MTS Systems Exceed 22 Series User manual

Manual Title
Additional Information
be certain.
Product Information
100-302-290 A
MTS Exceed™22 Series

MTS Exceed™ 22 Series Product Information
2
Copyright
Information
© 2014 MTS Systems Corporation. All Rights Reserved.
Trademark
Information
MTS is a registered trademark while Exceed is a trademark of MTS Systems
Corporation in the United States. These trademarks are also protected in other
nations.
Ownership
Information
Software usage and licensing are managed via MTS End Customer Licensing
Agreement. It regulates all rights reserved by MTS and granted to end users. All
software is proprietary properties and classified information of MTS Systems
Corporation, and therefore should not be otherwise reproduced, copied,
dissembled, decompiled, reverse engineered, or distributed without prior written
consent of MTS.
Software
Authentication and
Certification
MTS software is developed according to already established quality systems and
hence up to ISO 9001 standards. As MTS software is provided in binary format,
users cannot make modifications. The software does not change over time. Many
releases are backward compatible, resulting in other authentication forms.
The operating status and authentication of MTS software will also be checked
during system verification and hardware calibration. These verification processes
will compare the final testing results after statistical analysis with expected
responses based on verification standards. By relying on these proven methods,
MTS can guarantee to its customers that MTS products are in compliance with
strict MTS quality standards at initial installation, and will continue to run with
excellent performances with the passing of time.
Release Information No. Date of Publication
100-302-289A November 2014

MTS Exceed™ 22 Series Product Information Table of Contents 3
Table of Contents
Technical Support 5
How to Get Technical Support 5
Before Contacting MTS Service Representative 5
Calling MTS 6
Preface 7
Before Getting Started 7
Conventions 8
Document Conventions 8
Safety 9
General Safety Measures 9
Safety Practices Before Operating the System 10
Safety Practices During System Operations 12
Danger Labels 14
Introduction 15
About This Manual 15
Improper Uses 15
Description 16
Components of Main Frame 17
Technical Specifications 20
General Technical Specifications 21
Dimensions 23
Installation 25
Positioning and Ventilation of Main Unit 26
Levelling the Main Frame 27
Installing Shields 28
Controller connection 33

MTS Exceed™ 22 Series Product Information
4Table of Contents
Connecting to the Main Power Source 33
Connecting Cables 34
Operation 35
Power Switch (I/O) 37
Dangers of Impact Zone 38
Pendulum Installation 39
Bearing Installation 40
Placing Specimen 41
Control Panel Operations 42
Checks and Preparations Before Use 52
Shortcut Operations 53
Maintenance 55
Routine Maintenance List 55
Troubleshooting 57
Equipment Disassembly 59
Maintenance and Service Logs 61
8 Hours/Day 62
40 Hours/Month 63
2000 Hours/Year 64
PC Maintenance and System Checks 64
2000 hours 65
System checks 65
2000 hours 66
Main Unit and Working Area 66

How to Get Technical Support
MTS Exceed™ 22 Series Product Information Technical Support 5
Technical Support
How to Get Technical Support
Getting Started
Using the Manual
The Manual contains most of the information required for the use and
maintenance of the equipment. If your equipment includes software, please check
on-line help and README file that contain additional product information .
If you cannot get an answer to your technical question from those resources, you
may contact MTS for help by using Internet, E-mail, telephone, or fax.
Methods for
Getting Technical
Support
After the system is installed, MTS will offer a full range of support services. If
you have any doubts about the system or product, please feel free to contact our
technical support engineers via any of the following channel.
Technical Support
outside the United
States
To get technical support outside the United States, please contact local sales and
service offices. For the list of global sales and service locations plus contact
information, please click Global MTS on MTS website.
www.mts.com > Global MTS > (Choose your region in the right column) >
(Choose the closest site)
Before Contacting MTS Service Representative
If you can learn about the following information before contacting us, then MTS
can provide supports to you more efficiently.
Your Location
Number and
System Number
The location number includes your company number and marks the type of your
equipment (material testing, simulation, etc.) Before the system is shipped out of
MTS, the location number is usually written on a label and placed on the
equipment. If you do not know the location number, please contact our sales
engineer.
If you have more than one MTS system, the system number is used to mark each
system. You can check the system number in your order file.
Problem
Verification
Before calling us for help, you should be able to describe the problem you are
experiencing and know answers to the following questions:
•How long has the problem been persisting? How often does it occur?
•Can you reproduce the problem?
•Did you make any changes to system hardware or software prior to the
occurrence of the problem?
•What is the model of the equipment?
•What is the type of the controller?
•What are system configurations?

