MTS 244 User Manual

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Series 244 Actuators Product Information

Models 244.11, 244.12, 244.20, 244.21, 244.22, 244.23,

244.31, 244.41, 244.51

011-551-304 G be certain.

Original Instructions (English): 011-551-304 G

Trademark Information

MTS, be certain., Bionix, ElastomerExpress, FlatTrac, FlexTest, Just In Case, LevelPlus, MTS Criterion, MTS EM Extend, MTS Insight, MTS Landmark, RPC, ServoSensor, SWIFT, Temposonics, TestWare, TestWorks are registered trademarks of MTS Systems Corporation within the United States. Acumen, Advantage, Aero ST, Aero-90, AeroPro, Criterion, CRPC, Echo, Flat-Trac, Landmark, MAST, MicroProfiler, MPT, MTS Acumen, MTS Echo, MTS Fundamentals, MTS TestSuite, ReNew, SilentFlo, TempoGuard, TestLine, and Tytron are trademarks of MTS Systems Corporation within the United States. These trademarks may be registered in other countries. All other trademarks are property of their respective owners.

Proprietary Software

Software use and license is governed by the MTS 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 the MTS 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 exacting quality standards when initially installed and will continue to perform as intended over time.

Manual Part Number—Publication Date—Release

011-551-304 G—October 2013 011-551-304 F—September 2008 011-551-304 E—July 2008 011-551-304 D—June 2002 011-551-304 C—May 2000 011-551-304 B—November 1998 011-551-304 A—September 1996 011-551-303 G—June 1994 011-551-303 F—July 1993 011-551-303 E—November 1991 011-551-303 D—June 1990 011-551-303 C—February 1989 011-551-303 B—February 1988 011-551-303 A—June 1987 011-551-302 A—September 1984 011-551-301 A—August 1983 011-551-300 A—December 1982

Contents

Technical Support 5

Preface 9

Introduction 13

How to Get Technical Support.................................................................................................................5

Before You Contact MTS.........................................................................................................................5

If You Contact MTS by Phone.................................................................................................................7

Problem Submittal Form in MTS Manuals..............................................................................................8

Before You Begin.....................................................................................................................................9

Documentation Conventions....................................................................................................................9

About the 244 Series Actuator...............................................................................................................14

What You Need to Know.......................................................................................................................14

Component Identication.......................................................................................................................15

Functional Description...........................................................................................................................17

About Actuator Mounting..........................................................................................................18

Actuator Operation.....................................................................................................................19

LVDT Operation.........................................................................................................................19

Specications.........................................................................................................................................20

Force Ratings..............................................................................................................................20

Environmental and Hydraulic Fluid Recommendations........................................................................21

Dimensions.............................................................................................................................................23

LVDT Housing Specications...............................................................................................................26

Pedestal Base Specications..................................................................................................................29

Safety 31

General Safety Practices: Hydraulic Power Units and Hydraulic Service Manifolds............................32

Safety Practices Before Operating the System.......................................................................................33

Safety Practices While Operating the System .......................................................................................37

Hazard Placard Placement......................................................................................................................38

Labels And Icons........................................................................................................................39

Warning Label................................................................................................................39

Caution Label.................................................................................................................40

Attached Mass Warning Label.......................................................................................40

Hydraulic Actuator ID Tag.............................................................................................41

Pressure Icon Label........................................................................................................42

Pressure Rating Label.....................................................................................................42

Lift Hole Thread Size.....................................................................................................43

Series 244 Actuators Product Information 3

Installation 45

About Installation...................................................................................................................................46

Load Units..............................................................................................................................................46

Installing a Fixture to the Actuator.........................................................................................................47

Mounting Bolt Specications.....................................................................................................48

Spiral Washers........................................................................................................................................50

Installing Fixtures with Spiral Washers..................................................................................................51

Multiple Fixtures With Different Ratings..................................................................................51

Removing Fixtures with Spiral Washers................................................................................................53

Multiple Fixtures With Different Ratings..................................................................................54

LVDT Cable Connection........................................................................................................................54

Hydraulic Connections...........................................................................................................................55

Operation 57

About Operation.....................................................................................................................................58

Actuator ID.............................................................................................................................................58

Operating Considerations.......................................................................................................................58

Sideload Forces..........................................................................................................................59

Sideload Calculation Procedure.............................................................................................................59

Sample Calculation.................................................................................................................................62

Maintenance 65

Maintenance Recommendations.............................................................................................................66

4 Series 244 Actuators Product Information

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.

Web site

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

www.mts.com > Contact Us (upper-right corner) > In the Subject field, choose To escalate a problem; Problem Submittal Form

Worldwide: tech.support@mts.comE-mail

Europe: techsupport.europe@mts.com

Worldwide: 1 800 328 2255 - toll free in U.S.; +1 952 937 4000 - outside U.S.Telephone

Europe: +800 81002 222, International toll free in Europe

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 number and system number

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

Series 244 Actuators Product Information 5

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

Know information from prior technical assistance

If you have contacted MTS about this problem before, we can recall your file based on the:

• MTS notification number

• Name of the person who helped you

Identify the problem

Describe the problem and know the answers to the following questions:

• How long and how often has the problem occurred?

• Can you reproduce the problem?

• Were any hardware or software changes made to the system before the problem started?

• What are the equipment model numbers?

• What is the controller model (if applicable)?

• What is the system configuration?

Know relevant computer information

For a computer problem, have the following information available:

• Manufacturer’s name and model number

• Operating software type and service patch information

• Amount of system memory

• Amount of free space on the hard drive where the application resides

• Current status of hard-drive fragmentation

• Connection status to a corporate network

Know relevant software information

For software application problems, have the following information available:

• The 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.

• The names of other applications on your computer, such as:

• Anti-virus software

• Screen savers

• Keyboard enhancers

• Print spoolers

• Messaging applications

6 Series 244 Actuators Product Information

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:

• Site number

• Name

• Company name

• Company address

• Phone number where you can be reached

If your issue has a notification number, please provide that number. A new issue will be assigned a unique notification 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:

• Electrodynamic material test system

• Electromechanical material test system

• Hydromechanical material test system

• Vehicle test system

• Vehicle component test system

• Aero test system

Be prepared to troubleshoot

Prepare to perform troubleshooting while on the phone:

• Call from a telephone close to the system so that you can implement suggestions made over the phone.

• Have the original operating and application software media available.

• If 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:

• Verify the notification number.

• Record the name of the person who helped you.

• Write down any specific instructions.

Series 244 Actuators Product Information 7

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 notification 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

8 Series 244 Actuators Product Information

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. 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.

Series 244 Actuators Product Information 9

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.

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.

10 Series 244 Actuators Product Information

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.

