test systems usually mount the actuator in a load unit assembly. The actuator can be mounted below the base plate or above the crosshead. The end of the actuator uses fixtures (such as grips) to attach the test specimen to it. Actuator Operation Actuator piston rod movement is accomplished by supplying high- pressure hydraulic fluid to one side of the actuator piston and opening the other side to a return line.
Introduction LVDT Components Item Description 1 Locking Setscrew 2 Core Mount Setscrew 3 LVDT Core Extension 4 Hollow Piston Rod 5 LVDT Coil 6 Locking Collar 7 Pedestal Base 8 LVDT Connector The LVDT is an electromechanical device that provides an output voltage which is proportional to the displacement of a moveable core extension. The core extension is mounted inside the hollow piston rod and moves as the piston rod moves.
Introduction 1 Model Force Rating Rod Diameter Effective Piston Area Number Kn mm cm 244.20 68 69.9 33.68 244.21 50 69.9 25.16 244.22 100 69.9 48.84 244.23 160 69.9 82.13 244.31 250 95.3 126.65 244.41 500 133.4 248.28 244.51 1000 152.4 487.70 2 Actuator Specifications (U.S. Customary) 2 Model Force Rating Rod Diameter Effective Piston Area Number Kip in in 244.11 3.3 1.75 1.17 244.12 5.5 1.75 2.10 244.20 15.0 2.75 5.22 244.21 11.0 2.75 3.
Introduction Operating temperature 5–40°C (41–104°F) Humidity 0–85% noncondensing Heat load < 630 kcal/hr (2500 Btu/hr) 3 3 Noise rating at 1 m 63 dB (A) fully compensated Hydraulic fluid Exxon Mobil DTE 25 or Shell Tellus 46 AW Typical operating temperature range 43–49°C (110–120°F) Filtration (microns) 3 microns nominal Sound pressure level [db (A)] is expressed as a free field value. Readings may vary with the acoustic environment.
Introduction Dimensions Series 244 Actuators Product Information 23
Introduction Actuator Dimensions Item Description 1 BASIC CYLINDER 2 FRONT END CAP 3 REAR END CAP 4 A (Cushion) 5 Stroke Length 6 C min.
Introduction Item Model Units 244.11 244.12 244.20 244.21 244.22 244.23 244.31 244.41 244.51 F mm 19.1 19.1 19.1 19.1 19.1 19.1 25.4 44.5 44.5 G mm 81.3 81.3 104.1 104.1 104.1 104.1 139.7 263.4 263.4 H UNC 3/8 - 16 3/8 - 16 5/8 - 11 5/8 - 11 5/8 - 11 5/8 - 11 7/8 - 9 7/8 - 9 1-8 K mm 19.1 19.1 25.4 25.4 25.4 25.4 38.1 38.1 44.5 L mm 88.9 88.9 127.0 127.0 127.0 127.0 191.3 254.0 280.
Introduction Item Model Units 244.11 244.12 244.20 244.21 244.22 244.23 244.31 244.41 244.51 K in. 0.75 0.75 1.00 1.00 1.00 1.00 1.50 1.50 1.75 L in. 3.50 3.50 5.00 5.00 5.00 5.00 7.53 10.00 11.06 M UNS 1/2 - 20 1/2 - 20 1 - 14 1 - 14 1 - 14 1 - 14 12/2 - 12 2 - 12 3 - 12 11 N 13 in. 1.75 1.75 3.02 3.02 3.02 1.98 4.18 5.11 4.50 in. 4.00 4.00 5.00 5.50 6.00 6.50 8.50 11.75 15.
Introduction Open LVDT Housing Item Description 1 Cushion 2 Stroke Length 3 A min. 4 68.6 mm (2.70 in) +Stroke Length 5 Rear End Cap LVDT Mounting 6 4 holes, “B” thread size, “C” deep, spaced as shown 7 2 holes, “B” thread size, “C” deep, spaced as shown Open Housing LVDT Specifications For Extra Piston Length* Model †,‡ A B C D Weight mm in UNC mm in mm in kg lb 244.11 149.9 5.90 3/8-16 19.1 0.75 N/A N/A 17.7 39 244.12 149.9 5.90 3/8-16 19.1 0.
