MTS Systems SilentFlo 505G2 Series User manual

Series 505G2 SilentFlo™ Hydraulic Power Unit
Model 505G2.07, Model 505G2.11
100-227-350 C

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Proprietary Software
Software use and license is governed by MTS’s End User License Agreement which defines all rights
retained by MTS and granted to the End User. All Software is proprietary, confidential, and owned by
MTS Systems Corporation 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 using established quality practices in accordance with the requirements
detailed in the ISO 9001 standards. Because MTS-authored software is delivered in binary format, it is
not user accessible. This software will not change over time. Many releases are written to be backwards
compatible, creating another form of verification. The status and validity of MTS’s operating software is
also checked during system verification and routine calibration of MTS hardware. These controlled
calibration processes compare the final test results after statistical analysis against the predicted
response of the calibration standards. With these established methods, MTS assures its customers that
MTS products meet MTS’s exacting quality standards when initially installed and will continue to perform
as intended over time.
Manual Part Number Publication Date
100-227-350 C
(English)
December 2013
100-227-350 B
(English)
February 2011
100-227-350 A
(English)
July 2010

Series 505G2 SilentFlo™ Hydraulic Power Unit 3
Technical Support 7
How to Get Technical Support 7
Start with your manuals 7
Technical support methods 7
Outside the U.S. 7
Before You Contact MTS 7
Know your site (if applicable) and system numbers 7
Know information from prior technical assistance 8
Identify the problem 8
Know relevant computer information 8
Know relevant software information 8
If You Contact MTS by Phone 9
Identify system type 9
Be prepared to troubleshoot 9
Write down relevant information 9
After you call 10
Problem Submittal Form in MTS Manuals 10
Preface 11
Before You Begin 11
Safety first! 11
Other MTS manuals 11
Documentation Conventions 11
Hazard conventions 11
Other special text conventions 12
Special terms 12
Illustrations 12
Electronic manual conventions 12
Hypertext links 12
Introduction 13
Overview 14
EU Declarations 14
Intended Use 14
Product Information CD 14
Component Identification 15
Functional Description 18
Pump 18
Pressure 18
Filtering 18
Contents

4Series 505G2 SilentFlo™ Hydraulic Power Unit
Heat exchanger 19
Auto-Cooling Valve (adjustable) 19
Electrical Control 19
Safety 21
General Safety Practices: Hydraulic Power Units and Hydraulic Service Manifolds 22
Read all manuals 23
Locate and read hazard placards/labels 23
Specimen temperature changes 23
Know facility safe procedures 23
Know controls 23
Have first aid available 24
Know potential crush and pinch points 24
Be aware of component movement with hydraulics off 24
Know electrical hazards 24
Keep bystanders safely away 24
Wear proper clothing 24
Remove flammable fluids 24
Check bolt ratings and torques 25
Practice good housekeeping 25
Protect hoses and cables 25
Provide proper hydraulic fluid filtration 25
Protect accumulators from moving objects 25
Do not exceed the Maximum Supply Pressure 25
Do not disable safety devices 25
Use appropriately sized fuses 26
Provide adequate lighting 26
Provide means to access out-of-reach components 26
Wear appropriate personal protection 26
Handle chemicals safely 26
Know system interlocks 26
Know system limits 26
Do not disturb sensors 26
Ensure secure cables 27
Stay alert 27
Contain small leaks 27
Stay clear of moving equipment/avoid crush points 27
Know the causes of unexpected actuator motions 27
Do not use RF transmitters 27
Know compressed gas hazards 27
Installation 31
Install the HPU 32
Contents

Series 505G2 SilentFlo™ Hydraulic Power Unit 5
HPU Setup 35
Operation 39
Operator’s Panel 40
Main Screen 40
Status Screen 43
Operating the HPU Locally or Remotely 45
Recovering from an Interlock 47
Changing the Water Flow 48
Resetting the Thermal Overloads and Circuit Breakers 49
Adjusting the Hydraulic Pressure 50
Adjusting the HPU Output Pressure Level 51
Auto-Cooling Valve (adjustable) 51
Low/High Pressure Functionality 54
Maintenance 57
Before You Begin 58
Spare parts 58
Lockout/tagout 58
Operating the HPU 58
Routine Maintenance Overview Checklist 58
Checking the Hydraulic Fluid 61
Replacing the Return Line Filter 62
Sample the Hydraulic Fluid 64
Appearance of Hydraulic Fluid Sample 66
Replacing the Hydraulic Fluid 67
Accessories 71
High Pressure Filter Kit 72
Replacing the Filter Element 72
Surge Suppressor Kit 73
Required equipment 73
Installation procedure 74
Precharging the Surge Suppressor Accumulator 75
Determining a pressure check interval 75
Checking precharge pressure 75
Changing the precharge pressure 76
Lifting Kit 77
Caster Kit 78
Appendix A: HPU Maintenance and Service Logs 81
Contents