Series 244 Actuators Product Information 11

Introduction

Topics:

•

About the 244 Series Actuator...............................................................................................................14

•

What You Need to Know........................................................................................................................14

•

Component Identification.......................................................................................................................15

•

Functional Description...........................................................................................................................17

•

Specifications.........................................................................................................................................20

•

Environmental and Hydraulic Fluid Recommendations.........................................................................21

•

Dimensions............................................................................................................................................23

•

LVDT Housing Specifications................................................................................................................26

•

Pedestal Base Specifications................................................................................................................29

Series 244 Actuators Product Information 13

Introduction

About the 244 Series Actuator

The Series 244 Actuator is a hydraulically powered device that provides displacement of (or forces into) a specimen or structure for testing.

What You Need to Know

MTS Systems Corporation assumes that you know how to use your controller. See the appropriate manual for information about performing any controller-related step in this manual’s procedure. You are expected to know how to perform the following procedures:

• Turn hydraulic pressure on and off.

• Select a control mode.

• Manually adjust the actuator position.

• Install a specimen.

• Define a simple test.

• Run a test.

14 Series 244 Actuators Product Information

Component Identification

Introduction

Series 244 Actuators Product Information 15

Introduction

Series 244 Hydraulic Actuator Major Components

DescriptionComponentItem

Piston rod end1

Bearing2

Cushion3

Extension Port/ Retraction Port

Piston seal5

The piston rod has a hardened steel insert that provides an internal thread for mounting load cells, swivels, and interface fixtures. The Model 244.51 Actuator has no insert; internal threads are machined directly into the piston rod end.

The high-capacity nonmetallic bearings bond directly to the end caps. The non-metallic bearings are standard because of their high side-load tolerance and resistance to failure from galling and seizure.

The cushions protect the actuator from the effects of high-speed and high-mass forces. They prevent the actuator from contacting the end caps. The Model 244.41 and 244.51 Actuators do not have hydraulic cushions.

High-pressure hydraulic fluid enters the cylinder through one of these control ports. As pressure is applied to one port, the other port is opened to a return line causing the actuator to extend or to retract. Fluid flow through these ports is controlled by the servovalve.

A reinforced Teflon seal (if equipped) on the piston provides a positive seal and reduces friction. Grooves on the piston lubricate the piston surface during short-stroke, side-loaded tests. For high-speed cyclic testing applications, the piston seal can be omitted. The close tolerance fit provides an effective viscous seal.

Piston rod6

Drainback Port7

High/Low Pressure Seals

The Series 244 Actuator is equipped with a double-ended piston rod. The double-ended piston has equal areas on both sides for balanced performance. It is machined from a single piece of heat-treated alloy steel and is hard-chrome plated. The piston rod is hollow to allow for installation and accurate alignment of a displacement transducer.

The drainback port allows fluid that manages to leak past the seals to be routed out of the actuator which prevents pressure pockets from interfering with actuator performance.

The piston rod seals consist of a high-pressure seal and a low-pressure/wiper seal in both the front end cap and the rear end cap.

Model 244.1x and 244.2x Actuators [with force ratings under 100 kN (22 kip)], that are used in load frame/unit applications do not contain high-pressure piston rod seals.

The high-pressure seal is designed for long life, low friction, and exceptional performance in high-frequency, low-displacement applications. A small amount of hydraulic fluid is allowed to flow past the high-pressure seal for continuous bearing lubrication. Drainback ports return the

16 Series 244 Actuators Product Information

DescriptionComponentItem

hydraulic fluid passed by the high-pressure seal back to the system hydraulic power supply.

The inner part of the low-pressure/wiper seal provides a hydraulic seal, while the outer part of the seal functions as a scraper ring to minimize external contamination of the seals and bearings. When a high-pressure seal is present, the inner part of the low-pressure seal wipes hydraulic fluid that gets by the high-pressure seal and guides the fluid into the drainback port.

Functional Description

The Series 244 Actuator is a double-acting, double-ended, heavy-duty actuator that operates under precision servovalve control in MTS closed-loop servohydraulic systems. The actuator is a hydraulically powered piston that can extend or retract (double-acting). The actuator provides displacement of (or force into) a specimen or structure for testing. It can also provide equal power in tension and compression (double-ended). The actuator includes an LVDT which measures the displacement of the actuator.

Introduction

The Series 244 Actuator is linear and is associated with axial control channels. A linear actuator consists of a cylinder that contains a piston.

The Series 244 Actuator is designed to accept a wide variety of options and accessories including force and displacement transducers, pedestal bases, swivel rod ends, and swivel bases. When equipped with the appropriate options and accessories, the actuator can be configured for precision testing of materials, structures, and components.

Series 244 Actuators Product Information 17

Introduction

Functional Diagram

DescriptionItem

LVDT Core Mount1

LVDT Core Extension2

LVDT Coil3

LVDT Connector4

Extension Port5

Retraction Port6

About Actuator Mounting

The actuator can be mounted to a wide variety of fixtures and assemblies:

• Component test systems usually have one end of the actuator connected to a custom test frame base and the other end connected to the test specimen. Either end of the actuator may use mounting fixtures (such as swivels) to attach it to the specimen or base.

18 Series 244 Actuators Product Information

• Material test systems usually mount the actuator in a load unit assembly. The actuator can be mounted below the base plate or above the crosshead. The end of the actuator uses fixtures (such as grips) to attach the test specimen to it.

Actuator Operation

Actuator piston rod movement is accomplished by supplying high- pressure hydraulic fluid to one side of the actuator piston and opening the other side to a return line. High-pressure hydraulic fluid is ported into the cylinder through the retraction port or the extension port. The differential pressure across the piston forces the piston rod to move. The amount of hydraulic fluid and the speed and direction of piston rod movement is controlled by a servovalve.

If the piston rod contacts some external reaction point, then a force is applied to that point equal to the effective piston area times the actuating pressure. The main criteria for selecting an actuator are the force and stroke (displacement) required for the job.

LVDT Operation

The internally mounted LVDT (linear variable differential transformer) provides an indication of the actuator piston rod displacement.

Introduction

Series 244 Actuators Product Information 19

Introduction

LVDT Components

DescriptionItem

Locking Setscrew1

Core Mount Setscrew2

LVDT Core Extension3

Hollow Piston Rod4

LVDT Coil5

Locking Collar6

Pedestal Base7

LVDT Connector8

The LVDT is an electromechanical device that provides an output voltage which is proportional to the displacement of a moveable core extension. The core extension is mounted inside the hollow piston rod and moves as the piston rod moves. The LVDT coil is secured to the pedestal base by a locking collar. The core extension is positioned in the LVDT coil to provide a zero reference point, and is locked in place with a locking setscrew.

As the piston rod moves during operation, the output voltage from the LVDT indicates how far the piston rod has moved from the zero reference point.

Specifications

Several types of specifications are listed on the following pages. All specifications are subject to change without notice. Contact MTS for verification of specifications critical to your needs.

Force Ratings

The following table lists the force rating of each actuator model. The rod diameter and effective piston area specifications are used in the “Operating Considerations.”

Actuator Specifications (Metric)

Model

Number

Force Rating

Rod Diameter

Effective Piston Area

7.5044.515244.11

Nominal force achieved with 21 MPa (3000 psi) hydraulic pressure.

