m be certain. 318 Load Unit Product Information Model 318.10 Model 318.25 Model 318.
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Contents Technical Support 7 How to Get Technical Support Before You Contact MTS 7 7 If You Contact MTS by Phone 9 Problem Submittal Form in MTS Manuals 10 Preface 11 Before You Begin Conventions 11 12 Documentation Conventions 12 Introduction 15 Load Unit: Overview 15 318 Load Unit: Component Identification 318 Load Unit: Component Description 318 Load Unit: Specifications 17 18 20 Series 661 Force Transducer: Specifications 318 Load Unit: Dimensions 24 26 Safety 33 General Safety Pract
Installation 47 318 Load Unit: Unpack Upright Configuration 47 318 Load Unit: Unpack Horizontal Configuration 318 Load Unit: Connect Cables 49 54 318 Load Unit: Connect Hydraulics 56 318 Load Unit: Unlock the Crosshead 56 Operation 59 Load Unit: Operation Preface 59 318 Load Unit: Control Module 60 318 Load Unit: Crush Point Hazards 62 318 Load Unit: Specimen Installation 62 318 Load Unit: Position the Crosshead Hydraulically 318 Load Unit: Position the Crosshead Manually 318 Load Unit: Adj
8 Hours/Daily 108 40 Hours/Weekly 109 80 Hours/Biweekly 110 500 Hours: Crosshead and Frame 500 Hours: Actuator 500 Hours: HSM 111 112 113 500 Hours: Hoses and Cables 114 500 Hours: Overall Complete System 115 500 Hours: Grips 116 1000 Hours 117 2000 Hours: Annual Maintenance 318 Load Unit 118 Contents 5
Contents 318 Load Unit
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 MTS software, look for online help and README files that contain additional product information. If you cannot find answers to your technical questions from these sources, you can use the internet, e-mail, telephone, or fax to contact MTS for assistance. Technical support methods MTS web site www.mts.
Know information from prior technical assistance Identify the problem Know relevant computer information Know relevant software information 8 Technical Support If you have contacted MTS about this problem before, we can recall your file.
If You Contact MTS by Phone Your call will be registered by a Call Center agent if you are calling within the United States or Canada. Before connecting you with a technical support specialist, the agent will ask you for your site number, name, company, company address, and the phone number where you can normally be reached. If you are calling about an issue that has already been assigned a notification number, please provide that number.
Problem Submittal Form in MTS Manuals Use the Problem Submittal Form to communicate problems you are experiencing with your MTS software, hardware, manuals, or service which have not been resolved to your satisfaction through the technical support process. This form includes check boxes that allow you to indicate the urgency of your problem and your expectation of an acceptable response time. We guarantee a timely response—your feedback is important to us.
Preface Before You Begin Safety first! Before you attempt to use your MTS product or system, read and understand the Safety manual and any other safety information provided with your system. Improper installation, operation, or maintenance of MTS equipment in your test facility can result in hazardous conditions that can cause severe personal injury or death and damage to your equipment and specimen. Again, read and understand the safety information provided with your system before you continue.
Conventions Conventions Documentation Conventions The following paragraphs describe some of the conventions that are used in your MTS manuals. Hazard conventions As necessary, hazard notices may be embedded in this manual. These notices 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.
Conventions Hypertext links 318 Load Unit 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.
Conventions 14 Preface 318 Load Unit
Introduction Load Unit: Overview The Load Unit is the primary structure for most materials testing. It is a standalone testing unit. The load unit consists of the load frame plus additional parts, such as hydraulic crosshead lifts and control modules. Load units come in different sizes and shapes. The following illustration shows typical load units with common accessories. The Load Units are designed for testing materials.
What you need to know 16 Introduction MTS Systems Corporation assumes that you know how to use your controller. See the appropriate manual for information about performing any controllerrelated step in this manual’s procedures.
318 Load Unit: Component Identification 12 2 1 11 3 10 9 4 5 7 8 6 Component Descriptions ITEM COMPONENT DESCRIPTION 1 Crosshead Moves the up and down the column to accommodate different sized specimens and fixtures. The crosshead is stiff and light weight; it is one end of the force train. 2 Crosshead locks Clamps the crosshead to the columns. The locks are hydraulically powered. 3 Crosshead lifts Raises and lowers the crosshead hydraulically to accommodate different specimen sizes.
Component Descriptions ITEM COMPONENT DESCRIPTION 4 Control panel The Emergency Stop button is standard; the other controls are optional. Clamps and unclamps the hydraulically controlled grips during specimen installation and removal. Grip controls Controls the crosshead lifts to raise and lower the crosshead hydraulically. Crosshea d lift control Removes hydraulic pressure from the load unit and issues an interlock signal to the controller to stop the test program.
Load frame The load frame is the basic structure which provides the reaction mass for the force train. The base of the load frame is one end of the reaction mass and the crosshead is the other end of the reaction mass. Installing a specimen and other fixtures or components between the load unit base and the crosshead create a force train. The load frame and the other hydraulic components mounted to it collectively create the load unit. The base houses the actuators, servovalves, and hydraulic manifold.
LVDT The LVDT measures the linear actuator’s travel. The LVDT consists of a transformer with one primary and two secondary coils wound on a common cylinder. The coil is stationary inside the actuator. A core is attached to the piston rod of the actuator. As it moves inside the coil, it produces an electrical signal that represents the position of the piston rod. The phase of the signal indicates the direction the actuator rod is moving. An LVDT requires an AC conditioner to process the signal.