6Series 505G2 SilentFlo™ Hydraulic Power Unit
8 Hours/Daily 82
40 Hours/Weekly 82
160 Hours/Biweekly 83
500 Hours 84
1000 Hours 85
2000 Hours 86
5000 Hours 87
10,000 Hours 87
Appendix B: Declaration of Conformity 89
Example 90
Contents

Technical Support
Series 505G2 SilentFlo™ Hydraulic Power Unit 7
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.
Type of
Support Details
Web site www.mts.com > Contact Us (upper-right corner) > In the Subject field, choose To
escalate a problem; Problem Submittal Form
E-mail Worldwide: [e-mail]
Europe: [e-mail]
Telephone Worldwide: 1 800 328 2255 - toll free in U.S.; [phone] - outside U.S.
Europe: [phone], International toll free in Europe
Outside the U.S.
For technical support outside the United States, contact your local sales and service office. For a list of
worldwide sales and service locations and contact information, use the Global MTS link at the MTS
web site:
www.mts.com > Global Presence > Choose a Region
Before You Contact MTS
MTS can help you more efficiently if you have the following information available when you contact us
for support.
Know your site (if applicable) and system numbers
The site number contains your company number and identifies your equipment type (such as material
testing or simulation). The number is typically written on a label on your equipment before the system
leaves MTS. If you do not know your MTS site number, contact your sales engineer.
Example site number: 571167
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: US1.42460

Technical Support
8Series 505G2 SilentFlo™ Hydraulic Power Unit
Know information from prior technical assistance
If you have contacted MTS about this problem before, we can recall your file based on the:
lMTS case number
lName of the person who helped you
Identify the problem
Describe the problem and know the answers to the following questions:
lHow long and how often has the problem occurred?
lCan you reproduce the problem?
lWere any hardware or software changes made to the system before the problem started?
lWhat are the equipment model numbers?
lWhat is the controller model (if applicable)?
lWhat is the system configuration?
Know relevant computer information
For a computer problem, have the following information available:
lManufacturer’s name and model number
lOperating software type and service patch information
lAmount of system memory
lAmount of free space on the hard drive where the application resides
lCurrent status of hard-drive fragmentation
lConnection status to a corporate network
Know relevant software information
For software application problems, have the following information available:
lThe software application’s name, version number, build number, and (if available) software
patch number. This information can typically be found in the About selection in the Help menu.
lThe names of other applications on your computer, such as:
lAnti-virus software
lScreen savers
lKeyboard enhancers
lPrint spoolers
lMessaging applications

Technical Support
Series 505G2 SilentFlo™ Hydraulic Power Unit 9
If You Contact MTS by Phone
A Call Center agent registers your call before connecting you with a technical support specialist. The
agent asks you for your:
lSite number (if applicable)
lEmail address
lName
lCompany name
lCompany address
lPhone number where you can be reached
If your issue has a case number, please provide that number. A new issue will be assigned a unique
case number.
Identify system type
To enable the Call Center agent to connect you with the most qualified technical support specialist
available, identify your system as one of the following types:
lElectrodynamic material test system
lElectromechanical material test system
lHydromechanical material test system
lVehicle test system
lVehicle component test system
lAero test system
Be prepared to troubleshoot
Prepare to perform troubleshooting while on the phone:
lCall from a telephone close to the system so that you can implement suggestions made over
the phone.
lHave the original operating and application software media available.
lIf you are not familiar with all aspects of the equipment operation, have an experienced user
nearby to assist you.
Write down relevant information
In case Technical Support must call you:
lVerify the case number.
lRecord the name of the person who helped you.
lWrite down any specific instructions.