20 Series 244 Actuators Product Information

13.5044.525244.12

Introduction

Model

Number

Model

Number

Force Rating

Actuator Specifications (U.S. Customary)

Force Rating

Kip

Rod Diameter

Effective Piston Area

33.6869.968244.20

25.1669.950244.21

48.8469.9100244.22

82.1369.9160244.23

126.6595.3250244.31

248.28133.4500244.41

487.70152.41000244.51

Effective Piston Area

Environmental and Hydraulic Fluid Recommendations

1.171.753.3244.11

2.101.755.5244.12

5.222.7515.0244.20

3.902.7511.0244.21

7.572.7522.0244.22

12.732.7535.0244.23

19.633.7555.0244.31

38.485.25110.0244.41

75.606.00220.0244.51

For use in a controlled environment.Environmental

Nominal force achieved with 21 MPa (3000 psi) hydraulic pressure.

Series 244 Actuators Product Information 21

Introduction

5–40°C (41–104°F)Operating temperature

0–85% noncondensingHumidity

< 630 kcal/hr (2500 Btu/hr)Heat load

63 dB (A) fully compensatedNoise3rating at 1 m

Exxon Mobil DTE 25 or Shell Tellus 46 AWHydraulic fluid

43–49°C (110–120°F)Typical operating temperature range

3 microns nominalFiltration (microns)

Sound pressure level [db (A)] is expressed as a free field value. Readings may vary with the acoustic environment.

22 Series 244 Actuators Product Information

Dimensions

Introduction

Series 244 Actuators Product Information 23

Introduction

Actuator Dimensions

DescriptionItem

BASIC CYLINDER1

FRONT END CAP2

REAR END CAP3

A (Cushion)4

Stroke Length5

C min.6

B+ Stroke Length7

-6 Drain8

Rod Insert: “M” thread size, “N” deep9

Structural10

Load Frame11

“D” holes, “E” thread size, “F” deep, equally spaced on a “G” diameter12

4 holes, “H” thread size, “F” deep, equally spaced on an “L” diameter13

8 holes, “H” thread size, “K” deep, spaced as shown on an “L” diameter14

Each dimension shown in this figure is listed in the table that follows.

Actuator Dimensions (SI Metric)

ModelItem

244.51244.41244.31244.23244.22244.21244.20244.12244.11Units

nonenone5.16.47.610.210.215.215.2mmA

342.6311.6256.5233.7233.7246.4246.4238.3238.3mmB

38.128.425.425.425.425.425.425.425.4mmC

This area includes a fully retracted standard length piston rod.

Load unit actuators have four mounting holes; structural actuators have two mounting holes.

24 Series 244 Actuators Product Information

88888882 or 42 or 4holes

1 - 81 - 85/8 - 111/2 - 131/2 - 131/2 - 131/2 - 133/8 - 163/8 - 16UNCE

Introduction

ModelItem

244.51244.41244.31244.23244.22244.21244.20244.12244.11Units

44.544.525.419.119.119.119.119.119.1mmF

263.4263.4139.7104.1104.1104.1104.181.381.3mmG

1 - 87/8 - 97/8 - 95/8 - 115/8 - 115/8 - 115/8 - 113/8 - 163/8 - 16UNCH

44.538.138.125.425.425.425.419.119.1mmK

280.9254.0191.3127.0127.0127.0127.088.988.9mmL

2 - 1212/2 - 121 - 141 - 141 - 141 - 141/2 - 201/2 - 20UNSM

3 - 12

mmM

M12 x

1.25

M76 x 2M52 x 2M36 x 2M27 x 2M27 x 2M27 x 2M27 x 2M12 x

114.33129.8106.250.376.776.776.744.544.5mmN

387.4298.5215.9165.1152.4139.7127.0101.6101.6mmP

Actuator Dimensions (U.S. Customary)

ModelItem

244.51244.41244.31244.23244.22244.21244.20244.12244.11Units

nonenone0.200.250.300.400.400.600.60in.A

13.4912.2710.109.209.209.709.709.389.38in.B

1.501.121.001.001.001.001.001.001.00in.C

88888882 or 42 or 4holes

Does not use a threaded rod insert

Does not use a threaded rod insert.

From end of piston rod to bottom of internal threads.

This area includes a fully retracted standard length piston rod.

Load unit actuators have four mounting holes; structural actuators have two mounting holes.

Series 244 Actuators Product Information 25

1 - 81 - 85/8 - 111/2 - 131/2 - 131/2 - 131/2 - 133/8 - 163/8 - 16UNCE

1.751.751.000.750.750.750.750.750.75in.F

10.3710.375.504.104.104.104.103.203.20in.G

1 - 87/8 - 97/8 - 95/8 - 115/8 - 115/8 - 115/8 - 113/8 - 163/8 - 16UNCH

Introduction

ModelItem

LVDT Housing Specifications

244.51244.41244.31244.23244.22244.21244.20244.12244.11Units

1.751.501.501.001.001.001.000.750.75in.K

11.0610.007.535.005.005.005.003.503.50in.L

3 - 122 - 1212/2 - 121 - 141 - 141 - 141 - 141/2 - 201/2 - 20UNSM

5.114.181.983.023.023.021.751.75in.N

4.50

15.2511.758.506.506.005.505.004.004.00in.P

Does not use a threaded rod insert.

From end of piston rod to bottom of internal threads.

26 Series 244 Actuators Product Information

Open LVDT Housing

DescriptionItem

Cushion1

Stroke Length2

A min.3

68.6 mm (2.70 in) +Stroke Length4

Rear End Cap LVDT Mounting5

4 holes, “B” thread size, “C” deep, spaced as shown6

2 holes, “B” thread size, “C” deep, spaced as shown7

Open Housing LVDT Specifications For Extra Piston Length*

Introduction

Model

1415161718

†,‡

DCBA

Weight

lbkginmminmmUNCinmm

3917.7N/AN/A0.7519.13/8-165.90149.9244.11

4118.6N/AN/A0.7519.13/8-165.90149.9244.12

7.07179.6244.21

7.07179.6244.20

7.07179.6244.22

7.07179.6244.23

12255.3N/AN/A1.0025.43/8-16

12657.1N/AN/A1.0025.43/8-16

13360.3N/AN/A1.0025.43/8-16

15168.5N/AN/A1.0025.43/8-16

282127.93.0677.70.6015.23/8-168.85224.8244.31

645292.63.96100.60.6015.23/8-169.25234.9244.41

1135514.83.96100.60.6015.23/8-169.82249.4244.51

* Specifications not listed in this table can be found in the table called “Dimensions.”

† This specification applies to a fully retracted standard extra length piston rod.

‡ Optional rod lengths are available for crosshead actuator mounting or other special mounting configurations.

§ For a 152 mm (6 in) stroke basic load frame/load unit cylinder assembly and open housing LVDT.