PARAMETER SPECIFICATION Weight* approximate minimum weight Base mount 318.10 318.25 318.50 500 kg (1100 lb) 960 kg (2120 lb) 1900 kg (4200 lb) Crosshead mount 318.10 318.25 318.50 * Force Ratings 555 kg (1225 lb) 1065 kg (2345 lb) 2100 kg (4625 lb) The weight specification is for lifting and moving purposes. The weight of accessories and special fixtures must be added. The actual shipping weight must be determined by a scale. The Series 318 Load Units include other products.
For the most accurate high frequency test results, use a load unit with a fatigue rating that is larger than its actuator’s force rating. C D B A For example, a Model 318.25 Load Unit with a 55 kip fatigue rating and a 22 kip actuator will have smaller deflections than a Model 318.10 Load Unit with a 22 kip fatigue rating and a 22 kip actuator. Spring rates are determined at each load unit’s full fatigue rating with its crosshead raised 1270 mm (50 in.) above the baseplate.
DEFLECTIONS MODEL 318.10 100 KN/22 KIP MODEL 318.25 250 KN/55 KIP MODEL 318.50 500 KN/110 KIP A - D overall frame 0.38 mm 0.58 mm 0.66 mm Spring rates 2.6 x 108 N/m (1.5 x 106 lb/in) 0.015 in 0.023 in 4.3 x 108 N/m (2.4 x 106 lb/in) 0.026 in 7.5 x 108 N/m (4.3 x 106 ib/in) Free Column Length (cm) 25 50 125 250 80 10 45 5 22 318.50 318.10 2 318.25 9 1 4.5 0.
Series 661 Force Transducer: Specifications The force transducer used with this system is a Series 661 Force Transducer. The following are the specifications for the force transducers. PARAMETER SPECIFICATION Maximum excitation voltage 15 V DC Bridge resistance 350 ¾ Maximum crosstalk 1.0% of full scale torsional to load Hysteresis 0.08% of full scale (250 N–2.5 kN) 0.05% of full scale (5 kN–50 kN) 0.15% of full scale (100 kN–500 kN) 0.20% of full scale (1000 kN) Nonlinearity 0.
MODEL LOAD CAPACITY THREAD SIZE* WEIGHT 661.20-01 25 kN (5.5 kip) M27 x 2.0 mm x 31.7 mm (1 - 14 UNS-3B x 1.25 in) 9.75 kg (21.5 lb) 661.20-02 50 kN (11 kip) M27 x 2.0 mm x 31.7 mm (1 - 14 UNS-3B x 1.25 in) 9.75 kg (21.5 lb) 661.20-03 100 kN (2.2 kip) M27 x 2.0 mm x 31.7 mm (1 - 14 UNS-3B x 1.25 in) 9.75 kg (21.5 lb) 661.22-01 250 kN (3.3 kip) M36 x 2.0 mm (1 1/2 - 12 UNC-2B) 13.2 kg (29 lb) 661.23-01 500 kN (5.5 kip) M52 x 2.0 mm x 48.3 mm (2.0 - 12 UN-2B x 1.9 in) 16 kg (35.
Weight: 1100 lbs (500 kg) is normal maximum weight. Accessories and special fixtures must be added. This weight specification is for lifting and moving purposes. Actual shipping weight must be determined by scale. Note: Dimensions are inches (mm) Standard column lengths indicated 318 Load Unit: Dimensions 318.
318.
318.50B Load Unit Dimensions 28 Introduction 318 Load Unit (mm Weight: 4200 lbs (1900 kg) is normal maximum weight. Accessories and special fixtures must be added. This weight specification is for lifting and moving purposes.
318.10B Load Unit with Crosshead Actuator Dimensions 318 Load Unit Introduction 29 Standard column lengths (mm Weight: 1100 lbs (500 kg) is normal maximum weight. Accessories and special fixtures must be added. This weight specification is for lifting and moving purposes. Actual shipping weight must be Note: Dimensions are Standard 6" (152.
318.25B Load Unit with Crosshead Actuator Dimensions 30 Introduction 318 Load Unit Weight: 2120 lbs (960 kg) is normal maximum weight. Accessories and special fixtures must be added. This weight specification is for lifting and moving purposes. Actual shipping weight must be determined by scale. Note: Dimensions are inches (mm) Standard 6" (152.
8.50B Load Unit with Crosshead Actuator Dimensions 318 Load Unit Introduction 31 Standard column lengths (mm Weight: 4200 lbs (1900 kg) is normal maximum weight. Accessories and special fixtures must be added. This weight specification is for lifting and moving purposes. Actual shipping weight Note: Dimensions are Standard 6" (152.
Introduction 318 Load Unit
Safety General Safety Practices This section provides information about safety issues that pertain to servohydraulic systems in general. These issues include statements to the intended use and foreseeable misuse of the system, the hazard zone, definition for the graphical hazard labeling that is affixed to your product, and other (more general) safety information that relates to the high-pressure and highperformance characteristics of MTS servohydraulic systems.
If you have system related responsibilities (that is, if you are an operator, service engineer, or maintenance person), you should study safety information carefully before you attempt to perform any test system procedure. You should receive training on this system or a similar system to ensure a thorough knowledge of your equipment and the safety issues that are associated with its use.
Locate and read hazard placards/labels Find, read, and follow the hazard placard instructions located on the equipment. These placards are placed strategically on the equipment to call attention to areas such as known crush points and electrical voltage hazards. Locate Lockout/tagout points Know where the lockout/tagout point is for all of the supply energies associated with your system.