MTS Exceed™ 22 Series Product Information
6
Calling MTS
Technical Support
Your PC
Information
Please provide the following information about your PC:
•Name of the manufacturer and PC model;
•OS type and service patches;
•System RAM capacity;
•Available space on the hard disk drive where applications are located;
•Current state of hard drive fragments
•How the equipment is connected to corporate network.
Your Software
Information
Please provide the following information about your software applications:
•Name, version number, and build number of the software as well as software
patch number. This information is usually accessible via Help & About.
•Names of other applications installed on the PC, such as:
– Antivirus software;
– Screen saver;
– Keyboard accelerator;
– Printing buffer;
– Communications application.
Calling MTS
Before connecting you to the technical support experts, the call center
representative will record your call and ask you about the following information:
•Location number;
•Your name;
•Company name;
•Company address;
•Phone number to reach you.

Before Getting Started
MTS Exceed™ 22 Series Product Information Preface 7
Preface
Before Getting Started
Safety First Before using MTS products or systems, please carefully read the safety
information attached to the product or system. Improper installation, operations,
or maintenance may cause serious personal injuries and equipment damages. So,
please once again remember to carefully read and understand the attached safety
information for the system before proceeding to next chapters.
Other MTS
Manuals
Except for this Manual, you may receive other manuals, in paper or via email.
You may also receive MTS system documentation CD-ROM thatcontains the
electronic manuals relating to the testing system, such as
•Mechanical parts manual;
•Assembly drawing;
•List of parts;
•Operation guide;
•Preventive maintenance guide.
The software CD-ROM usually includes manuals for controllers and application
software.

MTS Exceed™ 22 Series Product Information
8
Conventions
Preface
Conventions
Document Conventions
This section introduces conventions used in MTS manuals.
Conventions on
Hazards
This Guide may contain hazard prompts, which cover safety information specific
to operations to be executed. Such prompts will appear right before steps or
procedures that might lead to such hazards. Please carefully read all hazard
prompts and follow all instructions and recommendations. There are three levels of
hazard prompts in this Manual. The following gives some examples of each level.
Note: For common safety information, please refer to part 9 of page Safety .
Danger indicates a high level risk; if not dealt properly, it may lead to death,
severe personal injuries or significant property losses.
Warning indicates a median level risk; if not dealt properly, it may lead to death,
severe personal injuries or significant property losses.
Caution indicates a low level risk; if not dealt properly, it may lead to medium or
mild personal injuries or equipment damages or endanger test integrity.
Note Note provides additional information on system operations or stresses
information that can be easily overlooked. For example:
Note: Resources listed on the hardware table are displayed at the tail of the table.
Special Terms Special terms will be presented in italics when appearing for the first time
Illustrations Illustrations in the manual are a description of the text. They are only examples
only and do not necessarily represent actual configurations of your system,
applications or software.
Conventions on
Electronic Version
This Manual is provisioned in PDF-based electronic version and can be viewed
on any PC that has installed the Adobe Acrobat Reader.
Hypertext Links The electronic version contains a host of hypertext links displayed in blue. All
words marked in blue in the text, all items in the table of contents, and all index
page numbers are hypertext links. If you click on a hypertext link, the application
will jump to the corresponding topic.