# Requires 5/8-11 to 3/8-16 insert thread (supplied on open housing LVDT assembly).

Series 244 Actuators Product Information 27

Introduction

Closed LVDT Housing

DescriptionItem

Stroke + A1

Spiral Washers or Adapter2

Model

1920212223

Closed Housing LVDT3

Closed Housing LVDT Specifications*

†

Weight

mminmm

3.1880.8244.11

3.1880.8244.12

2.7670.2244.21

2.7670.2244.20

––––

‡

lbkgin

4319.5––––

4520.4––––

12456.2––––

12858.1––––

13561.21.0426.42.7670.2244.22

15369.41.0426.42.7670.2244.23

295133.81.3033.02.3669.9244.31

1.9649.8244.41

0.389.6244.51

92.0

712322.93.62

1307592.84.00 5101.6

* Specifications not listed in this table can be found in the table called “Dimensions.”

† Refers to the length of the closed housing LVDT assembly.

‡ For a 152 mm (6 in) stroke basic load frame/load unit cylinder assembly and open housing LVDT.

§ Do not require spiral washers or an adapter

# Use an adapter instead of spiral washers.

28 Series 244 Actuators Product Information

Pedestal Base Specifications

Introduction

Pedestal Base Specifications

WeightDCBAModel

inmminmmin

lbkginmm

5.95.50139.74.50114.30.5614.21.5038.1244.11

135.95.50139.74.50114.30.5614.21.5038.1244.12

2712.27.38187.45.75146.00.6817.31.7544.4244.21

2712.27.38187.45.75146.00.6817.31.7544.4244.20

2712.27.38187.45.75146.00.6817.31.7544.4244.22

2712.27.38187.45.75146.00.6817.31.7544.4244.23

5826.39.00228.67.25184.20.9423.92.5063.5244.31

13762.113.88352.611.00279.41.3133.32.5063.5244.41

16574.814.00355.611.00279.41.5639.63.0076.2244.51

Series 244 Actuators Product Information 29

Safety

Topics:

•

General Safety Practices: Hydraulic Power Units and Hydraulic Service Manifolds.............................32

•

Safety Practices Before Operating the System.....................................................................................33

•

Safety Practices While Operating the System ......................................................................................37

•

Hazard Placard Placement....................................................................................................................38

Series 244 Actuators Product Information 31

Safety

General Safety Practices: Hydraulic Power Units and Hydraulic Service Manifolds

The hydraulic power unit (HPU) provides high pressure hydraulic fluid to system components for system operation. The hydraulic service manifold (HSM) controls distribution of that hydraulic fluid pressure. This section provides general information about safety issues that pertain to system hydraulic supply and distribution components. These issues include statements to the intended use and foreseeable misuse of the system and 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 high-performance characteristics of MTS servohydraulic and electromechanical systems.

When you prepare to operate a system that includes hydraulic components, ensure the following:

• Do not use or allow personnel to operate the system who are not experienced, trained, or educated in the inherent dangers associated with high-performance servo hydraulics and who are not experienced, trained, or educated with regard to the intended operation as it applies to this test system.

• Do not disable safety components or features (including limit detectors, light curtains, or proximity switches/detectors).

• Do not attempt to operate the system without appropriate personal safety gear (for example, hearing, hand, and eye protection).

• Do not modify the system or replace system components using parts that are not MTS component parts or effect repairs using parts or components that are not manufactured to MTS specifications.

• Do not use the system in a test area where uncontrolled access to the test system is allowed when the system is in operation.

• For servohydraulic systems, do not operate the system unless an interlock is installed to monitor supply pressure into the HSM and initiate a system interlock if a low or no pressure event occurs.

• Mists of DTE 25 are combustible. Refer to MSDS. Customer is responsible for fire prevention measures as per facility or building or other local regulations and codes

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. In addition, you should gain an understanding of system functions by studying the other manuals supplied with your test system. Contact MTS for information about the content and dates of training classes that are offered.

It is very important that you study the following safety information to ensure that your facility procedures and the system’s operating environment do not contribute to or result in a hazardous situation. Remember, you cannot eliminate all the hazards associated 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 can establish appropriate training and operating procedures and acquire appropriate safety equipment (such as gloves, goggles, and hearing protection).

Each test system operates within a unique environment which includes the following known variables:

• Facility variables (facility variables include the structure, atmosphere, and utilities)

• Unauthorized customer modifications to the equipment

• Operator experience and specialization

32 Series 244 Actuators Product Information

• Test specimens

Because of these variables (and the possibility of others), your system can operate under unforeseen circumstances that can result in an operating environment with unknown hazards.

Improper installation, operation, or maintenance of your system can result in hazardous conditions that can cause death, personal injury, or damage to the equipment or to the specimen. Common sense and a thorough knowledge of the system’s operating capabilities can help to determine an appropriate and safe approach to its operation.

Safety Practices Before Operating the System

Before you apply power to the test system, review and complete all of the safety practices that are applicable 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 inspections, the integrity of specific system components.

Read all manuals

Study the contents of this manual and the other manuals provided with your system before attempting to perform any system function for the first time. Procedures that seem relatively simple or intuitively obvious can require a complete understanding of system operation to avoid unsafe or dangerous situations.

Safety

Locate lockout/tagout points

Know where the lockout/tagout point is for each of the supply energies associated with your system. This includes the hydraulic, pneumatic, electric, 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 facilities have internal procedures and rules regarding safe practices within the facility. Be aware of these safe practices and incorporate them into your daily operation of the system.

Locate Emergency Stop buttons

Know the location of all the system Emergency Stop buttons so that you can stop the system quickly in an emergency. Ensure that an Emergency Stop button is located within close proximity of the operator at all times.

Know controls

Before you operate the system for the first time, make a trial run through the operating procedures with the power off. Locate all hardware and software controls and know what their functions are and what adjustments they require. If any control function or operating adjustment is not clear, review the applicable information until you understand it thoroughly.

Have first aid available

Accidents can happen even when you are careful. Arrange your operator schedules so that a properly trained person is always close by to render first aid. In addition, ensure that local emergency contact information is posted clearly and in sight of the system operator.

Series 244 Actuators Product Information 33

Safety

Know potential crush and pinch points

Be aware of potential crush and pinch points on your system and keep personnel and equipment clear of these areas.

An important consideration for servohydraulic systems is that when power is interrupted, it is likely that stored accumulator pressure will persist for some time within the system. In addition, it is likely that as stored energy dissipates, gravity will cause portions of the system to move.

Be aware of component movement with hydraulics off

For hydraulic systems, be aware that mechanical assemblies can shift or drift due to changes within hydraulic hardware when hydraulics are turned off. This non-commanded movement is because oil can transfer between the pressure and return ports and across internal components of the hydraulic hardware. Be aware that this can happen and clear the area around the mechanical assemblies when hydraulics are turned off.

Know electrical hazards

When the system electrical power is turned on, minimize the potential for electrical shock hazards. Wear clothing and use tools that are properly insulated for electrical work. Avoid contact with exposed wiring or switch contacts.

Whenever possible, turn off electrical power when you work on or in proximity to any electrical system component. Observe the same precautions as those given for any other high-voltage machinery.

Make sure that all electrical components are adequately grounded. Grounds must remain connected and undisturbed at all times.

