MTS Systems Exceed 40 Series User manual

Manual Title
Additional Information
be certain.
Product Manual
MTS Exceed™ Series 40
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100-303-147 A

MTS Exceed™ Series 40 Product Manual
2
Copyright information ©2011 -2014 MTS Systems Corporation. All rights reserved.
Trademark information MTS and MTS Ex eed are registered trademarks of MTS Systems Corporation
within the United States. These trademarks may be prote ted in other ountries.
Proprietary information Software use and li ense is governed by MTS’ End User Li ense Agreement
whi h defines all rights retained by MTS and granted to the End User. All
Software is proprietary, onfidential, and owned by MTS Systems Corporation
and annot be opied, reprodu ed, disassembled, de ompiled, reverse
engineered, or distributed without express written onsent of MTS.
Software alidation and
erification
MTS software is developed using established quality pra ti es in a ordan e
with the requirements detailed in the ISO 9001 standards. Be ause MTS-
authored software is delivered in binary format, it is not user a essible. This
software will not hange over time. Many releases are written to be ba kwards
ompatible, reating another form of verifi ation.
The status and validity of MTS’ operating software is also he ked during
system verifi ation and routine alibration of MTS hardware. These ontrolled
alibration pro esses ompare the final test results after statisti al analysis
against the predi ted response of the alibration standards. With these established
methods, MTS assures its ustomers that MTS produ ts meet MTS’ exa ting
quality standards when initially installed and will ontinue to perform as intended
over time.
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MTS Exceed™ Series 40 Product Manual Contents
3
Contents
Technical Support 7
How to Get Te hni al Support 7
Before You Conta t MTS Servi e Representative 7
If You Conta t MTS by Phone 8
Preface 11
Before You Begin 11
Conventions 12
Do umentation Conventions 12
Safety 13
General Safety Pra ti es 13
Safety Pra ti es Before System Operation 14
Safety Pra ti es While the System Is in Operation 17
Hazard Labels 18
Introduction 21
About This Manual 21
Inappropriate Use 21
Des ription 22
Frame Controller 22
Software 22
Load Frame Components 24
Spe ifi ations 30
Common Spe ifi ations 31
Model Spe ifi ations 32
Dimensions 36
Installation 43
Frame Lo ation and Ventilation 44
Leveling the Load Frame 45
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MTS Exceed™ Series 40 Product Manual
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Contents
Leveling the Table-Top Load Frame 45
Leveling the Floor-Standing Load Frame 46
Controller Conne tions 47
Conne ting the Main Power 47
Installing Cables 48
A essory Mounting Dimensions 54
Model E42.503 A essory Mounting Dimensions 55
Model E43 .104A essory Mounting Dimensions 56
Model E44 A essory Mounting Dimensions 57
Model E45.105 A essory Mounting Dimensions 59
Model E45.305 A essory Mounting Dimensions 62
Model E45.605 A essory Mounting Dimensions 65
Operation 67
Main Power Swit h (I/O) and Emergen y-Stop 68
Setting Crosshead Travel Limits 69
Crush Zone Hazards 71
Fixture Mounting 72
Handset Control 73
Maintenance 75
Routine Maintenan e Overview Che klist 75
76
Other servi e 76
Trou leshooting 77
Decommissioning 79
Appendix 81
Additional Digital I/O Information 81
Maintenance and Service Logs 83
8 Hours/Daily 84
40 Hours/Weekly 85
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MTS Exceed™ Series 40 Product Manual Contents
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2000 Hours/Annual 86
PC Maintenan e and System Inspe tion 86
2000 Hours 87
System Che ks 87
2000 Hours 88
Lubri ation 88
2000 Hours 89
Frame and Work Area 89
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How to Get Technical Support
MTS Exceed™ Series 40 Product Manual Technical Support
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 in ludes software, look for
online help and README files that ontain additional produ t information.
If you annot find answers to your te hni al questions from these sour es, you
an use the Internet, e-mail, telephone, or fax to onta t MTS for assistan e.
Technical support
methods
MTS provides a full range of support servi es after your system is installed. If
you have any questions about a system or produ t, onta t Te hni al Support in
one of the following ways.
