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MTS Landmark™ Tabletop Load Units - Product Information

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Safety

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Contents

Summary of Contents for Bionix

Page 1: ...MTS Landmark Tabletop Load Units Product Information Landmark Axial Load Unit Landmark 100 Hz Elastomer Bionix Axial Torsional 100 206 897 F...

Page 2: ...oration and cannot be copied reproduced disassembled decompiled reverse engineered or distributed without express written consent of MTS Software Verification and Validation MTS software is developed...

Page 3: ...1 Be prepared to troubleshoot 11 Write down relevant information 11 After you call 12 Problem Submittal Form 12 Preface 13 Before You Begin 13 Safety first 13 Other MTS manuals 13 Documentation Conven...

Page 4: ...equate lighting 21 Provide adequate ventilation 21 Provide means to access out of reach components 21 Safety Practices While Operating the System 22 Wear appropriate personal protection 22 Provide tes...

Page 5: ...essure control 41 Transducers 41 Series 661 Force Transducers 42 Dimensions 43 Series 662 Force Transducers 44 Dimensions 45 Specifications 45 Installation 47 About Installation 48 Lifting and Moving...

Page 6: ...Light Curtain 79 Additional Station Manager and Interlock Functionality Units equipped with elec tromagnetic rotary servo motor only 81 Maintenance 83 Routine Maintenance Overview Checklist 85 Other M...

Page 7: ...djusting the Mechanical Null 118 Adjust the Mechanical Null 118 Performing Sensor Calibration 122 Decommissioning 123 Decommission the System 123 Declarations 127 Declaration of Conformity 128 Origina...

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Page 9: ...m Europe techsupport europe mts com Telephone Worldwide 1 800 328 2255 toll free in U S 1 952 937 4000 outside U S Europe 800 81002 222 International toll free in Europe Outside the U S For technical...

Page 10: ...el numbers l What is the controller model if applicable l What is the system configuration Know relevant computer information For a computer problem have the following information available l Manufact...

Page 11: ...your system as one of the following types l Electrodynamic material test system l Electromechanical material test system l Hydromechanical material test system l Vehicle test system l Vehicle componen...

Page 12: ...lem Submittal Form Use the Problem Submittal Form to communicate problems with your software hardware manuals or service that are not resolved to your satisfaction through the technical support proces...

Page 13: ...raphs describe some of the conventions that are used in your MTS manuals Hazard conventions Hazard notices may be embedded in this manual These notices contain safety information that is specific to t...

Page 14: ...the route you should follow to a referenced item in the software Example Examples show specific scenarios relating to your product and appear with a shaded background Special terms The first occurrenc...

Page 15: ...Landmark Tabletop Load Units Product Information 15 Safety General Safety Practices 16 Safety Practices Before Operating the System 17 Safety Practices While Operating the System 22 Load Unit Hazard...

Page 16: ...es Use these safety guidelines to help learn and identify hazards so that you can establish appropriate training and operating procedures and acquire appropriate safety equipment such as gloves goggle...

Page 17: ...procedures Most facilities have internal procedures and rules regarding safe practices within the facility Be aware of these safe practices and incorporate them into your daily operation of the syste...

Page 18: ...system component Observe the same precautions as those given for any other high voltage machinery Make sure that all electrical components are adequately grounded Grounds must remain connected and und...

Page 19: ...el that can damage your hearing l Ensure that all pressurized air or gas is bled out of a pneumatic or gas charged device before you start to disassemble it A thorough understanding of the assembly an...

Page 20: ...ions 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 Provide proper hydraulic fluid filtration For hydraulic sy...

Page 21: ...explode Either instance creates a fire hazard Provide adequate lighting Ensure adequate lighting to minimize the chance of operation errors equipment damage and personal injury Provide adequate venti...

Page 22: ...cted parts or materials from test specimens and to control access to the machinery the Customer must provide a Test Area Enclosure to protect personnel Specimen temperature changes During cyclic testi...

Page 23: ...d long periods of repetitious unvarying or monotonous work because these conditions can contribute to accidents and hazardous situations If you are too familiar with the work environment it is easy to...

Page 24: ...or motion 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...

Page 25: ...tion 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 whil...

Page 26: ...lic 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 Val...

Page 27: ...bletop Load Units Product Information 27 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 Fi...