Ensure Correct Cable Connection

If a system cable has been disconnected, ensure that you establish the correct cable-to-connector relationship during reconnection. Incorrect cable connections can result in improper servo loop phasing or an open servo loop condition, either of which can cause unstable or unexpected and potentially dangerous system motions. Verify the correct cable-to-connector relationship by observing the cable and connector labeling and the system wiring schematics.

Keep bystanders safely away

Keep bystanders at a safe distance from all equipment. Never allow bystanders to be in close proximity of specimens or equipment while the test is running.

Wear proper clothing

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.

Remove flammable fluids

Remove flammable fluids from their containers or from components before you install the container or component. If desired, you can replace the flammable fluid with a non-flammable fluid to maintain the proper proportion of weight and balance.

Know compressed gas hazards

Your system may contain accumulators that require a high-pressure gas precharge (pressures that exceed 138 bar [2000 psi]). High-pressure devices are potentially dangerous because a great amount of energy is available in the event of an uncontrolled expansion or rupture.

Observe the following safety practices when you work with high-pressure air or gases:

34 Series 244 Actuators Product Information

Safety

• 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.”) Do not use compressed air or oxygen for precharging: the temperature increase caused by rapid gas compression can result in highly explosive conditions when hydraulic fluid is in the presence of oxygen or compressed air.

• Always follow the recommended bleeding procedures before you remove or disassemble components that contain pressurized gas. When you bleed a gas or remove a fitting, hose, or component that contains a gas, remember that many gases cannot support life. Therefore, as the ratio of released gas to oxygen increases, so does the potential for suffocation.

• Wear appropriate safety devices to protect your hearing. Escaping air or gas can create a noise level that can damage your hearing.

• Ensure that all pressurized air or gas is bled out of a pneumatic or gas-charged device before you start to disassemble it. A thorough understanding of the assembly and its pressurized areas is necessary before you undertake any maintenance. Refer to the appropriate product information for the correct bleeding procedure.

It may not be obvious or intuitive which bolts or fittings are used to restrain a pressurized area. On some assemblies, you must remove a cover plate to gain access to the structural bolts. Sometimes, to protect you from a rapid release of trapped gases, a small port is exposed when you remove this cover plate. Exposing this port ensures that the gas precharge is fully bled before disassembly. However, this is not the recommended procedure for bleeding a pneumatic or gas-charged device, because it can expose you to the dangers of escaping compressed gas and particulates that are expelled from the chamber or around the seals. Do not assume that cover plates and ports are installed in all the critical locations.

Consult MTS when in doubt about the safety or reliability of any system-related procedure or modification that involves devices that contain any type of compressed gas.

Check bolt ratings and torques

To ensure a reliable product, fasteners (such as bolts and tie rods) used in MTS-manufactured systems are torqued to specific requirements. If a fastener is loosened or the configuration of a component within the system is modified, refer to the system and component assembly drawings (located on the System Documentation CD) to determine the correct fastener, fastener rating, and torque. Over torquing or under torquing a fastener can create a hazardous situation due to the high forces and pressures present in MTS test systems.

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. Industrial chemicals, such as hydraulic fluid, that are spilled on any type of floor can result in a dangerous, slippery surface. Do not leave tools, fixtures, or other items not specific to the test, lying about on the floor, system, or decking.

Protect hoses and cables

Protect electrical cables from spilled fluids and from excessive temperatures that can cause the cables to harden and eventually fail. Ensure that all cables have appropriate strain relief devices installed at the cable and near the connector plug. Do not use the connector plug as a strain relief.

Series 244 Actuators Product Information 35

Safety

Protect all system hoses and cables from sharp or abrasive objects that can cause the hose or cable to fail. Use a cable cover or cable tray where cables are in traffic locations. Never walk on hoses or cables or move heavy objects over them. Route hoses and cables away from areas that expose them to possible damage.

Provide proper hydraulic fluid filtration

For hydraulic systems equipped with a non-MTS hydraulic power unit, make sure that hydraulic fluid filtration is established to maintain fluid cleanliness standards as stated in the Hydraulic Fluid Care Manual (see the System Documentation CD). Particles present in the hydraulic fluid can cause erratic or poor system response.

Protect accumulators from moving objects

For systems equipped with accumulators, protect accumulators with supports or guards. Do not strike accumulators with moving objects. This could cause the accumulator(s) to separate from the manifold resulting in equipment damage and personal injury.

Record changes

If you change any operating procedure, write the change and the date of the change in the appropriate manual.

Provide test area guards

Use protective guards such as cages, enclosures, and special laboratory layouts when you work with hazardous test specimens (for example, brittle or fragmenting materials or materials that are internally pressurized).

Do not exceed the Maximum Supply Pressure

For hydraulic systems and components, make sure that hydraulic supply pressure is limited to the maximum pressure defined by the system operating limits. Read and review “System Operating Limits” for the system.

Do not disable safety devices

Your system may have active or passive safety devices installed to prevent system operation if the device indicates an unsafe condition. Do not disable such devices as it may result in unexpected system motion.

Use appropriately sized fuses

Whenever you replace fuses for the system or supply, ensure that you use a fuse that is appropriately sized and correctly installed. Undersized or oversized fuses can result in cables that overheat and fuses that explode. Either instance creates a fire hazard.

Provide adequate lighting

Ensure adequate lighting to minimize the chance of operation errors, equipment damage, and personal injury.

Provide adequate ventilation

Make sure work and maintenance areas are adequately ventilated to minimize the risks associated with the collection of hazardous fumes (such as vaporized hydraulic fluid). This is of special concern in confined areas where hydraulic equipment is operating at high pressure in confined areas.

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.

36 Series 244 Actuators Product Information

Safety Practices While Operating the System

Wear appropriate personal protection

Wear eye protection when you work with high-pressure hydraulic fluid, high-pressure air pressure, breakable specimens, or when anything characteristic to the specimen could break apart.

Wear ear protection when you work near electric motors, pumps, or other devices that generate high noise levels. This system may create sound pressure levels that exceed 70 dbA during operation.

Wear appropriate protection (gloves, boots, suits, respirators) whenever you work with fluids, chemicals, or powders that may irritate or harm the skin, respiratory system, or eyes.

Provide test area enclosures

Use protective enclosures such as cages or shields, and special laboratory layouts when you work with hazardous test specimens (for example, brittle or fragmenting materials or materials that are internally pressurized).

Customer must evaluate risks due to ejected parts or materials from the test specimens. If the MTS Test Area Enclosure option is not selected by the customer, then for protection against ejected parts or materials from test specimens and to control access to the machinery, the Customer must provide a Test Area Enclosure to protect personnel.

Safety

Specimen temperature changes

During cyclic testing, the specimen temperature can become hot enough to cause burns. Wear personal protection equipment (gloves) when handling specimens.

Handle chemicals safely

Whenever you use or handle chemicals (for example, hydraulic fluid, batteries, contaminated parts, electrical fluids, and maintenance waste), refer to the appropriate MSDS documentation for that material and determine the appropriate measures and equipment required to handle and use the chemical safely. Ensure that the chemical is disposed of appropriately.