Technical Support
10 Series 505G2 SilentFlo™ Hydraulic Power Unit
After you call
MTS logs and tracks all calls to ensure that you receive assistance for your problem or request. If you
have questions about the status of your problem or have additional information to report, please
contact Technical Support again and provide your original case number.
Problem Submittal Form in MTS Manuals
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 process. The 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.
You can access the Problem Submittal Form at www.mts.com > Contact Us (upper-right corner) > In
the Subject field, choose To escalate a problem; Problem Submittal Form

Preface
Series 505G2 SilentFlo™ Hydraulic Power Unit 11
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.
Other MTS manuals
In addition to this manual, you may receive additional manuals in paper or electronic form.
You may also receive an MTS System Documentation CD or flash drive. It contains an electronic copy
of the manuals that pertain to your test system.
Controller and application software manuals are typically included on the software CD distribution disc
(s).
Documentation Conventions
The following paragraphs 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 the activity 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 all directions and
recommendations. Three different levels of hazard notices may appear in your manuals. Following are
examples of all three levels. (for general safety information, see the safety information provided with
your system.)
Danger: Danger notices indicate the presence of a hazard with a high level of risk which, if
ignored, will result in death, severe personal injury, or substantial property damage.
Warning: Warning notices indicate the presence of a hazard with a medium level of risk
which, if ignored, can result in death, severe personal injury, or substantial property damage.
Caution: Caution notices indicate the presence of a hazard with a low level of risk which, if
ignored, could cause moderate or minor personal injury or equipment damage, or could
endanger test integrity.

Preface
12 Series 505G2 SilentFlo™ Hydraulic Power Unit
Other special text conventions
Important:
Important notices provide information about your system that is essential to its proper function.
While not safety-related, if the important information is ignored, test results may not be reliable,
or your system may not operate properly.
Note:
Notes provide additional information about operating your system or highlight easily
overlooked information.
Recommended:
Recommended notes provide a suggested way to accomplish a task based on what MTS has
found to be most effective.
Tip:
Tips provide helpful information or a hint about how to most efficiently accomplish a task.
Access:
Access provides 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 occurrence of special terms is shown in italics.
Illustrations
Illustrations appear in this manual to clarify text. They are examples only and do not necessarily
represent your actual system configuration, test application, or software.
Electronic manual conventions
This manual is available as an electronic document in the Portable Document File (PDF) format. It can
be viewed on any computer that has Adobe Acrobat Reader installed.
Hypertext links
The electronic document has many hypertext links displayed in a blue font. All blue words in the body
text, along with all contents entries and index page numbers, are hypertext links. When you click a
hypertext link, the application jumps to the corresponding topic.

Introduction
Series 505G2 SilentFlo™ Hydraulic Power Unit 13
Introduction
Overview 14
EU Declarations 14
Intended Use 14
Product Information CD 14
Component Identification 15
Functional Description 18
Auto-Cooling Valve (adjustable) 19
Electrical Control 19

Introduction
14 Series 505G2 SilentFlo™ Hydraulic Power Unit
Overview
The MTS Model 505.07 Hydraulic Power Unit (HPU) and Model 505.11 HPU provide high-pressure
hydraulic fluid for test system operation. This section contains general information about the HPU.
EU Declarations
EC Declaration of Conformity (Machinery Directive 2006/42/EC Annex II 1A)
If applicable, a Declaration of Conformity is supplied with the machinery; an example of the Declaration
of Conformity is provided at the end of this manual.
Intended Use
The intended use of the Hydraulic Power Unit (HPU) is:
lHydraulic supply for servohydraulic testing systems.
lPower supply for other hydraulically operated machinery, presses, or test systems.
Product Information CD
A Product Information CD is supplied with the HPU (MTS part number 100-227-354). The Product
Information CD includes the electrical and hydraulic schematics along with the configuration drawings.
The Product Information CD also contains the product specifications and other reference documents
to aid MTS qualified service personnel. These documents include:

Introduction
Series 505G2 SilentFlo™ Hydraulic Power Unit 15
Drawing
Number Description
700005313 Product Specifications
100025526 Series 505 SilentFlo™ HPU Lift and Move
Instructions
700005263 505.07 Configuration Drawing
700000263 505.07 Hydraulic schematic
700004937 505.07 small PLC Electrical Schematic (200 - 480
VAC)
700005213 505.07 large PLC Electrical Schematic (200 - 480
VAC)
700004942 505.07 small PLC Electrical Schematic (575 VAC)
700005293 505.07 large PLC Electrical Schematic (575 VAC)
700005263 505.11 Configuration Drawing
700000264 505.11 Hydraulic schematic
700004965 505.11 small PLC Electrical Schematic (200 - 480
VAC)
700005214 505.11 large PLC Electrical Schematic (200 - 480
VAC)
700004966 505.11 small PLC Electrical Schematic (575 VAC)
700005294 505.11 large PLC Electrical Schematic (575 VAC)
050000536 Hydraulic Fluid Care Guide
015164000 Heat Exchanger Care Guide
Component Identification

Introduction
16 Series 505G2 SilentFlo™ Hydraulic Power Unit
Item Component Description
1 Output Pressure Gage Displays the hydraulic pressure being output from the HPU.
2 Auto-Cooling Valve Keeps the hydraulic fluid clean and cool by circulating the
fluid through the return filter and the heat exchanger while
the HPU is in high pressure mode and the fluid demand by
the external circuit is very low.
3 Pressure Relief Valve Prevents the HPU from exceeding 22.4 MPa (3250 psi).
4 Fluid Sample Port Access port for obtaining hydraulic fluid samples from the
HPU. A quick disconnect port is provided. Use the optional
sampling kit that includes a needle valve to regulate the flow
through the sample port.
5 Electrical Enclosure Houses the electrical and control components of the HPU.
The main power lines enter the unit at the top. The power
disconnect switch removes electrical power whenever the
enclosure door is opened.
6 Low
level/Overtemperature
Sensor
Senses the hydraulic fluid level and temperature. Control
interlocks automatically shut the HPU down if the fluid level
drops too low or the hydraulic fluid temperature rises above
the temperature sensor’s setting.
7 Fluid Level Gage Displays the level of the hydraulic fluid.
Component Descriptions (part of )

Introduction
Series 505G2 SilentFlo™ Hydraulic Power Unit 17
Item Component Description
8 Filler Cap Vents the hydraulic fluid reservoir. This is where you add
hydraulic fluid.
9 Reservoir Holds the hydraulic fluid and houses the hydraulic pump and
motor. The surge suppressor (optional) is mounted to the
pump.
10 Hydraulic and Water
Connections
Connection points for the hydraulic fluid distribution system,
water source, and return lines.
11 Water Flow Regulator Sets the amount of water flowing through the heat
exchanger. Adjust the water flow to regulate the temperature
of the hydraulic fluid.
12 Drain Valve Drains the hydraulic fluid from the reservoir.
13 High Pressure Filter
Location
The high pressure filter is optional. If provided, it would be
located where indicated in the figure.
14 Output Pressure
Control
Sets the output pressure of the HPU.
15 Heat Exchanger Cools the hydraulic fluid by using an oil-to-water heat
exchanger. The heat exchanger removes most of the heat
generated by the HPU.
16 Temperature Gage Displays the temperature of the hydraulic fluid.
17 Return Filter Filters particles out of the hydraulic fluid as it is returned to
the HPU.
18 Power Disconnect
Switch
Disconnects the incoming power from the HPU. The switch
is a lockable, mechanical latch. Power is removed whenever
the door to the electrical enclosure is open (the switch is in
the off position). However, incoming power lines to the
switch are live unless power is removed externally. The
power disconnect switch is located on the front panel of the
electrical enclosure (item 5).