•Website:http://www.mts hina. om
•Tel:[phone]
•Fax:[phone]
Before You Contact MTS Service Representative
MTS an help you more effi iently if you have the following information
available when you onta t us for support.
Know your contact
num er and system
num er
The onta t number ontains your ompany number and identifies your
equipment type (su h as material testing or simulation). The number is typi ally
written on a label on your equipment before the system leaves MTS. If you do
not know your MTS onta t number, onta t your sales engineer.
When you have more than one MTS system, the system model number and series
number identifies your system. You an find your these number in your order
paperwork or dire tly on your equipment.
Identify the pro lem Des ribe the problem and know the answers to the following questions:
•How long and how often has the problem o urred?
•Can you reprodu e the problem?
•Were any hardware or software hanges made to the system before the
problem started?
•What are the equipment model numbers?
•What is the ontroller model (if appli able)?
•What is the system onfiguration?
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MTS Exceed™ Series 40 Product Manual
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If You Contact MTS y Phone
Technical Support
Know relevant
computer information
For a omputer problem, have the following information available:
•Manufa turer’s name and model number
•Operating software type and servi e pat h information
•Amount of system memory
•Amount of free spa e on the hard drive where the appli ation resides
•Current status of hard-drive fragmentation
•Conne tion status to a orporate network
Know relevant
software information
For software appli ation problems, have the following information available:
•The software appli ation’s name, version number, build number, and (if
available) software pat h number. This information an typi ally be found
in the About sele tion in the Help menu.
•The names of other appli ations on your omputer, su h as:
– Anti-virus software
– S reen savers
– Keyboard enhan ers
– Print spoolers
– Messaging appli ations
If You Contact MTS y Phone
A Call Center agent registers your all before onne ting you with a te hni al
support spe ialist. The agent asks you for your:
•Conta t number
•Name
•Company name
•Company address
•Phone number where you an be rea hed
If your issue has a notifi ation number, please provide that number. A new issue
will be assigned a unique notifi ation number.
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If You Contact MTS y Phone
MTS Exceed™ Series 40 Product Manual Technical Support
9
Identify system type To enable the Call Center agent to onne t you with the most qualified te hni al
support spe ialist available, identify your system as one of the following types:
•Ele trome hani al material test system
•Hydrome hani al material test system
•Vehi le test system
•Vehi le omponent test system
•Aero test system
Be prepared to
trou leshoot
Prepare to perform troubleshooting while on the phone:
•Call from a telephone lose to the system so that you an implement
suggestions made over the phone.
•Have the original operating and appli ation software media available.
•If you are not familiar with all aspe ts of the equipment operation, have an
experien ed user nearby to assist you.
Write down relevant
information
In ase Te hni al Support must all you:
•Verify the notifi ation number.
•Re ord the name of the person who helped you.
•Write down any spe ifi instru tions.
After you call MTS logs and tra ks all alls to ensure that you re eive assistan e for your
problem or request. If you have questions about the status of your problem or
have additional information to report, please onta t Te hni al Support again and
provide your original notifi ation number.
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Before You Begin
MTS Exceed™ Series 40 Product Manual Preface
11
Preface
Before You Begin
Safety first! Before you use your MTS produ t or system, read and understand the Safety
manual and any other safety information provided with your system. Improper
installation, operation, or maintenan e an result in hazardous onditions that an
ause severe personal injury or death, or damage to your equipment and
spe imen. Again, read and understand the safety information provided with your
system before you ontinue. 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 re eive additional manuals in paper or
ele troni form.
Manuals lo ated on the produ t information CD will ontain information that
pertains to your test system, su h as:
•Hydrauli and me hani al a essory manuals
•Assembly drawings
•Parts lists
•Operation instru tions
•Preventive maintenan e tasks
Controller and appli ation software manuals are typi ally in luded on the
software CD distribution dis (s).
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MTS Exceed™ Series 40 Product Manual
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Conventions
Preface
Conventions
Documentation Conventions
The following paragraphs des ribe some of the onventions that are used in your
MTS manuals.