Introduction Closed LVDT Housing Item Description 1 Stroke + A 2 Spiral Washers or Adapter 3 Closed Housing LVDT Closed Housing LVDT Specifications* Model A † ‡ B Weight mm in mm 244.11 80.8 3.18 –––– § –––– 244.12 80.8 3.18 –––– § 244.21 70.2 2.76 –––– 244.20 70.2 2.76 –––– 244.22 70.2 2.76 26.4 244.23 70.2 2.76 244.31 69.9 244.41 244.51 in kg lb § 19.5 43 –––– § 20.4 45 § –––– § 56.2 124 § –––– § 58.1 128 1.04 61.2 135 26.4 1.04 69.
Introduction Pedestal Base Specifications Pedestal Base Specifications Model A B C D Weight mm in mm in mm in mm in kg lb 244.11 38.1 1.50 14.2 0.56 114.3 4.50 139.7 5.50 5.9 13 244.12 38.1 1.50 14.2 0.56 114.3 4.50 139.7 5.50 5.9 13 244.21 44.4 1.75 17.3 0.68 146.0 5.75 187.4 7.38 12.2 27 244.20 44.4 1.75 17.3 0.68 146.0 5.75 187.4 7.38 12.2 27 244.22 44.4 1.75 17.3 0.68 146.0 5.75 187.4 7.38 12.2 27 244.23 44.4 1.75 17.3 0.
Safety Topics: • General Safety Practices: Hydraulic Power Units and Hydraulic Service Manifolds.............................32 • Safety Practices Before Operating the System.....................................................................................33 • Safety Practices While Operating the System ......................................................................................37 • Hazard Placard Placement..................................................................................
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 • 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. Improper installation, operation, or maintenance of your system can result in hazardous conditions that can cause death, personal injury, or damage to the equipment or to the specimen.
Safety Know potential crush and pinch points Be aware of potential crush and pinch points on your system and keep personnel and equipment clear of these areas. An important consideration for servohydraulic systems is that when power is interrupted, it is likely that stored accumulator pressure will persist for some time within the system. In addition, it is likely that as stored energy dissipates, gravity will cause portions of the system to move.
Safety • When you charge an accumulator, follow all the charging instructions provided in the appropriate product information manuals. When precharging accumulators, properly identify the type of gas to be used and the type of accumulator to be precharged. • Use only dry-pumped nitrogen to precharge nitrogen-charged accumulators. (Dry-pumped nitrogen can also be labeled “oil pumped” or “dry water pumped.
Safety Protect all system hoses and cables from sharp or abrasive objects that can cause the hose or cable to fail. Use a cable cover or cable tray where cables are in traffic locations. Never walk on hoses or cables or move heavy objects over them. Route hoses and cables away from areas that expose them to possible damage.
Safety Safety Practices While Operating the System Wear appropriate personal protection Wear eye protection when you work with high-pressure hydraulic fluid, high-pressure air pressure, breakable specimens, or when anything characteristic to the specimen could break apart. Wear ear protection when you work near electric motors, pumps, or other devices that generate high noise levels. This system may create sound pressure levels that exceed 70 dbA during operation.
Safety Ensure secure cables Ensure that all cable connections (electrical supply, control, feedback, sensor, communications, and so forth) are either locking type, or are secured, to ensure that they cannot be disconnected by a simple act. 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 Labels And Icons The following labels and icons may be found on an actuator. Warning Label Part #46-140-101 WARNING Hydraulic pressure above 3000 psi can rupture components. Can cause severe personal injury or damage to equipment. Do not exceed 3000 psi (20.7 MPa). Read instructions before operating or servicing. Warning Label Part #46-140-201 WARNING Hydraulic pressure above 4000 psi can rupture components. Can cause severe personal injury or damage to equipment. Do not exceed 4000 psi (27.
Safety Caution Label Part #045-283-501 CAUTION High drain pressure can cause rod seal damage and hydraulic oil leakage. Remove drain line shipping cap and connect drain hose before operating. Attached Mass Warning Label Part #057-230-041 Attached mass warning. Do not exceed maximum attached mass.