Keep bystanders safely away Wear proper clothing Remove flammable fluids Know compressed gas hazards 36 Safety Keep bystanders at a safe distance from all equipment. Never allow bystanders to touch specimens or equipment while the test is running. Do not wear neckties, shop aprons, loose clothing or jewelry, or long hair that could get caught in equipment and result in an injury. Remove loose clothing or jewelry and restrain long hair.
Observe the following safety practices when you work with high-pressure air or gases: • 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.
On rare occasions, a fastener can fail even when it is correctly installed. Failure usually occurs during torquing, but it can occur several days later. Failure of a fastener can result in a high velocity projectile. Therefore, it is a good practice to avoid stationing personnel in line with or below assemblies that contain large or long fasteners. Practice good housekeeping Keep the floors in the work area clean.
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.
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.
Hazard Icons Following are the hazard icons used on the MTS products. ICON DESCRIPTION Moving parts; pinch points. Keep clear of areas noted with this label High pressure fluid or gasses. Do not tamper with fittings or hoses. Possible explosive or flying debris. Wear appropriate protection such as safety goggles and hearing protection. Possible tipping hazard. The machine should only be moved by qualified riggers familiar with moving heavy, delicate equipment.
ICON DESCRIPTION Alternate read the manuals or instructions. Become familiar with safety information. Also become familiar with operating and maintenance information. Hot surfaces. Possible burn hazard. Wear personal protective equipment such as gloves when working near hot surfaces. Object is heavy. Requires more that one person to lift and move. 318 Load Unit: Hazard Labels This section provides information on hazard labeling.
Base Assembly 2 1 1 3 5 4 View A-A ITEM PART NUMBER DESCRIPTION 1 045-384-101 Warning. High force moving parts. Can cause severe injury or equipment damage. Stay clear and use eye protection while test is in progress. Read instructions before operating or servicing. 2 037-588-901 Identification label. Includes model number, part number, serial number, force capacity, and manufacture date. 3 050-275-301 Information label. No step. 4 050-275-201 Caution.
Cylinder Assembly 1 2 ITEM PART NUMBER DESCRIPTION 1 037-588-801 Identification label. Includes model number, serial number, assembly number, force, effective date, static stroke, dyn stroke, and hydrostatic bearing. 2 038-202-801 Warning. Subjecting this equipment to working pressure above 3000 psi (21 MPa) can result in component rupture and injury to personnel. See the product manual for safety precautions before operating.
318 Load Unit: Crush Point Hazards It is important to stay clear of any potential crush points when the system is operating. Know where the crush points are in your system and protect yourself and others from those crush points with appropriate safety devices. The following paragraphs describe crush points and precautions to take while working around crush points.
Safety 318 Load Unit
Installation 318 Load Unit: Unpack Upright Configuration 1. Unpack the load unit. A. Remove the shipping container (if used). B. Remove the protective wrapping around the columns. C. Use a clean cloth to wipe the columns clean. Note D. The load unit can be moved by a fork lift as long as the load unit is attached to its pallet. Remove the bolts from the wooden beams clamping the load unit to the pallet.
2. Inspect the load unit for shipping damage. Look for the following: • Scratches in the load unit or lift cylinder columns • Damaged electrical connections • Damaged hydraulic connections • Dents and other structural damage • Torn, kinked, or breaking hoses Report any damage found to both the carrier and MTS. In the U.S. and Canada, call the MTS HELPLine at 1-800-328-2255. Elsewhere, contact your local MTS office. 3. Move the load unit to its final location.
WARNING Airmounts can be overinflated and then explode. You can be seriously hurt if an airmount explodes, sending fragments flying. Do not overinflate the airmounts. 318 Load Unit: Unpack Horizontal Configuration Prerequisites 318 Load Unit The load unit is shipped horizontally on a wooden pallet.
WARNING The load unit is extremely heavy. The weight of the load unit can seriously hurt you and damage your load unit. Do not allow the load unit to drop or topple. Observe the following precautions: • Ensure that your chains, slings, and crane have a working capacity greater than the load unit’s weight. • Ensure that the lifting eyebolts are tight. • Ensure that the crosshead locking bolts are fully tightened. • Lift the load unit only high enough to clear its pallet.
CAUTION Scratches in the load unit columns can affect how the crosshead performs. Chains will scratch the columns. Use slings to lift the load unit from its pallet.
2. Inspect the load unit for shipping damage. Look for the following: • Scratches in the load unit or lift cylinder columns • Damaged electrical connections • Damaged hydraulic connections • Dents and other structural damage • Torn, kinked, or breaking hoses Report any damage found to both the carrier and MTS. In the U.S. and Canada, call the MTS HELPLine at 1-800-328-2255. Elsewhere, contact your local MTS office. 3. Wrap slings around the columns at the load unit’s balance point. A.
C. Once the load unit is upright, raise it slightly so that the pallet can be removed. Crane travel 30° maximum Bringing the Load Unit Upright Before you move the load unit, that: • The floor where the load unit will sit can bear its weight. • The path to where the load unit will sit is clear and uncluttered. • The area where the load unit will sit is clean and well lit, with all hoses and cables moved out of harm’s way. • The eyebolts are tight. • The crosshead is manually locked.