Know servohydraulic system interlocks

Interlock devices should always be used and properly adjusted. Interlock devices are designed to minimize the chance of accidental damage to the test specimen or the equipment. Test all interlock devices for proper operation immediately before a test. Do not disable or bypass any interlock devices as doing so could allow hydraulic pressure to be applied regardless of the true interlock condition. The Reset/Override button is a software function that can be used to temporarily override an interlock while attempting to start the hydraulic power unit and gain control of the system.

Know system limits

Never rely on system limits such as mechanical limits or software limits to protect you or any personnel. System limits are designed to minimize the chance of accidental damage to test specimens 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, disconnect, or otherwise disturb a sensor (such as an accelerometer or extensometer) or its connecting cable when hydraulic pressure is applied.

Series 244 Actuators Product Information 37

Safety

Ensure secure cables

Ensure that all cable connections (electrical supply, control, feedback, sensor, communications, and so forth) are either locking type, or are secured, to ensure that they cannot be disconnected by a simple act. 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. An open control loop condition can cause a rapid, unexpected system response which can result in severe personal injury, death, or damage to equipment. Also, ensure that all cables are connected after you make any changes in the system configuration.

Stay alert

Avoid long periods of work without adequate rest. In addition, avoid long periods of repetitious, unvarying, or monotonous work because these conditions can contribute to accidents and hazardous situations. If you are too familiar with the work environment, it is easy to overlook potential hazards that exist in that environment.

Contain small leaks

Do not use your fingers or hands to stop small leaks in hydraulic or pneumatic hoses. Substantial pressures can build up, especially if the hole is small. These high pressures may cause the oil or gas to penetrate your skin, causing painful and dangerously infected wounds. Turn off the hydraulic supply and allow the hydraulic pressure to dissipate before you remove and replace the hose or any pressurized component.

Stay clear of moving equipment/avoid crush points

Stay clear of mechanical linkages, connecting cables, and hoses that move because you may get pinched, crushed, tangled, or dragged along with the equipment. High forces generated by the system can pinch, cut, or crush anything in the path of the equipment and cause serious injury. Stay clear of any potential crush points. Most test systems can produce sudden, high-force motion. Never assume that your reactions are fast enough to allow you to escape injury when a system fails.

Know the causes of unexpected actuator motions

The high force and velocity capabilities of MTS actuators can be destructive and dangerous (especially if actuator motion is unexpected). The most likely causes of unexpected actuator response are operator error and equipment failure due to damage or abuse (such as broken, cut, or crushed cables and hoses; shorted wires; overstressed feedback devices; and damaged components within the servocontrol loop). Eliminate any condition that could cause unexpected actuator motion.

Do not use RF transmitters

Keep radio frequency (RF) transmitters away from the workstation computers, remote terminals, and electronics consoles. Intense RF fields can cause erratic operation of the more sensitive circuits in the system.

Hazard Placard Placement

Hazard placards contain specific safety information and are affixed directly to the system so they are plainly visible.

Each placard describes a system-related hazard. When possible, international symbols (icons) are used to graphically indicate the type of hazard and the placard label indicates its severity. In some instances, the placard may contain text that describes the hazard, the potential result if the hazard is ignored, and general instructions about how to avoid the hazard.

38 Series 244 Actuators Product Information

Labels And Icons

The following labels and icons may be found on an actuator.

Warning Label

Part #46-140-101

Safety

WARNING

Hydraulic pressure above 3000 psi can rupture components. Can cause severe personal injury or damage to equipment.

Do not exceed 3000 psi (20.7 MPa).

Read instructions before operating or servicing.

Warning Label

Part #46-140-201

WARNING

Hydraulic pressure above 4000 psi can rupture components. Can cause severe personal injury or damage to equipment.

Do not exceed 4000 psi (27.6 MPa).

Read instructions before operating or servicing.

Series 244 Actuators Product Information 39

Safety

Caution Label

Part #045-283-501

CAUTION

High drain pressure can cause rod seal damage and hydraulic oil leakage.

Remove drain line shipping cap and connect drain hose before operating.

Attached Mass Warning Label

Part #057-230-041

Attached mass warning.

Do not exceed maximum attached mass.

40 Series 244 Actuators Product Information

Hydraulic Actuator ID Tag

Part #700-004-198

Hydraulic Actuator ID tag lists the following:

Safety

• Model Number

• Serial Number

• Assembly number/Rev

• Force rating

• Effective Area

• Static Stroke

• Dynamic Stroke

• Hydrostatic/Non-Hydrostatic

• Maximum attached mass

Hydraulic Actuator ID Tag

Part #037-588-801

Series 244 Actuators Product Information 41

Safety

Hydraulic Actuator ID tag lists the following:

• Model Number

• Serial Number

• Assembly number/Rev

• Force rating

• Effective Area

• Static Stroke

• Dynamic Stroke

• Hydrostatic/Non-Hydrostatic

Pressure Icon Label

Part #57-237-711

Pressure icon.

Can be used alone, or in conjunction with pressure rating label (Part # 57-238-5xx).

Pressure Rating Label

Part #57-238-5xx

Pressure rating. Actual rating listed on this label will vary. This label is used in conjunction with the Pressure icon (Part # 57237711). Located directly beneath pressure icon on actuator.

42 Series 244 Actuators Product Information

Lift Hole Thread Size

Part #57-806-13

Lift hole. Thread size will be specified on the actual label.

Safety

Series 244 Actuators Product Information 43

Installation

Topics:

•

About Installation...................................................................................................................................46

•

Load Units..............................................................................................................................................46

•

Installing a Fixture to the Actuator.........................................................................................................47

•

Spiral Washers.......................................................................................................................................50

•

Installing Fixtures with Spiral Washers..................................................................................................51

•

Removing Fixtures with Spiral Washers................................................................................................53

•

LVDT Cable Connection........................................................................................................................54

•

Hydraulic Connections...........................................................................................................................55

Series 244 Actuators Product Information 45

Installation

About Installation

Installing the Series 244 Actuator depends on the testing application.

• For materials or component testing, the actuator is typically installed in a load frame or test fixture.

• For structural or vibration testing, the actuator is typically secured to a reaction mass using a swivel or pedestal base.

Load Units

When the Series 244 Actuator is mounted in a load frame configuration, the actuator is installed in the load frame at the factory. Actuator options, such as servovalves and manifolds, are also installed on the actuator at the factory. The only installation required is to connect system hydraulic hoses and system cables.

46 Series 244 Actuators Product Information

See the system assembly drawing, system functional drawing, and console assembly drawing (typically located in a System Reference manual supplied with your system documentation) for information about hydraulic and electrical connections.

Note:

Actuators mounted in a load unit should not be removed from the load unit. Proper alignment should not be performed in the field.

When an actuator is mounted in a load frame, the actuator is hidden behind other hydraulic components as shown here.

Installing a Fixture to the Actuator

Fixtures can be mounted to the pedestal base, the actuator piston rod, or the upper end cap.