General Safety Measures
MTS Exceed™ 22 Series Product Information Safety 9
Safety
General Safety Measures
This section provides general safety information about the pendulum impact
system, including system functions and foreseeable misuses, danger zones,
definition of danger labels posted on the product, and other safety information
relating to high-performance features of MTS pendulum impact system.
By design, MTS test system can generate movement and impact energy, which is
then applied to the tested specimen.
When you are ready to operate the system or perform system operations, make
sure to comply with the following rules:
•Do not allow those having no operational experience, untrained, or having
not learnt potential hazards of the high-performance electrical machinery
and equipment or those having no operational experience, training or
education about operations to be performed to perform such operations.
•Do not disable safety devices or safety functions (including limit switch,
dust curtain, or proximity switch)
•Do not perform system operations without wearing appropriate personal
safety gears (such as gloves, goggles, etc.).
•Do not use combustible, flammable, over-pressured or explosive specimens.
•Use pliers or similar tools to hold specimen during installation of the
specimen.
•Do not use people as test subject or allow people to ride on the specimen or
system for any purpose, unless the system is tailor-made for people and all
safety related conditions have been strictly implemented.
•Do not make changes to the system, or use non-MTS parts to replace system
components, or use parts not up to MTS product specifications to maintain
the equipment.
•Do not operate the system in an explosive atmosphere.
•Do not use the system in a test area with unregulated traffic during system
operations.
If you are relevant to the system (that is, you are an operator, service engineer, or
maintenance engineer), you need to carefully learn relevant safety information
before trying to perform any operations on the system.
You should receive training on this system or similar systems, to ensure that you
have fully understood safety precautions relating to your equipment and the use
of the equipment. In addition, you should also read other manuals delivered
alongside the system, to further learn about system functions. For details on
training courses, such as contents and dates, please contact MTS.

MTS Exceed™ 22 Series Product Information
10
Safety Practices Before Operating the System
Safety
It is important for you to read the following safety information, to assure that
your operations and system working environment will not contribute to or cause
hazards. Keep in mind that you cannot eliminate all hazards of the system, so you
should understand and remember all applicable hazards at all times. These safety
guidelines can help you understand and identify hazards such that you can
develop appropriate training and operating procedures and acquire proper safety
gears (such as gloves, goggles, and hearing protections, etc.).
Each test system is run in a particular operating environment, which includes the
following known variables:
•factors of the site (such as architectural structure, environment, and its
functions);
•the customer's unauthorized modification of equipment;
•experience and professionalism of operators;
•test specimen.
Because of the above variables and other possible factors, your system may work
under unforeseen circumstances that might contain unknown hazards. Incorrect
system installation, operation, or maintenance may lead to death, personal
injuries or equipment/specimen damages. Common sense and thorough
knowledge of the system's performances may help you develop proper and safe
operating methods.
Safety Practices Before Operating the System
Check all safety practices applicable to the system before powering on the
system. The purpose of this is to improve the safety awareness of all personnel
relating to the system and observe and maintain the integrity of specific system
components through naked eye.
Reading All
Manuals
Prior to your first attempt to perform any system operations, you should read this
Manual and all other manuals companying the system. This will help you get a
general idea of the system, so as to avoid possible hazards.
Finding and
Reading
Danger Labels/
Signs
Find and read danger labels posted on the equipment and follow their
instructions. These labels are posted at corresponding danger areas to draw
attention (such as easily crush zones, electrical danger zones, etc.).
Locating Close/
Switch Points
You should learn about the close/switch positions corresponding to each energy
source of the system, including hydraulic, gas, electricity, and water sources, to
make sure these energy sources can be isolated from the system when necessary.
Knowing Plant's
Safety Processes
Most facilities have their own internal procedures and regulations as safety
practices. You should learn about these safety practices and apply them in daily
system operations.
Learning Controls When operating the system for the first time, you should run the system according
to operating procedures without powering the system on. Check all hardware and
software controls, and understand their functions and what adjustments should be
made. If you feel fuzzy about any control functions or adjustment methods, please
consult relevant information until you have a pretty clear mind.