• If your load unit has airmounts, inflate each airmount in 5 mm (0.20 in) increments to level the load unit. – Check the airmounts’ pressures often to ensure that they do not exceed 0.55 MPa (80 psi). – Check the airmounts’ inflated heights to ensure that they are all between 83 and 88 mm (3.25 and 3.5 in). – Adjust the air pressure to level the load unit. WARNING Airmounts can be overinflated and then explode. You can be seriously hurt if an airmount explodes, sending fragments flying.
Prerequisite You must have either a cable assembly drawing of your test system, or you must know the system controller well enough to determine each type of cable connection. Ê Ë Ì Í Î Ï 1. The force transducer is connected to a DC conditioner in the controller. 2. The ground connection is located on the back of the control panel. This is usually connected to a chassis ground on a console or the controller chassis. 3. The load unit control panel is connected to the controller.
7. Return to the installation procedure. 318 Load Unit: Connect Hydraulics The procedure describes how to connect the load unit to the hydraulic power source. The load unit may be connected directly to the hydraulic power unit (also called HPU), to hydraulic plumbing in the workplace, or through a hydraulic service manifold. Note The internal hydraulic connections from the actuator manifold and accessories such as the hydraulic lifts and locks should already be made. 1.
2. Fully loosen the manual crosshead locking bolts in the order shown in the following figure. 1 2 318.10 136 N·m (100 lbf·ft) 3 1 4 1 318.25 2 3 271 N·m (200 lbf·ft) 4 318.50 271 N·m (200 lbf·ft) 2 Loosening the Manual Lock Bolts 3. Cycle the lock control to unclamp, and then reclamp, the crosshead. 4. Use the lock control to unclamp the crosshead. The unclamped symbol is shown at the right. Wait 30 seconds for the pressure in the crosshead locks to drop to zero. 5.
Installation 318 Load Unit
Operation Load Unit: Operation Preface This section describes the load unit controls, crush point hazards, and procedures performed during the normal, day-to-day operation of the load unit. Application note Special considerations must be followed when using low force transducers in a high force systems. Small force transducers are commonly used in larger systems. You need to be aware that the load unit can produce forces that exceed the rating of the low force transducer.
318 Load Unit: Control Module The controls for the 318 Load Unit are located on a module mounted to the front of the load unit. Crosshead Lift / Lock Control Emergency Stop Hydraulic Grip Control Pressure 1 2 3 Rate Series 318 Load Unit Controls CONTROL DESCRIPTION Hydraulic Grip Controls Controls the optional hydraulic grips. Hydraulic grips let you quickly and easily install and remove specimens. The left handle controls the lower grip and the right handle controls the upper grip.
Series 318 Load Unit Controls CONTROL DESCRIPTION Crosshead Lift/Lock Controls Controls the movement and clamping of the crosshead. The left handle raises and lowers the crosshead. The right handle locks and unlocks the crosshead. The crosshead must not be moved while it is clamped. Up Unlock Lock Stop Down Emergency Stop 318 Load Unit Shuts down the hydraulic pressure and stops the test program. Press this button to shut down hydraulic power, and twist the switch clockwise to release it.
318 Load Unit: Crush Point Hazards It is important to stay clear of any potential crush points when the system is operating. Know where the crush points are in your system and protect yourself and others from those crush points with appropriate safety devices. The following paragraphs describe crush points and precautions to take while working around crush points.
Prerequisite You must have the necessary grips and/or fixturing installed. You must also have the controller set up to control the actuator movement, and you must have a test program defined. CAUTION When changing hydraulic grips, make sure you cap or plug the hydraulic hoses when removed to prevent oil spillage. Oil spillage can create an environmental concern and slippery surface that can cause personal injury. Promptly clean up any oil that might have spilled when hoses were removed.
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 in its path. Unlock the crosshead only to reposition it. Always lock the crosshead after you have repositioned it, and never leave the crosshead unlocked. 2. Set the crosshead position.
CAUTION Before testing, ensure both grips are clamped and the specimen is secure. An insufficiently gripped specimen can cause specimen damage, equipment damage and the possibility of specimen fragmentation. 318 Load Unit: Position the Crosshead Hydraulically 1. This step pressurizes the lift actuators. The crosshead might have shifted position while hydraulic pressure was turned off.
4. Use the Crosshead Lift/Lock Controls to clamp the crosshead to its current position. Wait 30 seconds for the locks to fully clamp the columns. 318 Load Unit: Position the Crosshead Manually This procedure describes how to position a crosshead for a load unit with no hydraulic crosshead lifts or locks. WARNING The crosshead is very heavy. A dropping crosshead can crush hands, damage grips, and smash specimens.
3. Remove the covers on the ends of the crosshead. The crosshead covers must be removed to access the manual locking bolts and to clean and lubricate the bolts. Six 1/4-20 screws (three top, three bottom) on each cover need 5/32 hex (not included). Hand-tighten when reinstalling the covers. 4. Loosen the crosshead locking bolts in 1/4 turn steps (counterclockwise). The following figure shows the sequence of loosening the crosshead bolts. 3 1 4 318.10 190 N·m (140 lbf·ft) 5 2 6 8 7 3 318.
WARNING The crosshead is very heavy. A dropping crosshead can crush hands, damage grips, and smash specimens. Observe the following precautions to reduce the possibility of unexpected crosshead movement: Prerequisite • Ensure that the crosshead is locked. • The overhead crane and lifting chains must be able to support the weight of the crosshead (see the Crosshead Weight table below). • Center the crane directly over the load unit.