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Page 29: ...n of Conformity Machinery Directive 2006 42 EC Annex II 1A 33 Declaration of Incorporation Machinery Directive 2006 42 EC Annex II 1B 33 Component Description 35 Functional Description 40 Load frame 4...

Page 30: ...Load Units These small load units are available in the following configurations 370 Axial Load Frame l The axial load unit has an actuator that applies linear forces to specimens l The 100 Hz elastome...

Page 31: ...nformation 31 370 Axial Torsional Load Frame with Hydraulic Rotary Actuator l The axial torsional load unit with hydraulic rotary actuator combines an axial actuator with a torsional actuator to simul...

Page 32: ...motor to simultaneously apply axial and torsional forces to specimens What you need to know MTS Systems Corporation assumes that you know how to use your controller For information about performing an...

Page 33: ...hanics tests The testing materials and components test specimens are supplied by customers or end users A combination of one each of an MTS load unit AND one each of an MTS Controller constitute machi...

Page 34: ...hydraulic power unit grips fixtures extensometers furnaces ovens and environmental chambers and so forth conforms to the requirements of Machinery Directive 2006 42 EC and other applicable EC Directiv...

Page 35: ...Introduction MTS Landmark Tabletop Load Units Product Information 35 Component Description Rear View of an Axial Torsional Load Frame with Hydraulic Rotary Actuator...

Page 36: ...ens and fixtures The crosshead is stiff and light weight it is one end of the force train 6 Clamp ring Provides additional protection against the crosshead slipping The clamp ring can be positioned an...

Page 37: ...a hydraulically powered device that provides linear displacement of or forces into a specimen Grips and fixtures can be mounted to the actuator 13 Control panel Grip controls Crosshead lift control E...

Page 38: ...e displacement of the linear actuator s travel The linear variable displacement transducer LVDT is located inside the actuator 2 Encoder Connector The encoder measures the angle of the rotary actuator...

Page 39: ...ic fluid under pressure to increase the actuator s response time One accumulator connects to the pressure line the other to the return line 9 Servovalve Controls both the amount and the direction of f...

Page 40: ...he crosshead is in an appropriate test position it is manually clamped to that position Manifold The actuator manifold acts as the hydraulic interface between the HPU and the components mounted to the...

Page 41: ...transducer an LVDT and an encoder l Force The force transducer also called load cell or force sensor measures the amount of tension or compression applied to it It has four strain gages that form a ba...

Page 42: ...ecification Capacity Model 661 19H 03 Model 661 19H 04 Static overload capacity 150 of rating 15 kN 25 kN Maximum excitation input 20 V DC Bridge resistance Axial 350 Hysteresis 0 05 of full scale Non...

Page 43: ...ons are rounded off to the nearest millimeter Item Dimensions A 104 6 mm 4 12 in B 31 8 mm 1 25 in C 0 8 mm 0 03 in D 66 5 mm 2 62 in E 32 0 mm 1 3 in F 6 4 mm 0 25 in G 5 1 mm 0 20 in H Depth Near Si...

Page 44: ...04 Model 662 20H 05 Axial Torsional 15 kN 150 N m 25 kN 250 N m Maximum excitation input 15 V DC Bridge resistance 350 Axial 700 Torsional Hysteresis 0 15 of full scale Nonlinearity 0 3 of full scale...

Page 45: ...0 mm 5 75 in C bolt circle diameter both ends 78 7 mm 3 10 in 120 7 mm 4 75 in D 127 0 mm 5 00 in 165 1 mm 6 50 in E both ends 55 9 mm 2 201 in 88 9 mm 3 501 in F 6 4 mm 0 25 in 9 6 mm 0 18 in G 6 4...

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Page 47: ...formation 47 Installation About Installation 48 Lifting and Moving the Load Unit 48 Overview 48 Lift and Move the Load Unit 49 Connecting Cables 56 Prerequisite 56 Cable connections 56 Low Flow Power...

Page 48: ...nit Do not allow the load unit to drop or topple Make sure that your chains slings and crane have a working capacity greater than the load unit s weight Make sure that the lifting hoist rings are tigh...

Page 49: ...or debris deposited during shipment 2 Inspect the load unit for shipping damage Look for the following l Scratches in the load unit or lift cylinder columns l Damaged electrical connections l Damaged...

Page 50: ...y Locked Crossheads 3 Manual locks not available on Models 370 25 and 370 50 Lock the Crosshead 4 Before you move the load unit check the following l The floor where the load unit will sit can bear it...