Safety Practices Before Operating the System
MTS Exceed™ 22 Series Product Information Safety 11
Getting First Aid
Supplies Ready
Accidents may occur even if you are very careful. Please properly arrange the
schedule of operators, to ensure that there will always be properly trained
personnel in the vicinity who can carry out first aids. Also, post the local
emergency contact information within the sight of system operators.
Knowing Potential
Crush Positions
Know potential crush positions on the system, and keep personnel and equipment
away from these areas.
Understanding
Electrical Hazards
Minimize risks of electrical shocks after the system is powered on. Wear
insulated coveralls and use fully insulated tools for any electrical operations, and
avoid touching bare wires or switch contacts. Turn off the power if possible
before operating or approaching any electrical system components. Abide by
precautions for other high-voltage machinery.
Safe Distance of
Irrelevant Personnel
Irrelevant personnel should be kept a safe distance from the equipment. When
conducting tests, do not let any irrelevant person to touch the specimen or
equipment.
Wearing
Appropriate Outfits
Do not wear a tie, shop aprons, loose clothing, or jewellery, or let the long hair
loose, to avoid them being stuck into equipment, thereby causing personal
injuries. Take off your loose clothing or jewellery, or tie your hair up.
Emptying
Combustible Liquids
in Specimen
Before installing the container or component, empty combustible liquids inside
the container or component. Where necessary, replace combustible liquids with
non-flammable ones, to maintain an appropriate proportion of weight and
balance.
Checking Bolt
Ratings and
Torques
In order to ensure product reliability, the torque of fasteners (such as bolts and
connecting rods) in MTS systems must comply with requirements specified. Due
to high strengths and high pressures of MTS testing equipment, the actual torque
higher than or lower than the ratings could lead to dangers.
In rare cases, failures may occur even when fasteners are correctly installed.
Faults often occur during tightening, and may even occur several days later. Such
faults may result in fasteners springing off at high speed. As a result, on-site
personnel are better to avoid being on a straight line with or under assemblies
that contain large or long fasteners.
Keeping
Indoor Area Clean
Keep the floor of the work area clean. Do not leave any tools, facilities, or other
items unrelated to the test on the floor, system or accessories.
Protecting Hoses
and Cables
Avoid cables to be overheated, as they can cause the hardening and, ultimately,
failures of cables. Ensure that appropriate strain relief apparatus is installed near
cables and plugs of connectors. Do not use plugs of connectors to release strain.
Avoid all system hoses and cables to get in touch with sharp or rough objects, as
they may cause damages to hoses or cables. It is forbidden to stampede or use
heavy objects to press against hoses or cables. During considerations of system
layout and cabling, cables and hoses should be placed away from areas that may
cause damages to them.
When you need to remove the hydraulic pipe due to maintenance of the
equipment or replacement of test parts (such as replacement of hydraulic
clamps), ensure to tightly cover the two ends of the pipe to prevent oil spills.

MTS Exceed™ 22 Series Product Information
12
Safety Practices During System Operations
Safety
Recording Changes
Made
In the event that you make any changes to any operating procedures, record all
changes made and the dates when they are made in the manual.
Test
Area Protection
When testing hazardous specimens (such as crisp or fragile materials, or
internally-pressurized materials), use protective shells, such as cages, shields and
special laboratory layout.
Do Not Disable
Safety
Apparatus
Your system may be equipped with active or passive safety apparatus. Do not
disable such apparatus to avoid unexpected system actions.
Using Fuses up to
Specifications
Whenever fuses of the system or power sources are replaced, ensure that a
suitable fuse is used and installed correctly. Fuses thicker or thinner than the
prescribed specifications may lead to overheat of cables and explosion of the
fuse. And either case may cause a fire.
Providing Adequate
Lighting
Ensure adequate lighting, to minimize the odds of mal-operations, equipment
damages, and personal injuries. Make sure to have a clear vision of all tasks.
Using Necessary
Tools to Overhaul
Components
Hard to Access
For system components that are hard for you to access when you stand on the
floor, be sure to use necessary tools. For example, you may need a ladder or
scaffolding to reach the joints of sensors that are located relatively high.
Ensuring Equipment
Stability
Ensure that the equipment is stable or has been installed with seismic isolation
device. Some tests may cause resonance to the equipment as well as shocks to
and movements of the equipment.
Safety Practices During System Operations
Wearing
Appropriate
Protective Gears
Wear goggles when operating the pendulum impact testing equipment or
performing tests on fragile specimens or on specimens that contain peculiar
fragile parts.
Wear earmuffs when approaching the motor, pump, or other devices that may
generate loud noises. Some systems may produce noise more than 70 decibels
during operations.
If you may be exposed to liquids, chemicals or powders that irritate or damage
the skin, the respiratory system or eyes, wear personal protective equipment
(such as gloves, boots, coveralls or respirators).
Provide test area
protection.
When testing hazardous specimens (such as crisp or fragile materials, or
internally-pressurized materials), use protective shells, such as cages, shields and
special laboratory layout.
Specimen
Temperature
Changes
During cyclic testing, the specimen may combust due to overheating. So, you
need to wear personal protective gears, such as gloves, when handling
specimens.