LOAD UNIT STEP 1 STEP 2 STEP 3 STEP 4* 318.25 20 N·m (15 lbf·ft) 244 N·m (180 lbf·ft) 271 N·m (200 lbf·ft) 271 N·m (200 lbf·ft) 318.50 20 N·m (15 lbf·ft) 244 N·m (180 lbf·ft) 271 N·m (200 lbf·ft) 271 N·m (200 lbf·ft) * This step ensures uniform tightness. 318 Load Unit: Adjust the Grips’ Clamp Rate The clamp rate determines how fast the grip can clamp a specimen. 1. Ensure that both the upper grip control and lower grip control are in the unclamp position. 2.
6. Fully install the dummy specimen in the lower grip. 7. Cycle the lower grip control between the clamp and unclamp positions to clamp and unclamp the specimen. A. Clamp Unclamp Watch the speed at which the lower grip clamps and unclamps the specimen. B. Adjust the Rate control counterclockwise for the desired speed. 318 Load Unit: Adjust the Grips’ Clamp Force The Pressure control adjusts the hydraulic pressure applied to the grips. The Rate control adjusts the grips’ clamping speed.
5. Adjust the Pressure control for the desired hydraulic pressure. Pressure More Less 6. If you exceed the desired pressure setting, adjust the Pressure control counterclockwise 1/2 turn. If pressure setting exceeds 20 MPa (3000 psi) cycle (clamp and unclamp) one of the grips. Return to Step 5.
Operation 318 Load Unit
Maintenance 318 Load Unit: Maintenance Intervals 318 Load Unit: Daily Inspections 318 Load Unit: Clean the Columns 318 Load Unit: Prevent Rust 77 78 78 79 318 Load Unit: Maintain Airmount Pressures 80 318 Load Unit: Bleed the Hydraulic Lift Cylinders 318 Load Unit: Adjust the Hydraulic Locks 81 83 318 Load Unit: Lubricate the Crosshead Locking Bolts 318 Load Unit: Align the Force Transducer 111 Accumulator: Maintenance Overview 86 87 93 111 Accumulator: Check and Change Precharge Pressure 244 Ac
Routine Maintenance Overview Checklist Routine Maintenance Overview Checklist Recommended service to be performed at each running time interval noted CALENDAR TIME USING 8 HOUR RUNNING TIME RATE DAILY WEEKLY BIWEEKLY RUNNING TIME-HOURS 8 80 Check Actuator Platen Area to be Clean X* Monitor Filter Indicators X ANNUALLY PER DAY 40 Check Hoses/Cables/Connectors X Check Crosshead/Lifts/Supports X Check Actuator to be Dry X Check Hydraulic Service Manifold X Check Lift Seal Condition to be
Routine Maintenance Overview Checklist Recommended service to be performed at each running time interval noted CALENDAR TIME USING 8 HOUR RUNNING TIME RATE DAILY WEEKLY BIWEEKLY 8 80 ANNUALLY PER DAY RUNNING TIME-HOURS 40 500 1000 1,500 2,000 Actuator Area is Dry MTS MTS MTS MTS Actuator Platen Area is Clean MTS MTS MTS MTS Piston Rod Wear is Acceptable MTS MTS MTS MTS Bionix Lubricate Axial/Torsional Spline (75-100 hrs) MTS MTS MTS MTS Cursory Check of Hydraulic Service Man
Routine Maintenance Overview Checklist Recommended service to be performed at each running time interval noted CALENDAR TIME USING 8 HOUR RUNNING TIME RATE DAILY WEEKLY BIWEEKLY 8 80 ANNUALLY PER DAY RUNNING TIME-HOURS 40 500 1000 1,500 2,000 Response to Full Stroke Waveform, Visual and Audible MTS MTS MTS MTS Valve Balance check displacement control MTS MTS MTS MTS Valve Dither Response MTS MTS MTS MTS Cursory Check of Grips/Grip Control MTS MTS MTS MTS Grip Supply Connecti
Routine Maintenance Overview Checklist 318 Load Unit: Maintenance Intervals The following table lists the recommended interval for each of these procedures. 318 Load Unit WHAT TO DO WHEN TO DO IT Make daily inspections Before the start of each day’s testing. Clean the load unit columns When the columns become greasy or dirty. Prevent rust Depends on the operating environment; more often in humid environments. Maintain airmount pressures When the load unit sits unevenly.
Routine Maintenance Overview Checklist 318 Load Unit: Daily Inspections Before the start of each day’s testing, do a quick inspection of your load unit. Following are typical things that should be checked daily: • Ensure that there are no leaks from lifts or locks. • Ensure that there are no leaks from the actuator, hydraulic service manifold, servovalve, or accumulators. • Ensure that electrical connections are tight, with no frayed or poorly routed cables.
Routine Maintenance Overview Checklist 318 Load Unit: Prevent Rust Where you operate the load unit determines how often you take rust prevention measures. Humid and corrosive environments require more prevention. Recommended supplies: • #1 grade kerosene • Silicone spray • 000 emery cloth • Touchup paint • Metal primer paint • Lint-free cloths WARNING The crosshead can slip if the columns are still damp with kerosene. You can be hurt and your equipment damaged.
Routine Maintenance Overview Checklist 318 Load Unit: Maintain Airmount Pressures Optional inflatable airmounts reduce vibration and noise. They are installed under the feet of the load unit. Inflation pressures must be maintained to both level and isolate the load unit. WARNING Airmounts can be overinflated and then explode. You can be seriously hurt if an airmount explodes, sending fragments flying. Do not overinflate the airmounts. 1. Check the inflation pressures on each airmount.