Page 51: ...high as necessary Lift Point Locations Item Description 1 M20 X 2 50 mm Holes for Swivel Hoist Rings supplied for lifting 2 Slings 5 Warning Airmounts can be overinflated and then explode You can be...

Page 52: ...of the load unit s leg should be 57 63 mm 2 25 2 5 in 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 in...

Page 53: ...lower the load unit onto the four isolation pads or airmounts A 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 B If...

Page 54: ...ove 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...

Page 55: ...rdware included with the isolation tie down kit 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 install...

Page 56: ...el the control panel contains the emergency stop and crosshead lock signals l The servovalve l The actuator manifold The actuator manifold might include a proportional valve or solenoid valves Control...

Page 57: ...ly as shown in the following figure If the load frame is equipped with a test area enclosure the door interlock jumper would be replaced with the cable from the test area enclosure Note Location of th...

Page 58: ...on 1 Main Power In 2 To Low Flow Solenoid 3 To Load Frame Rear Panel 4 Door Interlock Jumper units without an enclosure Cable from Test Area Enclosure units with an enclosure Cable from Drive Enclosur...

Page 59: ...U to the hydraulic port on the manifold labeled R 2 Connect the pressure line from the HPU to the hydraulic port on the manifold labeled P 3 Connect the drain line s to the HPU A Connect a drain line...

Page 60: ...raulic 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...

Page 61: ...ft Loosen the Manual Crosshead Locking Bolts 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...

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Page 63: ...d Hydraulically 71 Adjust the Grip Clamp Rate 72 Adjust the Grip Clamp Force 73 Handset Control 73 Handset Control Functions 73 Standard Test Area Enclosure Operation 75 Hydraulic Power Off 75 Specime...

Page 64: ...and unclamping the optional lower hydraulic grip Item 2A adjusts the lower grip clamping rate Item 2B is the lower grip pressure gage 3 Grip Pressure Adjust Adjusts the amount of hydraulic pressure t...

Page 65: ...to help you during specimen installation and test execution The handset also has an alphanumeric display and LEDs to provide feedback Specimen Installation The procedure to install a specimen varies...

Page 66: ...Apply load unit station low hydraulic pressure D If the system has a Series 494 based controller enable the Gate Interlock E Set the actuator velocity limiting switch to the tortoise restricted flow...

Page 67: ...lications There are a variety of configurations of this grip l The Advantage Grips mechanical are specifically designed for static or fatigue testing applications The Advantage Mechanical Wedge grip i...

Page 68: ...ad cannot be securely clamped to greasy or damp columns 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...

Page 69: ...lowing figure shows the sequence of loosening the crosshead bolts Item Description 1 190 N m 140 lbf ft Crosshead Locking Bolt Torque Item Description 1 190 N m 140 lbf ft 2 271 N m 200 lbf ft Crosshe...

Page 70: ...damp columns 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...

Page 71: ...on a crosshead for a Series 370 Load Unit equipped with hydraulic crosshead lifts 1 Pressurize the lift actuators The crosshead may have shifted position while hydraulic pressure was turned off Briefl...

Page 72: ...rip control and lower grip control are in the unclamp position 2 Turn on electrical power at the test controller 3 Turn on low or high hydraulic pressure 4 If needed move the crosshead or actuator so...

Page 73: ...Turn on low or high hydraulic pressure 4 If needed move the crosshead or actuator so that the dummy specimen can be easily installed in the lower grip Caution Grips are designed to operate within a ra...

Page 74: ...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...

Page 75: ...Select Enter Selects the highlighted line in the display 15 Display Four lines 20 characters per line Standard Test Area Enclosure Operation There are four operating modes for an MTS Landmark Test Sy...

Page 76: ...on the system will detect this and activate the limited actuator velocity mode and put the controller into program interlock mode Specimen Installation and Setup Interrupt Operation To interrupt opera...

Page 77: ...be used by trained individuals Emergency Stop and Actuator Velocity Limiting Switch The emergency stop switch and actuator velocity limiting switch function the same as those on the control panel Ite...

Page 78: ...nformation Interlock logic The interlock logic is as follows Item Description 1 Door Interlock 2 Solenoid Contacts 3 Test Controller Program Interlock Input Open Interlock 4 To Low Flow Power Supply 5...

Page 79: ...sed in QC elastomer applications It includes operator control panels that require both hands outside the test area to start the test If the actuator is moving and the light curtain beam is interrupted...