Safety Hydraulic Actuator ID Tag Part #700-004-198 Hydraulic Actuator ID tag lists the following: • Model Number • Serial Number • Assembly number/Rev • Force rating • Effective Area • Static Stroke • Dynamic Stroke • Hydrostatic/Non-Hydrostatic • Maximum attached mass Hydraulic Actuator ID Tag Part #037-588-801 Series 244 Actuators Product Information 41
Safety Hydraulic Actuator ID tag lists the following: • Model Number • Serial Number • Assembly number/Rev • Force rating • Effective Area • Static Stroke • Dynamic Stroke • Hydrostatic/Non-Hydrostatic Pressure Icon Label Part #57-237-711 Pressure icon. Can be used alone, or in conjunction with pressure rating label (Part # 57-238-5xx). Pressure Rating Label Part #57-238-5xx Pressure rating. Actual rating listed on this label will vary.
Safety Lift Hole Thread Size Part #57-806-13 Lift hole. Thread size will be specified on the actual label.
Installation Topics: • About Installation...................................................................................................................................46 • Load Units..............................................................................................................................................46 • Installing a Fixture to the Actuator.........................................................................................................47 • Spiral Washers...........
Installation About Installation Installing the Series 244 Actuator depends on the testing application. • For materials or component testing, the actuator is typically installed in a load frame or test fixture. • For structural or vibration testing, the actuator is typically secured to a reaction mass using a swivel or pedestal base. Load Units When the Series 244 Actuator is mounted in a load frame configuration, the actuator is installed in the load frame at the factory.
Installation See the system assembly drawing, system functional drawing, and console assembly drawing (typically located in a System Reference manual supplied with your system documentation) for information about hydraulic and electrical connections. Note: Actuators mounted in a load unit should not be removed from the load unit. Proper alignment should not be performed in the field. When an actuator is mounted in a load frame, the actuator is hidden behind other hydraulic components as shown here.
Installation Note: See the Series 249 Swivels manual (MTS part number 100-237-294) for more information about using swivels with the actuator. Base Types Item Description 1 Swivel Base 2 Pedestal Base Mounting Bolt Specifications A Series 244 Actuator equipped with a pedestal base or a swivel base typically has the base bolted to a reaction mass. The following table lists information for the mounting bolt specifications.
Installation Swivel Base Mounting Bolt Specifications Model RecommendedMounting Bolt Size Mounting Bolt Torque RecommendedBolt Grade mm UNC N·m lbf-ft ISO SAE 244.11 M10 x 1.50 3/8-16 53 34 12.9 12.9 244.12 M10 x 1.50 3/8-16 53 34 12.9 12.9 244.20 M16 x 2.00 5/8-11 230 160 12.9 12.9 244.21 M16 x 2.00 5/8-11 230 160 12.9 12.9 244.22 M16 x 2.00 5/8-11 230 160 12.9 12.9 244.23 M16 x 2.00 5/8-11 230 160 12.9 12.9 244.31 M24 x 3.00 1-8 780 680 12.9 12.
Installation Spiral Washers The optional Model 601 Spiral Washers are typically used to provide fatigue-resistant connections between elements of the force train and to minimize the effects of backlash. If the operating procedure requires changing of preloaded force train elements such as the load cell or grips, the spiral washers must be readjusted. The spiral washers are placed over the connector studs at each connection, and adjusted to place a constant preload on the stud.
Installation Item Description 3 Upper End Cap 4 Actuator Rod 5 Spiral Washers 6 Connector Studs 7 Swivel Head Installing Fixtures with Spiral Washers This procedure requires two spanner wrenches and assumes that you are familiar with all operating aspects of your system. Multiple Fixtures With Different Ratings Sometimes you may have multiple fixtures in the force train that have different force ratings.
Installation Spiral Washer Rotation Item Description 1 Connector Stud 2 Spiral Washer Rotation to Increase Thickness 3 Medium Thickness 6. Place the spiral washers together with the spiral surfaces facing each other. 7. Place the set of spiral washers over the connector stud and rotate them until they are at minimum thickness. Mount the appropriate fixture (load cell, grip, and so forth) on the connector stud and tighten the fixture against the spiral washers by hand. 8.
Installation Warning: Do not exceed the maximum HPS output pressure or apply a force greater than any force train component capacity. Exceeding the tensile load capacity of any element in the force train can cause equipment damage or personal injury. It is necessary to temporarily exceed the tensile load capacity to achieve the requirements of Step 5 in this procedure. This is accomplished by increasing the output pressure of the HPU. Contact MTS Systems Corporation. 11.