Hazard conventions Hazard noti es may be embedded in this manual. These noti es ontain safety
information that is spe ifi to the a tivity to be performed. Hazard noti es
immediately pre ede the step or pro edure that may lead to an asso iated hazard.
Read all hazard noti es arefully and follow all dire tions and re ommendations.
Three different levels of hazard noti es may appear in your manuals. Following
are examples of all three levels.
Note Refer to “Safety” on page 13 for general safety information.
Danger noti es indi ate the presen e of a hazard with a high level of risk whi h,
if ignored, will result in death, severe personal injury, or substantial property
damage.
Warning noti es indi ate the presen e of a hazard with a medium level of risk
whi h, if ignored, can result in death, severe personal injury, or substantial
property damage.
Caution noti es indi ate the presen e of a hazard with a low level of risk whi h,
if ignored, could ause moderate or minor personal injury or equipment damage,
or ould endanger test integrity.
Notes Notes provide additional information about operating your system or highlight
easily overlooked items. For example:
Note Resources that are put back on the hardware lists show up at the end of the list.
Special terms The first o urren e of spe ial terms is shown in italics.
Illustrations Illustrations appear in this manual to larify text. They are examples only and do
not ne essarily represent your a tual system onfiguration, test appli ation, or
software.
Electronic manual
conventions
This manual is available as an ele troni do ument in the Portable Do ument
File (PDF) format. It an be viewed on any omputer that has Adobe A robat
Reader installed.
Hypertext links The ele troni do ument has many hypertext links displayed in a blue font. All
blue words in the body text, along with all ontents entries and index page
numbers, are hypertext links. When you li k a hypertext link, the appli ation
jumps to the orresponding topi .
DANGER
WARNING
CAUTION
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General Safety Practices
MTS Exceed™ Series 40 Product Manual Safety
13
Safety
General Safety Practices
This se tion provides information about safety issues that pertain to
ele trome hani al systems in general. These issues in lude statements to the
intended use and foreseeable misuse of the system, the hazard zone, definition for
the graphi al hazard labeling that is affixed to your produ t, and other (more
general) safety information that relates to the high-performan e hara teristi s of
MTS Ex eed ele trome hani al systems.
MTS Ex eed test systems are designed to generate motions and for es and impart
these motions and for es into a test spe imen.
When you prepare to operate the system and during system operation, ensure the
following:
•Do not use or allow personnel to operate the system who are not
experien ed, trained, or edu ated in the inherent dangers asso iated with
high-performan e ele trome hani al ma hines and who are not
experien ed, trained, or edu ated with regard to the intended operation as it
applies to this test system.
•Do not disable safety omponents or features (in luding limit dete tors,
light urtains, or proximity swit hes/dete tors).
•Do not attempt to operate the system without appropriate personal safety
gear (for example, hearing, hand, and eye prote tion).
•Do not use spe imens that are ombustible, flammable, pressurized, or
explosive.
•Whenever possible, use tongs or similar devi e to handle spe imens during
spe imen installation.
•Do not use humans as spe imens or allow humans to ride in or on the test
spe imen or the test system for any purpose unless the system is man-rated
and all asso iated safety onditions are stri tly enfor ed.
•Do not modify the system or repla e system omponents using parts that are
not MTS omponent parts or effe t repairs using parts or omponents that
are not manufa tured to MTS spe ifi ations.
•Do not operate the system in an explosive atmosphere.
• Do not use the system in a test area where un ontrolled a ess to the test
system is allowed when the system is in operation.
If you have system related responsibilities (that is, if you are an operator, servi e
engineer, or maintenan e person), you should study safety information arefully
before you attempt to perform any test system pro edure.
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MTS Exceed™ Series 40 Product Manual
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Safety Practices Before System Operation
Safety
You should re eive training on this system or a similar system to ensure a
thorough knowledge of your equipment and the safety issues that are asso iated
with its use. In addition, you should gain an understanding of system fun tions
by studying the other manuals supplied with your test system. Conta t MTS for
information about the ontent and dates of training lasses that are offered.