Routine Maintenance Overview Checklist 318 Load Unit: Bleed the Hydraulic Lift Cylinders Bleed both hydraulic lift cylinders whenever the crosshead does not move smoothly. Also bleed them whenever the sealed side of the hydraulic system has been opened to air. The following figure shows the location of the bleed ports for the two types of lifts commonly used.
Routine Maintenance Overview Checklist CAUTION The crosshead can slowly drift down the columns if the locks are turned off and the hydraulic 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 it, and never leave the crosshead unlocked. 1. Make sure your crosshead is locked. 2. Turn on system electrical power. 3.
Routine Maintenance Overview Checklist 7. Briefly turn the Lift Control to the lift crosshead position to pressurize the lift cylinders. Then return it to the stop crosshead position. No bubbles Close 8. Shut the bleed port when bubble-free fluid begins oozing out. If necessary, again pressurize the lift cylinders to force all the air out. 9. Repeat Step 6 through Step 8 to bleed the air out of the other lift cylinder.
Routine Maintenance Overview Checklist B. Turn on high hydraulic pressure. C. If there is a specimen in the load unit, remove it. D. Move the crosshead to a comfortable working height. CAUTION The crosshead can slowly drift down the columns if the locks are turned off and the hydraulic pressure is turned off. The crosshead can damage any test fixtures, grips, and specimen in its path. Unlock the crosshead only to reposition it.
Routine Maintenance Overview Checklist 4. Use the Lock Control to lock the crosshead. Then torque the manual crosshead locking bolts in the order shown in the following illustration. 5. Turn off hydraulic pressure. 6. Use the Lock Control to the unlock crosshead position to remove pressure from the hydraulic locks. Wait two minutes for the pressure in the locks to drop to zero before going on to the next step. 7. Tighten each lock’s cap screw until its piston bottoms out.
Routine Maintenance Overview Checklist 14. Move the crosshead, locking and unlocking it, to check for smooth operation. 318 Load Unit: Lubricate the Crosshead Locking Bolts Lubricate the locking bolts in a manually locked crosshead whenever they begin to be hard to tighten or sticky when loosened. 1. Remove the covers on the ends of the crosshead. The crosshead covers must be removed to lubricate the crosshead locking bolts.
Routine Maintenance Overview Checklist 318 Load Unit: Align the Force Transducer This section describes how to align a force transducer with the load unit actuator. The load units shown may vary from what you may have. The 318.10 and some 318.25 Load Units come with two types of transducer mounting hardware. One preloads the force transducer with a hex nut; the other uses a preloader collar with jackbolts or captive set screws. The 318.50 and some 318.
Routine Maintenance Overview Checklist A. Position the actuator at midstroke. B. Set and enable the test controller’s upper and lower limit detect interlocks to limit the actuator’s movement to 2 mm (0.10 in) in each direction. C. Move the crosshead so there is about 360 mm (14 in) between the top of the actuator and the bottom of the force transducer. D. Lock the crosshead. WARNING Alignment takes place in a crush zone with hydraulic pressure on.
Routine Maintenance Overview Checklist 3. Check the alignment. In this step, you check the alignment between the force transducer and the actuator. . Read along the edge Zero Read along the edge Zero 360° 360° Attaching and Zeroing the Indicator A. Attach the dial indicator to the actuator. On a low profile force transducer, adjust the indicator to take the reading along the edge of the loading surface.
Routine Maintenance Overview Checklist 4. Prepare the force transducer. Depending on the type of force transducer you have, perform one of the following procedures: Hex nut mount only • Hex nut mount only • Preloader collar mount only The following procedure applies only to force transducers that are mounted to the crosshead with a single hex nut. A. Put blocks of wood between the actuator and the force transducer. They will support the force transducer when its mounting nut is loosened. B.
Routine Maintenance Overview Checklist Preloader collar mount only The following procedure applies only to force transducers that are mounted to the crosshead using a preload collar. Loosen the six jack bolts or setscrews in 1/4 turn steps to remove most of the tension on the preloader collar, following a standard crisscross torque sequence. • If your preloader collar has jackbolts, remove and lubricate them one at a time. Lubricate the washer underneath the jackbolt.
Routine Maintenance Overview Checklist B. Tighten to 5% of the torque recorded on the identification plate. Hex nut—Tighten the nut to 5% of the final torque shown on the identification plate. Preloader collar—Tighten the jackbolts or setscrews to 5% of the final torque shown on the identification plate. 1 C. Rotate the indicator to see if the TIR is still 0.038 mm (0.0015 in) or less. If not, loosen the nut or preloader collar and return to Step 4.
Routine Maintenance Overview Checklist C. Turn the load unit’s hydraulic pressure to off. Unscrew/Tighten Anti-Rotate Actuator—Tightening the Cap Screws D. If your load unit has an antirotate actuator, tighten the four antirotate cap screws to a torque listed in the following table. (The actuator force rating is stated on an identification plate at the rear of the load unit.) ACTUATOR FORCE RATING TORQUE RATING 25 kN (5.5 kip) 3.7 N·m (2.
Routine Maintenance Overview Checklist Use the following guidelines to determine when maintenance is required. • Check the precharge pressure at periodic intervals. The length of time between 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 determine another interval is more appropriate. • Maintain a log book on the condition of the precharge at each check.
Routine Maintenance Overview Checklist Prerequisite To prepare the accumulator for precharge check: WARNING Accumulators are pressurized devices. Pressurized accumulators and their parts can become lethal projectiles if disassembled and can cause death to persons and/or damage to equipment. Do not remove an accumulator that is pressurized. Completely remove hydraulic pressure and discharge the accumulator before any parts, except the protective cover and valve stem cap, are removed. 1.