Introduction
18 Series 505G2 SilentFlo™ Hydraulic Power Unit
Item Component Description
19 Hazard placards Hazard placards contain specific safety information and are
affixed directly to the system so they are plainly visible. Each
placard describes a product-related hazard. When possible,
international symbols (icons) are used to graphically indicate
the type of hazard and the placard label indicates its severity.
The hazard placards are located on the front panel of the
electrical enclosure (item 5).
20 User Interface Panel Controls the operation of the HPU and indicates the current
status of several detectors. Also used for HPU setup. The
user interface panel is located on the front panel of the
electrical enclosure (item 5).
21 Nameplate Provides basic product information such as model number,
serial number, and electrical information. The nameplate is
located on the electrical enclosure (item 5).
Functional Description
Pump
A variable volume pump draws hydraulic fluid from the reservoir and pressurizes it to the adjusted
output pressure, typically 21 MPa (3000 psi). A check valve prevents hydraulic fluid from being
siphoned back into the reservoir. The pressurized fluid is controlled by a control manifold that contains
the high/low pressure solenoid valve and a non-adjustable relief valve set at 22.4 MPa (3250psi).
Pressure
The start/low/high switch on the front panel of the electrical enclosure controls the hydraulic pressure
of the HPU. The start/low/high switch operates like an automotive ignition switch; turn and hold the
switch in the start position until the motor starts running. The switch returns to the low position.
The unit automatically starts in low pressure to reduce the amperage needed for starting, which will
extend pump and motor life. When operating at this setting, low-pressure fluid is available to the
hydraulic circuit. Low pressure is achieved by diverting a portion of the hydraulic fluid through the high
pressure solenoid and returning it to the reservoir. Selecting high pressure blocks the low pressure
return path and makes all of the pressurized hydraulic fluid available to the hydraulic circuit.
The output pressure can be adjusted from about 1 MPa (145 psi) to 21 MPa (3000 psi). The HPU is
designed to provide 21 MPa (3000 psi). A nonadjustable relief valve is set at 22MPa (3190 psi) to
protect the hydraulic system from excessive pressure.
Filtering
As hydraulic fluid returns to the reservoir, it is filtered by a 3-micron element. This ensures that all
hydraulic fluid is filtered whether it travels out through the circuit or returns by way of the unit’s control
manifold under low pressure. Filter cleanliness is automatically monitored. An indicator lights on the
front panel signaling when the filter needs an element change.

Introduction
Series 505G2 SilentFlo™ Hydraulic Power Unit 19
Heat exchanger
Hydraulic fluid temperature is maintained with a heat exchanger that cools the fluid. The water-cooled
heat exchanger cools the hydraulic fluid as it passes over water-filled plates. A regulating valve
monitors the temperature of the hydraulic fluid and adjusts the flow of water through the plates. The
flow of cooling water regulates the temperature of the hydraulic fluid.
lThe typical operating temperature range of the hydraulic fluid is
43–49°C (110–120°F).
lIf the hydraulic fluid temperature exceeds 55ºC (131ºF), a switch opens and shuts down the
HPU.
lWhen the HPU is shut off, the flow of water is also stopped by a shutoff solenoid valve.
Note: For additional information see the Heat Exchanger Care and Water Quality Guide (part
number 015-164-000).
Auto-Cooling Valve (adjustable)
The auto-cooling function is integrated into the control manifold. During periods of low flow demand
from the external hydraulic circuit, this feature provides two important benefits: a re-circulating flow that
ensures hydraulic fluid filtering whenever the unit is on, and safeguarding against hydraulic fluid over-
temperature. It functions by opening a hydraulic flow path through the fluid conditioning circuit when
external hydraulic demand for flow is low. When the external demand increases, this feature closes the
path to provide the full flow of the HPU to the external demand.
The effective operating range of the auto-cooling circuit is between system pressures of 14 MPa (2000
psi) to 21 MPa (3000 psi). In order for the Auto-Cooling Valve to function properly, it must be re-
adjusted anytime the output pressure will be changed for longer than 10 minutes.
Note: If the test condition requires a maximum pressure level less than 14 MPa (2000 psi),
consult MTS.
Electrical Control
The HPU can be controlled locally using the front panel controls, or remotely through a controller. A
PLC (programmable logic controller) manages the electrical systems within the HPU. The controls
included in the electrical enclosure include the following:
A user interface panel that contains a touch screen to program preferences and operational settings.
The screens on the user interface panel provide quick indication of the unit’s condition, including
motors status, running time displays for each motor, hydraulic fluid level and temperature, and filter
condition.
lWye-delta starting reduces the initial current rush when the motor starters are engaged.
lThermal overloads protect the individual HPU motors from excessive current draw.
lA latchable Emergency Stop button prevents inadvertent starts.
lInterlocks protect the HPU against low hydraulic fluid level, overtemperature, and dirty filters.

Introduction
20 Series 505G2 SilentFlo™ Hydraulic Power Unit
lA Reset button brings the unit back into operation after a fault has been detected and
corrected.
lA dirty filter signal will not shut the unit down, but will prevent the unit from starting.
lThe power disconnect switch on the door of the main electrical enclosure ensures that power
is removed whenever the door is opened. This device is a TÜV-certified, lockable, main-
disconnect switch.