It is very important that you study the following safety information to ensure that
your fa ility pro edures and the system’s operating environment do not
ontribute to or result in a hazardous situation. Remember, you annot eliminate
all the hazards asso iated with this system, so you must learn and remain aware
of the hazards that apply to your system at all times. Use these safety guidelines
to help learn and identify hazards so that you an establish appropriate training
and operating pro edures and a quire appropriate safety equipment (su h as
gloves, goggles, and hearing prote tion).
Ea h test system operates within a unique environment whi h in ludes the
following known variables:
•Fa ility variables (fa ility variables in lude the stru ture, atmosphere, and
utilities)
•Unauthorized ustomer modifi ations to the equipment
•Operator experien e and spe ialization
•Test spe imens
Be ause of these variables (and the possibility of others), your system an
operate under unforeseen ir umstan es that an result in an operating
environment with unknown hazards.
Improper installation, operation, or maintenan e of your system an result in
hazardous onditions that an ause death, personal injury, or damage to the
equipment or to the spe imen. Common sense and a thorough knowledge of the
system’s operating apabilities an help to determine an appropriate and safe
approa h to its operation.
Safety Practices Before System Operation
Before you apply power to the test system, review and omplete all of the safety
pra ti es that are appli able to your system. The goal, by doing this, is to
improve the safety awareness of all personnel involved with the system and to
maintain, through visual inspe tions, the integrity of spe ifi system
omponents.
Read all manuals Study the ontents of this manual and the other manuals provided with your
system before attempting to perform any system fun tion for the first time.
Pro edures that seem relatively simple or intuitively obvious an require a
omplete understanding of system operation to avoid unsafe or dangerous
situations.
Locate and read hazard
placards/labels
Find, read, and follow the hazard pla ard instru tions lo ated on the equipment.
These pla ards are pla ed strategi ally on the equipment to all attention to areas
su h as known rush points and ele tri al voltage hazards.
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Safety Practices Before System Operation
MTS Exceed™ Series 40 Product Manual Safety
15
Locate lockout/tagout
points
Know where the lo kout/tagout point is for all of the supply energies asso iated
with your system. This in ludes the hydrauli , pneumati , ele tri , and water
supplies (as appropriate) for your system to ensure that the system is isolated
from these energies when required.
Know facility safe
procedures
Most fa ilities have internal pro edures and rules regarding safe pra ti es within
the fa ility. Be aware of these safe pra ti es and in orporate them into your daily
operation of the system.
Locate Emergency Stop
buttons
Know the lo ation of all the system Emergency Stop buttons so that you an
stop the system qui kly in an emergen y. Ensure that an Emergency Stop button
is lo ated within 2 meters (6 feet) of the operator at all times.
Know controls Before you operate the system for the first time, make a trial run through the
operating pro edures with the power off. Lo ate all hardware and software
ontrols and know what their fun tions are and what adjustments they require. If
any ontrol fun tion or operating adjustment is not lear, review the appli able
information until you understand it thoroughly.
Ha e first aid a ailable A idents an happen even when you are areful. Arrange your operator
s hedules so that a properly trained person is always lose by to render first aid.
In addition, ensure that lo al emergen y onta t information is posted learly and
in sight of the system operator.
Know potential crush
and pinch points
Be aware of potential rush and pin h points on your system and keep personnel
and equipment lear of these areas.
Know electrical hazards When the system ele tri al power is turned on, minimize the potential for
ele tri al sho k hazards. Wear lothing and use tools that are properly insulated
for ele tri al work. Avoid onta t with exposed wiring or swit h onta ts.
Whenever possible, turn off ele tri al power when you work on or in proximity
to any ele tri al system omponent. Observe the same pre autions as those given
for any other high-voltage ma hinery.
Keep bystanders safely
away
Keep bystanders at a safe distan e from all equipment. Never allow bystanders to
tou h spe imens or equipment while the test is running.
Wear proper clothing Do not wear ne kties, shop aprons, loose lothing or jewelry, or long hair that
ould get aught in equipment and result in an injury. Remove loose lothing or
jewelry and restrain long hair.
Remo e flammable
fluids from test specimen
Remove flammable fluids from their ontainers or from omponents before you
install the ontainer or omponent in a test system. If desired, you an repla e the
flammable fluid with a non-flammable fluid to maintain the proper proportion of
weight and balan e.