The actuator is equipped with an upper end cap and a pedestal base which has from two to eight threaded mounting holes.

The pedestal base also contains a center position threaded hole which may be used to attach a swivel mounting accessory. The piston rod also contains a center position threaded hole. This mounting hole is typically used to attach a swivel mounting accessory or a specimen supporting fixture (shaker head or vibration table) to the actuator.

Installation

Series 244 Actuators Product Information 47

Installation

Note:

See the Series 249 Swivels manual (MTS part number 100-237-294) for more information about using swivels with the actuator.

Base Types

DescriptionItem

Swivel Base1

Pedestal Base2

Mounting Bolt Specifications

A Series 244 Actuator equipped with a pedestal base or a swivel base typically has the base bolted to a reaction mass. The following table lists information for the mounting bolt specifications.

48 Series 244 Actuators Product Information

Swivel Base Mounting Bolt Specifications

Installation

Model

RecommendedBolt GradeMounting Bolt TorqueRecommendedMounting

Bolt Size

SAEISOlbf-ftN·mUNCmm

12.912.934533/8-16M10 x 1.50244.11

12.912.934533/8-16M10 x 1.50244.12

12.912.91602305/8-11M16 x 2.00244.20

12.912.91602305/8-11M16 x 2.00244.21

12.912.91602305/8-11M16 x 2.00244.22

12.912.91602305/8-11M16 x 2.00244.23

12.912.96807801-8M24 x 3.00244.31

12.912.9140016001 1/4-7M30 x 3.50244.41

12.912.9240032001 1/2-4M42 x 4.50244.51

Pedestal Base Mounting Bolt Specifications

Model

RecommendedBolt GradeMounting Bolt TorqueRecommendedMounting

Bolt Size

SAEISOlbf-ftN·mUNCmm

812.984931/2-13M12 x 1.75244.11

812.984931/2-13M12 x 1.75244.12

812.91602305/8-11M16 x 2.00244.21

812.91602305/8-11M16 x 2.00244.20

812.91602305/8-11M16 x 2.00244.22

812.91602305/8-11M16 x 2.00244.23

812.94544507/8-9M20 x 2.50244.31

812.9140016001 1/4-7M30 x 3.50244.41

812.9240032001 1/2-6M42 x 4.50244.51

Series 244 Actuators Product Information 49

Installation

Spiral Washers

The optional Model 601 Spiral Washers are typically used to provide fatigue-resistant connections between elements of the force train and to minimize the effects of backlash. If the operating procedure requires changing of preloaded force train elements such as the load cell or grips, the spiral washers must be readjusted.

The spiral washers are placed over the connector studs at each connection, and adjusted to place a constant preload on the stud.

When cyclic loads below the tensile force level of the preload are applied to the connections, the load is distributed between the surfaces of the spiral washers and the stud in a ratio of the relative stiffness of the parts. The spiral washers have a large surface area and therefore greater stiffness. They react to most of the load and keep the stress in the stud below its fatigue run out level. In addition to providing fatigue-resistant connections, the spiral washers also minimize the possibility of backlash due to loose-fitting or worn stud threads.

DescriptionItem

Compliant Material1

Load Cell2

50 Series 244 Actuators Product Information

Force Train Components

DescriptionItem

Upper End Cap3

Actuator Rod4

Spiral Washers5

Connector Studs6

Swivel Head7

Installing Fixtures with Spiral Washers

This procedure requires two spanner wrenches and assumes that you are familiar with all operating aspects of your system.

Installation

Multiple Fixtures With Different Ratings

Sometimes you may have multiple fixtures in the force train that have different force ratings. When installing the fixtures pretensioned with spiral washers, install the fixtures with the lowest force rating first. Then install any other fixtures from the lowest to the highest force rating.

1. Ensure that system hydraulic pressure has been reduced to zero before proceeding. To do this, turn off the hydraulic power unit and exercise the actuator until it stops moving.

2. Clean the connector studs and the internal threads of the force train element(s). Inspect the thread mating surfaces for signs of contamination or corrosion. All damaged threads should be repaired or the component replaced.

3. Apply a thin layer of Molykote G paste, or equivalent, to all thread mating surfaces.

4. When installing a load cell, place a small piece of compliant material inside the load cell to keep the stud from contacting the bottom of the hole (see the figure called “Force Train Components”).

5. Slowly turn the connector stud into an element of the force train (for example, the actuator rod). The connector stud should turn freely. If any resistance is encountered, disassemble and correct the problem before proceeding.

Series 244 Actuators Product Information 51

Installation

Spiral Washer Rotation

DescriptionItem

Connector Stud1

Spiral Washer Rotation to Increase Thickness2

Medium Thickness3

6. Place the spiral washers together with the spiral surfaces facing each other.

7. Place the set of spiral washers over the connector stud and rotate them until they are at minimum thickness. Mount the appropriate fixture (load cell, grip, and so forth) on the connector stud and tighten the fixture against the spiral washers by hand.

8. Repeat Steps 2 through 7 for all spiral washers in the force train of the same rating.

9. Connect a coupling (dummy specimen) in the force train or install the actuator into a suitable fixture such that it can withstand a tensile load 10 – 20% greater than the maximum load to be applied to the connector stud during testing.

10. Select force control with the system controller.

52 Series 244 Actuators Product Information

Installation

Warning:

Do not exceed the maximum HPS output pressure or apply a force greater than any force train component capacity.

Exceeding the tensile load capacity of any element in the force train can cause equipment damage or personal injury.

It is necessary to temporarily exceed the tensile load capacity to achieve the requirements of Step 5 in this procedure. This is accomplished by increasing the output pressure of the HPU. Contact MTS Systems Corporation.

11. Turn on the system hydraulic pressure.

Note:

Be sure that all components in the force train can accommodate the required tensile load.

12. Apply a static tensile load 10–20% higher than the maximum load to be applied during testing.

13. If your test requires the maximum tensile load of the force train, you will need to adjust the output pressure of the HPS to reach the required tensile load.

Caution:

If the spiral washers are not sufficiently tightened, the connector stud can break when subjected to cyclic loads.

Follow the instructions in Step 13 and ensure that the spiral washers are properly tightened.

14. Using the spanner wrenches, rotate the spiral washers in opposite directions to tighten them. The opening between the washers must not exceed an arc of 30° from the closed position (see the figure on the previous page).

15. If more than a 30° arc is created, remove the tensile load from the specimen. Then remove the specimen and the connector stud. Examine the connector stud for any signs of thread wear. If wear is noticed, replace the stud and repeat Step 1 through Step 14.

Removing Fixtures with Spiral Washers

This procedure requires two spanner wrenches and assumes that you are familiar with all operating aspects of your system.

Series 244 Actuators Product Information 53

Installation

Multiple Fixtures With Different Ratings

Sometimes you may have multiple fixtures in the force train that have different force ratings. When removing the fixtures pretensioned with spiral washers, remove the fixtures with the lowest force rating first. Then remove any other fixtures from the lowest to the highest force rating.