Routine Maintenance Overview Checklist 2. With an open-end wrench, turn the locknut counterclockwise on the accumulator valve assembly to open the valve. Read the pressure on either the high or low accumulator charging kit pressure gage. • If the pressure reading is other than the required pressure level recorded on the accumulator, continue with the next subsection, “Change the Precharge Pressure”.
Routine Maintenance Overview Checklist WARNING Mixing gases can produce unpredictable results. Do not use another gas to precharge an accumulator. Use only dry nitrogen gas to precharge accumulators. 3. Connect the nitrogen supply hose from the supply bottle pressure regulator output to the input check valve on the charging kit. 4. Open the nitrogen bottle valve. Check the nitrogen bottle pressure gage on the regulator. (The bottle must contain sufficient pressure to provide an adequate gas volume.) 5.
Routine Maintenance Overview Checklist 244 Actuator: Maintenance The 244 Actuator is designed for extended periods of operation without extensive maintenance requirements. A summary of the routine maintenance procedures is listed below: Weekly Clean exposed areas of the actuator piston rod with a clean, dry, lint free rag. If the actuator is continually exposed to a dirty operating environment, clean the piston rod on a daily basis.
Routine Maintenance Overview Checklist CAUTION Mixing different brands of hydraulic fluid can contaminate your system. Contaminated 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 Shell Tellus 46 AW hydraulic fluid.
Routine Maintenance Overview Checklist 252 Servovalve: Maintenance Overview Maintaining the Series 252 Servovalves typically involves changing the filter element (Series 252.3x only) and setting the mechanical null adjustment. Except for these procedures, further disassembly, inspection, or repair of the servovalve is not recommended and may void the servovalve warranty. MTS does not recommend changing the 35-micron filter element in the Series 252.2x/.4x Servovalve (revision C).
Routine Maintenance Overview Checklist Procedure To replace the filter element, perform the following procedure. Care should be exercised to prevent dirt or other contaminants from entering the servovalve body, filter passages, or manifold/actuator ports. Refer to the following figure during the procedure. Socket Head Screws (4) 1 3 4 Filter Cover Plate 2 Filter Plug Filter Plug O-Rings Filter O-Ring Filter Filter Cover Filter Housing Model 252.2x/.4x Filter Location Model 252.
Routine Maintenance Overview Checklist D. Lightly lubricate the filter with clean hydraulic fluid and insert the filter into the housing. E. Secure the filter cover plate to the housing using the four socket head screws and washers removed in Step A. For the Series 252.3x Servovalve proceed as follows: A. Remove the four socket head screws and washers that secure the filter cover plate to the filter housing as shown below. B.
Routine Maintenance Overview Checklist During the servovalve mechanical null adjustment procedure, the actuator must be able to move through full displacement in either direction without contacting a reaction surface. Valve balance adjustments MTS controllers have an electronic mechanical null adjustment called valve balance. The valve balance adjustment is a convenient way to compensate for a servovalve that needs a mechanical null adjustment.
Routine Maintenance Overview Checklist CAUTION Excessive torquing may shear off the adjustor pin eccentric. Do not apply more than 12 lbf-in. (1.36 N•m) of torquing force to the adjustor pin. If the pin does not turn using very little force, proceed to Step C of this task. 104 Maintenance B. Slowly rotate the adjustor pin until the actuator movement is reduced to a minimum, and then go back to Step 2. If the pin does not turn using very little force, proceed to the next step. C.
Routine Maintenance Overview Checklist G. Using the offset wrench, loosen (but do not remove) the self-locking nut. Mechanical Null Adjustor Pin H. Turn the adjustor pin until the scribe mark on the adjustor pin is pointing toward the base of the servovalve. I. Tighten the self-locking nut until 1.13 to 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.