Check bolt ratings and
torques
To ensure a reliable produ t, fasteners (su h as bolts and tie rods) used in MTS
manufa tured systems are torqued to spe ifi requirements. Over torquing or
under torquing a fastener an reate a hazardous situation due to the high for es
and pressures present in MTS test systems.
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MTS Exceed™ Series 40 Product Manual
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Safety Practices Before System Operation
Safety
On rare o asions, a fastener an fail even when it is orre tly installed. Failure
usually o urs during torquing, but it an o ur several days later. Failure of a
fastener an result in a high velo ity proje tile. Therefore, it is a good pra ti e to
avoid stationing personnel in line with or below assemblies that ontain large or
long fasteners.
Practice good
housekeeping
Keep the floors in the work area lean. Do not leave tools, fixtures, or other items
not spe ifi to the test, lying about on the floor, system, or de king.
Protect hoses and
cables
Prote t ele tri al ables from ex essive temperatures that an ause the ables to
harden and eventually fail. Ensure that all ables have appropriate strain relief
devi es installed at the able and near the onne tor plug. Do not use the
onne tor plug as a strain relief.
Prote t all system hoses and ables from sharp or abrasive obje ts that an ause
the hose or able to fail. Never walk on hoses or ables or move heavy obje ts
over them. Consider system layout and route hoses and ables away from areas
that expose them to possible damage.
When removing hydrauli hoses for equipment repair or hanging testing
omponents (for example, hydrauli grips), make sure to ap the hose ends to
avoid spilling hydrauli fluid.
Record changes If you hange any operating pro edure, write the hange and the date of the
hange in the appropriate manual.
Pro ide test area guards Use prote tive guards su h as ages, en losures, and spe ial laboratory layouts
when you work with hazardous test spe imens (for example, brittle or
fragmenting materials or materials that are internally pressurized).
Do not disable safety
de ices
Your system might have a tive or passive safety devi es installed to prevent
system operation if the devi e indi ates an unsafe ondition. Do not disable su h
devi es as it an result in unexpe ted system motion.
Use appropriately sized
fuses
Whenever you repla e fuses for the system or supply, ensure that you use a fuse
that is appropriately sized and orre tly installed. Undersized or oversized fuses
an result in ables that overheat and fuses that explode. Either instan e reates a
fire hazard.
Pro ide adequate
lighting
Ensure adequate lighting to minimize the han e of operation errors, equipment
damage, and personal injury. You need to see what you are doing.
Pro ide means to
access out-of-reach
components
Make sure you an a ess system omponents that might be out of rea h while
standing on the floor. For example, ladders or s affolding might be required to
rea h load ell onne tors on tall load units.
Ensure equipment is
secure
Make sure the equipment is se ure or provide vibration isolation. Some testing
an be performed at resonant frequen ies that might ause the equipment to
vibrate and move during testing.
Perodically run
consistancy checks
Pressing the Emergency-Stop button auses the system to automati ally run a
onsisten y he k. The Emergency-Stop button should be pressed o asionally
to run the onstan y he k.
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Safety Practices While the System Is in Operation
MTS Exceed™ Series 40 Product Manual Safety
17
Safety Practices While the System Is in Operation
Wear appropriate
personal protection
Wear eye prote tion when you work with ele trome hani al testing ma hines,
breakable spe imens, or when anything hara teristi to the spe imen ould
break apart.
Wear ear prote tion when you work near ele tri motors, pumps, or other devi es
that generate high noise levels. Some systems an reate sound pressure levels
that ex eed 70 dbA during operation.
Wear appropriate personal prote tion equipment (gloves, boots, suits, respirators)
whenever you work with fluids, hemi als, or powders that an irritate or harm
the skin, respiratory system, or eyes.
Pro ide test area guards Use prote tive guards su h as ages, en losures, and spe ial laboratory layouts
when you work with hazardous test spe imens (for example, brittle or
fragmenting materials or materials that are internally pressurized).
Expect specimen
temperature changes
During y li testing, the spe imen temperature an be ome hot enough to ause
burns. Wear personal prote tion equipment (gloves) when handling spe imens.