Safety Practices During System Operations
MTS Exceed™ 22 Series Product Information Safety 13
Handling Chemicals
Safely
When using or handling chemicals (such as cleaning fluids, hydraulic oil,
batteries, contaminated parts, electro-hydraulic solutions, or maintenance
wastes), first consult the MSDS document corresponding to the concerned
material, and then adopt measures and devices suitable for the safe handling and
use of the chemical. Ensure that chemicals are handled appropriately.
Do Not Interfere
with Encoder
When the power is switched on, do not crash, swing, adjust, disconnect, or
otherwise interfere with the encoder or its cables.
Ensuring Cable
Safety
Do not make any changes to cable connections when the system is powered on.
Changing cable connections during equipment operations may lead to fast,
abnormal system responses, which may further lead to personal injuries or death
or equipment damages. In addition, make sure that all cables are properly
connected after you have made any changes to system configurations.
Remaining Vigilant Avoid working for long time without taking rests. Also, try not to do repetitive,
unchanging or monotonous work over long periods, as this may easily cause
accidents or hazards. If you are over familiar with the work environment, you
tend to overlook potential hazards in the environment.
Avoiding Moving
Equipment/
Crush Points
Keep clear of mechanical linkage devices, connection cables, and moving hoses,
as you may be caught, squeezed, or wrapped therein, or dragged by their
movements. Forces generated by the system can pinch, cut or crack any object by
which the system passes, causing serious injuries. So, avoid all potential crush
points. Most test systems can produce sudden, strong movements. Do not think
that your reaction is fast enough to keep you from any dangers in the case of
system failures.
Do Not Use
RF Transmitter
Ensure that workstation PCs, remote terminals, and electronic consoles are far
away from the radio frequency (RF) transmitter. Strong RF electromagnetic
fields can make sensitive circuits of the system unstable.

MTS Exceed™ 22 Series Product Information
14
Danger Labels
Safety
Danger Labels
The following table lists labels that are affixed on the equipment.
Label Description
Indicates the vertical lifting device
Indicates the presence of moving parts.
Moving parts may squeeze or cut objects, so
your hands need to keep clear of them.
Indicates splashes, which may easily injure
eyes, so you need to wear goggles.
Indicates that the equipment may easily tip.
When the equipment is tilted, use support
frame.
Indicates that you need to read and
understand instructions before starting,
operating, or maintaining the equipment.
Indicates that the equipment has no
maintenance tools that can be utilized by
customer.

About This Manual
MTS Exceed™ 22 Series Product Information Introduction 15
Introduction
About This Manual
Objectives This Manual intends to help you understand your test system, its capabilities, and
operational requirements. It covers all information relating to Exceed 22 series of
metal pendulum impact testers, with pendulum energy at 450J, 300J, and 150J.
Please read each section carefully and refer to this Manual when you need help.
Improper Uses
Read and understand this Manual before you perform any operations on Exceed
22 series of metal pendulum impact testers. Incorrect product installation or
operations may lead to dangers, which may further cause damages to your
equipment and specimen and even serious personal injuries or deaths.
Content Description 16
Components of Main Frame 17
Technical Specifications 20