Routine Maintenance Overview Checklist 106 Maintenance 318 Load Unit
Servohydraulic Load Frame Maintenance and Service Logs Contents 8 Hours/Daily 108 40 Hours/Weekly 109 80 Hours/Biweekly 110 500 Hours: Crosshead and Frame 500 Hours: Actuator 500 Hours: HSM 111 112 113 500 Hours: Hoses and Cables 114 500 Hours: Overall Complete System 500 Hours: Grips 1000 Hours 115 116 117 2000 Hours: Annual Maintenance 118 Servohydraulic Load Frame Maintenance and Service Logs 107
8 Hours/Daily 8 Hours/Daily 8 Hours/Daily Service Interval Recommendation DATE 108 CHECK ACTUATOR PLATEN AREA TO BE CLEAN MONITOR FILTER INDICATORS PERFORMED BY PERFORMNED BY NOTES Servohydraulic Load Frame Maintenance and Service Logs
40 Hours/Weekly 40 Hours/Weekly 40 Hours/Weekly Service Interval Recommendation DATE CHECK HOSES/ CABLES/ CONNECTORS CHECK CHECK CHECK CROSSHEAD/ ACTUATOR AREA HYDRAULIC LIFTS/SUPPORTS TO BE DRY SERVICE MANIFOLD PERFORMED BY PERFORMNED BY PERFORMNED BY PERFORMNED BY PERFORMNED BY PERFORMNED BY NOTES CHECK LIFT CHECK LOCK SEAL CONDITION SEAL CONDITION TO BE DRY TO BE DRY Servohydraulic Load Frame Maintenance and Service Logs 109
80 Hours/Biweekly 80 Hours/Biweekly 80 Hours/Biweekly Service Interval Recommendation BIONIX LUCRICATE CHECK AXIAL/TORSIONAL ACTUATOR SPLINE (75-100 HRS) DATE 110 PERFORMED BY PERFORMNED BY NOTES Servohydraulic Load Frame Maintenance and Service Logs
500 Hours: Crosshead and Frame 500 Hours: Crosshead and Frame 500 Hours Service Interval Recommendation CHECK CROSSHEAD/ LIFTS/ SUPPORTS DATE LIFT SEAL CONDITION IS DRY LOCK SEAL CONDITION IS DRY CROSSHEAD COLUMNS ARE CLEAN COLUMN ABRASIONS ARE ACCEPTABLE PERFORMED BY PERFORMNED BY PERFORMNED BY PERFORMNED BY PERFORMNED BY NOTES 500 Hours Service Interval Recommendation DATE CROSSHEAD SPEED IS APPROPRIATE CROSSHEAD LOAD FRAME UNLOCK CAUSES SUPPORT/ PROGRAM AIRBAGS/PADS INTERLOCK PERFORMNED BY PE
500 Hours: Actuator 500 Hours: Actuator 500 Hours Service Interval Recommendation DATE CURSORY CHECK OF ACTUATOR ACTUATOR AREA IS DRY ACTUATOR PLATEN AREA IS CLEAN PERFORMED BY PERFORMED BY PERFORMED BY NOTES 500 Hours Service Interval Recommendation DATE 112 BIONIX LUBRICATE AXIAL/TORSIONAL SPLINE (75-100 HRS) PISTON ROD WEAR IS ACCEPTABLE PERFORMED BY PERFORMED BY NOTES Servohydraulic Load Frame Maintenance and Service Logs
500 Hours: HSM 500 Hours: HSM 500 Hours Service Interval Recommendation CURSORY CHECK MONITOR FILTER INDICATORS SERVICE MANIFOLD MANIFOLD HOSE ACCUMULATOR CONNECTIONS CONNECTIONS ARE DRY ARE TIGHT PERFORMED BY PERFORMNED BY PERFORMNED BY OF HYDRAULIC DATE PERFORMNED BY NOTES 500 Hours Service Interval Recommendation DATE ACCUMULATOR CONNECTIONS ARE TIGHT ACCUMULATOR CAPS/GUARDS ARE PRESENT PERFORMNED BY PERFORMNED BY PERFORMNED BY OIL ON THE GAS SIDE OF THE PISTON CHECK AND ADJUST PRESSURE I
500 Hours: Hoses and Cables 500 Hours: Hoses and Cables 500 Hours Service Interval Recommendation DATE 114 CURSORY CHECK OF HOSES/CABLES/ CONNECTORS ABSENCE OF HOSE ABRASIONS, BLISTERS, VULCANIZING PERFORMED BY PERFORMNED BY PERFORMNED BY PERFORMNED BY PERFORMNED BY CABLE CONDITION AND ROUTING IS ACCEPTABLE CHECK TRANSDUCER CONNECTIONS Servohydraulic Load Frame Maintenance and Service Logs HOSE CONNECTIONS AND CRIMPS ARE DRY NOTES
500 Hours: Overall Complete System 500 Hours: Overall Complete System 500 Hours Service Interval Recommendation DATE OVERALL SYSTEM CONDITION IS ACCEPTABLE TO USE APPROPRIATE/ SYSTEM STABLE PERFORMED BY PERFORMNED BY PERFORMNED BY PERFORMNED BY TUNING PARAMETERS E-STOP IS WORKING IF APPLICABLE ARE RESPONSE TO FULL STROKE WAVEFORM, VISUAL AND AUDIBLE NOTES 500 Hours Service Interval Recommendation VALVE BALANCE CHECK VALVE DITHER RESPONSE DISPLACEMENT CONTROL DATE PERFORMNED BY PERFORMNED BY
500 Hours: Grips 500 Hours: Grips 500 Hours Service Interval Recommendation DATE 116 CURSORY CHECK OF GRIPS/GRIP CONTROL GRIP SUPPLY CONNECTIONS ARE DRY GRIP SEALS ARE DRY PERFORMED BY PERFORMNED BY PERFORMNED BY PERFORMNED BY PERFORMNED BY NOTES GRIP ACTION IS ACCEPTABLE Servohydraulic Load Frame Maintenance and Service Logs LUBRICATE GRIP INSERTS
1000 Hours 1000 Hours 1000 Hours Service Interval Recommendation DATE ALL 500 HR MAINTENANCE PROCEDURES HYDRAULIC CROSSHEAD LOCKS ARE FUNCTIONING PROPERLY BLEED CROSSHEAD LIFT CYLINDERS PERFORMED BY PERFORMNED BY PERFORMNED BY NOTES Servohydraulic Load Frame Maintenance and Service Logs 117
2000 Hours: Annual Maintenance 2000 Hours: Annual Maintenance 2000 Hours Service Interval Recommendation ALL 1000 HR MAINTENANCE PROCEDURES DATE 118 LUBRICATE MANUAL CROSSHEAD LOCK BOLTS CHANGE HYDRAULIC SERVICE MANIFOLD FILTERS PERFORMED BY PERFORMNED BY PERFORMNED BY LOW PRESSURE ADJUSTMENT (MODEL 294 HSM) PERFORMNED BY NOTES Servohydraulic Load Frame Maintenance and Service Logs
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.