Handle chemicals safely Whenever you use or handle hemi als (for example, leaning fluids, hydrauli
fluid, batteries, ontaminated parts, ele tri al fluids, and maintenan e waste),
refer to the appropriate MSDS do umentation for that material and determine the
appropriate measures and equipment required to handle and use the hemi al
safely. Ensure that the hemi al is disposed of appropriately.
Know system interlocks Interlo k devi es should always be used and properly adjusted. Interlo k devi es
are designed to minimize the han e of a idental damage to the test spe imen or
the equipment. Test all interlo k devi es for proper operation immediately before
a test. Do not disable or bypass any interlo k devi es as doing so ould allow
rosshead movement regardless of the true interlo k ondition.
Know system limits Never rely on system limits, su h as me hani al limits or software limits, to
prote t you or any personnel. System limits are designed to minimize the han e
of a idental damage to test spe imens or to equipment. Test all limits for proper
operation immediately before a test. Always use these limits and adjust them
properly.
Do not disturb sensors Do not bump, wiggle, adjust, dis onne t, or otherwise disturb a sensor (su h as
an a elerometer or extensometer) or its onne ting able when power is applied.
Ensure secure cables Do not hange any able onne tions when ele tri al power is applied. If you
attempt to hange a able onne tion while the system is in operation, an open
ontrol loop ondition an result. An open ontrol loop ondition an ause a
rapid, unexpe ted system response whi h an result in severe personal injury,
death, or damage to equipment. Also, ensure that all ables are onne ted after
you make any hanges in the system onfiguration.
Stay alert Avoid long periods of work without adequate rest. In addition, avoid long periods
of repetitious, unvarying, or monotonous work be ause these onditions an
ontribute to a idents and hazardous situations. If you are too familiar with the
work environment, it is easy to overlook potential hazards that exist in that
environment.
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MTS Exceed™ Series 40 Product Manual
18
Hazard La els
Safety
Stay clear of mo ing
equipment/a oid crush
points
Stay lear of me hani al linkages, onne ting ables, and hoses that move
be ause you an get pin hed, rushed, tangled, or dragged along with the
equipment. High for es generated by the system an pin h, ut, or rush anything
in the path of the equipment and ause serious injury. Stay lear of any potential
rush points. Most test systems an produ e sudden, high-for e motion. Never
assume that your rea tions are fast enough to allow you to es ape injury when a
system fails.
Know the causes of
unexpected crosshead
motions
The high for e and velo ity apabilities of MTS systems an be destru tive and
dangerous (espe ially if rosshead motion is unexpe ted). The most likely auses
of unexpe ted rosshead response are operator error and equipment failure due to
damage or abuse (su h as broken, ut, or rushed ables and hoses; shorted wires;
overstressed feedba k devi es; and damaged omponents within the ontrol
loop). Eliminate any ondition that ould ause unexpe ted rosshead motion.
Do not use RF
transmitters
Keep radio frequen y (RF) transmitters away from the workstation omputers,
remote terminals, and ele troni s onsoles. Intense RF fields an ause errati
operation of the more sensitive ir uits in the system.
Hazard La els
The following hazard labels and i ons are lo ated on the test frame.
L ABEL D ESCRIPTION
Lift the machine upright.
Moving parts present.
Moving parts can crush and cut.
Keep hands away from moving parts.
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Hazard La els
MTS Exceed™ Series 40 Product Manual Safety
19
WEEE The Waste Ele tri al and Ele troni Equipment (WEEE) symbol ( ) means
that the ontroller and its ele troni parts must not be disposed of as unsorted
muni ipal waste. Proper disposal is required by approved ele troni waste
olle tion agen ies. Customers in the EC region who desire to return an end-of-
life ontroller and its ele troni parts are en ouraged to onta t your lo al MTS
Systems Sales/Servi e Offi es for instru tions.
Flying o jects.
Danger of eye injury.
Wear safety glasses.
Tip over hazard.
Use outriggers when machine is standalone.
Do not start, operate, or service machine
until you read and understand the operator’s
manual.
Failure to do so could result in serious injury.
There are no customer-servicea le parts on
the MTS Exceed electromechanical frames.
L ABEL D ESCRIPTION
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