MTS Exceed™ 22 Series Product Information
16
Description
Introduction
Description
Each Exceed 22 pendulum impact tester consists of the main unit, pendulum
device, brake device, manual safety pin, specimen recovery device, protection
device, and electrical control system.
Main unit The main unit consists of the main frame, pendulum shaft, jaw, etc. The main
frame is in double simple beam support structure. The pendulum shaft is
mounted on the main frame through pendulum-dedicated precision bearings, and
the pendulum hanging device is fixed to the main frame through screws and pins.
Meanwhile, the brake device is bolted to the shaft and main frame.
The drive system of the main unit is located on the back of the main frame and
the drive motor is connected to the shaft via two-stage gearbox and clutch. When
the clutch is released, the shaft can rotate freely; when the clutch is energized and
pulls in, the motor can drive the shaft to rotate.
Pendulum device The pendulum device can directly perform impacts toward the specimen. It is a
round object connecting to the shaft and replaceable. It has three kinds of energy:
450J, 300J, and 150J.
Brake device The brake device locks the pendulum to any position, thereby serving the
protection function. When the protection device is opened, the safety pin is
extruded, or there is unexpected power outage of the equipment, the brake device
can immediately lock the position of the pendulum.
Safety pin device The safety pin device is used during equipment commissioning and maintenance.
When the pendulum is in the swing state, protrude the safety pin, to avoid
personnel being impacted by the pendulum when performing the pendulum
lowering inspection. When the safety pin is protruded, the brake device will
immediately lock the pendulum, and all actions will be invalid toward the
equipment.
Specimen
recovery device
The device uses the conveyor belt structure to retrieve the specimen. The shield
has no deflector device inside, so broken specimen will directly fall on the
conveyor belt. You can set the estimated absorption energy, and the equipment
will then automatically distinguish the specimen based on absorption energy.
Protection device The protection device is used to avoid the splashing of the specimen during the
test and hence protect personnel safety. It consists of one main shield, two side
shields, and several deflector boards. When the protection device is opened, the
pendulum device is locked immediately, thereby realizing protection function.
★Note: If the protection device is opened during the commissioning state, the
pendulum can swing freely.
Electrical control
system
The electrical control system consists of a touch screen, main control cabinet,
front control panel, pendulum fetching and placement motor, and recovery motor.
It uses a programmable controller that can control the clearing, pendulum
fetching, pendulum placement, impact, and other actions of the main unit. You
can set specimen size, gravity acceleration, pendulum energy, and other
important parameters on the touch screen. In addition, the touch screen can also
display the real-time pendulum angle as well as the pre-elevation angle, lift angle
and absorption energy of each impact test.

Components of Main Frame
MTS Exceed™ 22 Series Product Information Introduction 17
Components of Main Frame
The following figure shows components of the main frame of E22.452. You can
refer to figures of your equipment model, to get familiar with various
components of your main frame.
For detailed specifications, please refer to Page 20“Technical Specifications”.
E22 main unit
Main frame
Speed reducer
Jaw anvil
Specimen
recovery
Dial pointer
Pendulum
hanging device
Safety pin
Motor
Brake
Pendulum
Base level

MTS Exceed™ 22 Series Product Information
18
Components of Main Frame
Introduction
E22 shield
Main unit
Sliding
door
Impact
button
Dial
pointer
Access control
Left
shield
Dial
shield Lock
Main shield
Access control
Right shield
Touch screen
Control panel

Components of Main Frame
MTS Exceed™ 22 Series Product Information Introduction 19
E22 shield (rear)
Electric control box
Hook
Back door
Speed
reducer
Motor
Encoder
Filter
Power switch
Power interface
Communication port

MTS Exceed™ 22 Series Product Information
20
Technical Specifications
Introduction
Technical Specifications
This section provides technical specifications of the main unit of MTS Exceed 22
series of metal pendulum impact testers and illustrates installation sizes of
accessories with graphics.
Note: Any changes of technical specifications will not be notified to you separately.
For any doubts, please contact MTS to confirm critical technical specifications.