Page 80: ...orm an applicable pass or fail procedure This is defined by the customer based on testing and part handling requirements 4 Remove the tested part 5 Repeat Steps 1 through 5 Note The following wiring d...

Page 81: ...e load frame in the actuator velocity limiting mode indicated by the turtle symbol the servo motor HSM is triggered in Station Manager to power off the servo motor and set an interlock This allows the...

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Page 83: ...aulic Locks 97 Lubricate the Crosshead Locking Bolts 101 Aligning the Force Transducer 102 Required Equipment 102 Align the Force Transducer 103 Series 111 Accumulator Maintenance Overview 106 Series...

Page 84: ...Load Units Product Information 252 Servovalve 115 Replacing the Servovalve Filter Element 115 Replace the Servovalve Filter Element 116 Adjusting the Mechanical Null 118 Adjust the Mechanical Null 11...

Page 85: ...y X Lubricate the axial torsional spline Bionix frame at 75 100 hrs X Ensure that the actuator is in working order X Inspect all labels to ensure they are attached and legible X Crosshead Load Frame E...

Page 86: ...sure the crosshead unlock causes a program interlock MTS MTS MTS MTS MTS Check the condition of all load frame support airbags and pads MTS MTS MTS MTS MTS Ensure that the crosshead movement is smooth...

Page 87: ...k 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 connec...

Page 88: ...e 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...

Page 89: ...Time using 8 hour Running Time Rate Per Day Daily Weekly Biweekly Annually Running Time Hours 8 40 80 500 1000 1 500 2 000 Ensure that the grip seals are dry MTS MTS MTS MTS Ensure that the grip acti...

Page 90: ...nly Align the force transducer After actuator or force transducer installation when a better alignment between the two is desired Check the accumulators precharge pressures Adjust if necessary At leas...

Page 91: ...irty or greasy columns You will need ethanol and lint free cloths to perform this procedure Warning The crosshead can slide down the columns Crosshead cleaning takes place in a crush zone where pinche...

Page 92: ...sures Humid and corrosive environments require more prevention Recommended Supplies l Ethanol l Silicone spray l 000 emery cloth l Touch up paint l Metal primer paint l Lint free cloths Warning The cr...

Page 93: ...Maintenance MTS Landmark Tabletop Load Units Product Information 93...

Page 94: ...faces 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 us...

Page 95: ...nit s leg should be 57 63 mm 2 25 2 5 in Warning Airmounts can be overinflated and then explode You can be seriously hurt if an airmount explodes sending fragments flying Only inflate airmounts that h...

Page 96: ...ion 1 5 mm 0 20 in 2 0 41 MPa 60 psi 3 57 63 mm 2 25 2 5 in Checking Airmount Inflated Heights 4 Check the airmounts inflated heights They should be between 83 86 mm 3 25 3 5 in If the load unit is le...

Page 97: ...ght of each airmount is between 83 86 mm 3 25 3 5 in 8 If any airmount pressures are above 0 41 MPa 60 psi or any airmount heights not between 57 63 mm 2 25 2 5 in repeat Steps 1 3 until the load unit...

Page 98: ...to Step 3 If not position the crosshead to a comfortable working level A Reset any active interlocks at the test controller B Turn on high hydraulic pressure C If there is a specimen in the load unit...

Page 99: ...abletop Load Units Product Information 99 Item Description 1 136 N m 100 lbf ft 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 Crosshe...

Page 100: ...e 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 tigh...

Page 101: ...shead position to pressurize the hydraulic locks 12 Fully loosen the manual crosshead locking bolts Then turn the Lock Control to the unlock crosshead position 13 Move the crosshead locking and unlock...

Page 102: ...eps 4 and 5 until all the bolts have been lubricated Aligning the Force Transducer A force transducer must be aligned with the actuator piston whenever the force transducer is installed or the actuato...

Page 103: ...or at midstroke Caution Do not leave a crosshead unlocked It can drift slowly down when hydraulic pressure is turned off and damage any test fixtures grips and specimen in its path Unlock the crosshea...

Page 104: ...to take the reading along the edge of the loading surface On cylindrical style force transducers adjust the indicator so that its stylus just touches the inside edge of the pilot Zero the dial indicat...

Page 105: ...st be raised above the mounting surface to access the threaded fasteners of the force transducer The threaded fasteners are accessed from the bottom of the load unit A Loosen the load unit s legs from...