Installation Multiple Fixtures With Different Ratings Sometimes you may have multiple fixtures in the force train that have different force ratings. When removing the fixtures pretensioned with spiral washers, remove the fixtures with the lowest force rating first. Then remove any other fixtures from the lowest to the highest force rating. 1. Ensure that system hydraulic pressure has been reduced to zero before proceeding.
Installation LVDT Cable Connection Item Description 1 Output 2 Ground 3 Excitation 4 Yellow 5 Blue 6 Green 7 Black 8 Red Hydraulic Connections Note: When the Series 244 Actuator is installed in a load unit, the hydraulic connections are made through a manifold connected to a Series 298 Actuator Manifold. Hydraulic connections to the Series 244 Actuator are made through a manifold that connects the ports of each end cap.
Installation Hydraulic Connections Item Description 1 Some manifolds support two servovalves. 2 Return Port 3 Drain Port 4 Pressure Port Caution: Do not use inferior quality hydraulic fluids. Using fluids other than those specified by MTS may cause component or system failure or both. Use Mobil DTE 25 or Shell Tellus 46 hydraulic fluid only.
Operation Topics: • About Operation.....................................................................................................................................58 • Actuator ID.............................................................................................................................................58 • Operating Considerations......................................................................................................................
Operation About Operation This section describes how to use the Series 244 Actuator when side loads are applied during testing. Warning: Exceeding the maximum attached mass can cause unpredictable actuator movement. Unexpected actuator movement can result in injury to personnel or damage to equipment. Ensure that the maximum attached mass listed on the actuator ID tag is not exceeded.
Operation Sideload Forces To avoid damaging the actuator bearings and to ensure proper actuator operation, tests that subject the actuator to nonaxial loads require special consideration. Nonaxial loading can occur from sideload forces applied directly to the piston rod (P in the figure) and from moments caused by off-center loads (F in the figure).
Operation Sideload Calculation Constants Model 244.11 244.12 244.21 244.22 244.23 244.31 244.41 244.51 Bearing Spacing A Bearing Length D Bearing Area E Rod Diameter G Cyclic Sideload K 5.960 1.7100 3.50 1.75 0.600 5.960 1.7100 3.50 1.75 0.600 5.820 1.9380 6.26 2.75 0.140 5.475 1.8630 5.84 2.75 0.140 5.425 1.8880 5.98 2.75 0.140 5.825 2.1340 10.03 3.75 0.068 6.530 2.8700 22.37 5.25 0.026 7.865 2.8125 24.69 6.00 0.
Operation Sideload Forces Item Description 1 Sideload Forces 2. Calculate the actuator bearing load (L) using the following formula: where: S = Actuator stroke A = Constant based on actuator bearing spacing D = Constant based on actuator bearing size 3. Divide the actuator bearing load (L) by the actuator area constant (E) to determine the bearing pressure (V). where: V = maximum allowable bearing pressure E = Constant based on actuator bearing area The maximum allowable bearing pressure (V) is 5.
Operation where: (MAPRV) = maximum allowable piston rod velocity 6. If the sideload force is applied to the actuator cyclically (sideload varies equally through zero), then determine the minimum frequency for the sideload force. If the test parameters require a lower sideload frequency, then you will have to select an actuator with a larger piston rod diameter.
Operation The result, 149.49 psi, is less than (950 psi). 4. Calculate the piston bending stress and ensure that the value is less than 40,000 psi. The result, 2283.67 psi, is less than 40,000 psi. Where: (PRS) = piston rod stress 5. The maximum allowable piston rod velocity is given by the following equation: Where: (MAPRV) = maximum allowable piston rod velocity 6.
Maintenance Topics: • Maintenance Recommendations...........................................................................................................
Maintenance Maintenance Recommendations The Series 244 Actuator is designed for extended periods of operation without extensive maintenance requirements. Warning: Changing the servovalve/actuator configuration will impact the actuator’s maximum attached mass for cushion design limit. Operating an actuator outside of its design limit can result in injury to personnel or damage to the equipment. Do not alter the given servovalve/actuator configuration.
011-551-304 G