Page 106: ...r an axial torsional system torque the screws to 24 N m 17 lb ft 6 Check the alignment again Take another reading to make sure the TIR remains within specifications l If the TIR remains within specifi...

Page 107: ...checks depends on how the system is used Some factors to consider when establishing this time interval are operating frequency displacement and duration Start with one month intervals until you determ...

Page 108: ...lator requires maintenance or the time interval between checks needs to be shortened l If the precharge pressure level increases at each check interval this indicates that fluid is collecting on the g...

Page 109: ...ment 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...

Page 110: ...uck valve to the accumulator valve stem 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 v...

Page 111: ...e pressure reading is other than the required pressure level recorded on the accumulator continue with the next subsection Change the Precharge Pressure B If the pressure level corresponds to the leve...

Page 112: ...evel required close the bleed valve 2 Close the locknut or close the chuck valve if you have a core type valve Open the bleed valve on the accumulator charging kit and remove the chuck valve from the...

Page 113: ...n the accumulator close the regulator shut off valve 8 Close the locknut or close the chuck valve for a core type valve 9 Open the bleed valve on the accumulator charging kit and remove the chuck valv...

Page 114: ...ontaminated hydraulic fluid can cause premature wear of the hydraulic components in your system Do not mix different brands of hydraulic fluid MTS Systems Corporation recommends using Mobil DTE 25 or...

Page 115: ...hen high hydraulic pressure to the actuator manifold and inspect the seal between the filter bowl and housing for any signs of leakage If leakage exists turn off system hydraulic and electrical power...

Page 116: ...rt 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 Repla...

Page 117: ...shers that secure the filter cover plug B Thread one of the socket head screws removed in Step A into the filter cover plug and pull it out of the filter housing C Remove the filter disk D Lightly lub...

Page 118: ...ull for the Series 252 Servovalve The mechanical null adjustment aligns the servovalve spool to a position that allows little or no actuator movement when there is no control signal Prerequisites Read...

Page 119: ...ct the servovalve cable and observe the actuator rod l If the actuator rod has no noticeable movement the servovalve is at the null position and does not need to be adjusted Proceed to Step 4 l If the...

Page 120: ...rn off electrical power to the controller E Remove the hex key and insert a 3 8 inch offset wrench over the self locking nut F Insert a torque wrench with a 3 32 inch hex key head adapter into the adj...

Page 121: ...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 Fin...

Page 122: ...accurately represent the physical condition they sense that is force or displacement When you calibrate a sensor you are calibrating the test system to properly interpret the sensor signal Sensors in...

Page 123: ...andles while reducing the pressure setting to release all pressure from the grips and hoses Turn off the Series 685 grip control and disconnect electrical power Remove the hoses If the unit has an int...

Page 124: ...when removing hydraulic components and allow any trapped or latent pressure to dissipate safely through a loosened connection before removing the component l Cap each hose port and hardline component...

Page 125: ...Landmark Tabletop Load Units Product Information 125 Always refer to local codes that govern the disposal of potentially hazardous materials and follow these codes for the proper handling and disposal...

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Page 127: ...Declarations MTS Landmark Tabletop Load Units Product Information 127 Declarations Declaration of Conformity 128 Declaration of Incorporation 131...

Page 128: ...Declarations 128 MTS Landmark Tabletop Load Units Product Information Declaration of Conformity Original Page 1 of 3 DoC Load Unit December 21 2009...

Page 129: ...Declarations MTS Landmark Tabletop Load Units Product Information 129 Original Page 2 of 3 DoC Load Unit December 21 2009...

Page 130: ...Declarations 130 MTS Landmark Tabletop Load Units Product Information Original Page 3 of 3 DoC Load Unit December 21 2009...

Page 131: ...Declarations MTS Landmark Tabletop Load Units Product Information 131 Declaration of Incorporation Original Page 1 of 3 DoI Load Unit December 21 2009...

Page 132: ...Declarations 132 MTS Landmark Tabletop Load Units Product Information Original Page 2 of 3 DoI Load Unit December 21 2009...

Page 133: ...Declarations MTS Landmark Tabletop Load Units Product Information 133 Original Page 3 of 3 DoI Load Unit December 21 2009...

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Page 136: ...MTS Systems Corporation 14000 Technology Drive Eden Prairie MN 55344 2290 USA Email info mts com www mts com ISO 9001 Certified Quality Management System...

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