1. Ensure that system hydraulic pressure has been reduced to zero before proceeding. To do this, turn off the hydraulic power unit and exercise the actuator until it stops moving.

2. Install a dummy specimen or a suitable fixture in the force train such that it can withstand a tensile load 10–20% greater than the maximum load to be applied during testing.

3. Select force control at the system controller.

4. Apply system hydraulic pressure according to applicable system procedures.

Warning:

Do not exceed the maximum HPS output pressure or apply a force greater than any force train component capacity.

Exceeding the tensile load capacity of any element in the force train can cause equipment damage or personal injury.

Note:

Be sure that all components in the force train can accommodate the required tensile load.

5. Apply a static tensile load 10 to 20% higher than the maximum load to be applied during testing.

6. Use the spanner wrenches to rotate the spiral washers to reduce their combined thickness to a minimum.

7. Reduce tensile load to zero and remove hydraulic pressure. Ensure that all residual pressure (including accumulator pressure) has bled off.

8. Remove all force train components (such as load cell, swivel rod end, grips, or fixtures) attached to the actuator.

LVDT Cable Connection

The following figure shows the electrical connections of the LVDT. See your controller manual for cable specifications or cable assembly numbers.

54 Series 244 Actuators Product Information

Installation

LVDT Cable Connection

DescriptionItem

Output1

Ground2

Excitation3

Yellow4

Blue5

Green6

Black7

Red8

Hydraulic Connections

Note:

When the Series 244 Actuator is installed in a load unit, the hydraulic connections are made through a manifold connected to a Series 298 Actuator Manifold.

Hydraulic connections to the Series 244 Actuator are made through a manifold that connects the ports of each end cap. The manifold has hydraulic pressure and return ports stamped P and R respectively. These ports are connected to matching ports located on a hydraulic service manifold (HSM).

See the servovalve manual for servovalve installation information.

Series 244 Actuators Product Information 55

Installation

Hydraulic Connections

DescriptionItem

Some manifolds support two servovalves.1

Return Port2

Drain Port3

Pressure Port4

Caution:

Do not use inferior quality hydraulic fluids.

Using fluids other than those specified by MTS may cause component or system failure or both.

Use Mobil DTE 25 or Shell Tellus 46 hydraulic fluid only.

56 Series 244 Actuators Product Information

Operation

Topics:

•

About Operation.....................................................................................................................................58

•

Actuator ID.............................................................................................................................................58

•

Operating Considerations......................................................................................................................58

•

Sideload Calculation Procedure............................................................................................................59

•

Sample Calculation................................................................................................................................62

Series 244 Actuators Product Information 57

Operation

About Operation

This section describes how to use the Series 244 Actuator when side loads are applied during testing.

Warning:

Exceeding the maximum attached mass can cause unpredictable actuator movement.

Unexpected actuator movement can result in injury to personnel or damage to equipment.

Ensure that the maximum attached mass listed on the actuator ID tag is not exceeded.

Actuator ID

A plate on the Series 244 Actuator (typically located on the front end cap opposite the drain line) contains the following information:

• Model number

• Serial number

• Force rating

• Area

• Stroke specifications

This information is required when contacting MTS Systems Corporation regarding the actuator.

Operating Considerations

Piston rod banding can occur if the actuator is operated for a long period of time at a moderate to high frequency, with short stroke displacement and loads of 25% or more of the actuator capacity. Piston rod banding is the aggravated erosion of the piston rod chrome plating in a band slightly wider than the width of the seal encircling the circumference of the piston rod.

If the actuator is being used for this type of testing, the starting position of the actuator piston rod should be changed approximately every one million cycles. This will extend the life of the piston rod and minimize the possibility of banding. If the system configuration allows it, the piston rod starting position can be changed by using the displacement transducer conditioner zero control and repositioning the load frame crosshead or fixture.

58 Series 244 Actuators Product Information

Sideload Forces

To avoid damaging the actuator bearings and to ensure proper actuator operation, tests that subject the actuator to nonaxial loads require special consideration.

Nonaxial loading can occur from sideload forces applied directly to the piston rod (P in the figure) and from moments caused by off-center loads (F in the figure).

Operation

Sideload Forces

DescriptionItem

Sideload Forces1

There are four things that must be considered to determine the suitability of an actuator for nonaxial loaded tests:

• Bearing pressure generated during the test

• Piston rod stress caused by sideload

• Maximum allowable piston rod velocity

• Minimum allowable sideload frequency

Sideload Calculation Procedure

The following procedure provides you with information to determine the suitability of a particular actuator model for tests requiring nonaxial loading. The following table lists the constants used in this procedure.

Series 244 Actuators Product Information 59

Operation

Sideload Calculation Constants

Model

244.11

244.12

244.21

244.22

244.23

244.31

244.41

244.51

Note:

The equations included in this procedure assume that the values of F and P are measured in pounds force and that B, C, and S (stroke) are measured in inches.

1. Determine the magnitude of nonaxial loads F and P and the point of application of these loads (B and C respectively). These parameters are dependent on the test setup configuration. If any parameter is variable during the test, use maximum values.

Cyclic Sideload KRod Diameter GBearing Area EBearing Length DBearing Spacing

0.6001.753.501.71005.960

0.1402.756.261.93805.820

0.1402.755.841.86305.475

0.1402.755.981.88805.425

0.0683.7510.032.13405.825

0.0265.2522.372.87006.530

0.0156.0024.692.81257.865

60 Series 244 Actuators Product Information

Operation

Sideload Forces

DescriptionItem

Sideload Forces1

2. Calculate the actuator bearing load (L) using the following formula:

where:

S = Actuator stroke

A = Constant based on actuator bearing spacing

D = Constant based on actuator bearing size

3. Divide the actuator bearing load (L) by the actuator area constant (E) to determine the bearing pressure (V).

where:

V = maximum allowable bearing pressure

E = Constant based on actuator bearing area

The maximum allowable bearing pressure (V) is 5.6 MPa (950 psi).

If the value produced by this step exceeds 5.6 MPa (950 psi), then you will have to select an actuator with a larger piston rod diameter.

4. Calculate the bending stress placed on the actuator piston rod.

where:

(PRS) = piston rod stress

G = actuator piston rod diameter

The maximum allowable piston rod stress is 275.8 MPa (40,000 psi).

If the value produced by this step exceeds 275.8 MPa (40,000 psi), then you will have to select an actuator with a larger piston rod diameter.

5. If the sideload force is applied to the actuator continuously, then determine the maximum allowable actuator piston rod velocity for the bearing pressure (V) calculated in Step 3. This is the highest velocity that the actuator can be allowed to experience when the current sideload is present.

Use the following equation:

Series 244 Actuators Product Information 61

Operation

where:

(MAPRV) = maximum allowable piston rod velocity

6. If the sideload force is applied to the actuator cyclically (sideload varies equally through zero), then determine the minimum frequency for the sideload force. If the test parameters require a lower sideload frequency, then you will have to select an actuator with a larger piston rod diameter.

Use the following equation:

where:

(MSF) = minimum sideload frequency

Sample Calculation

The following example uses the sideload calculation procedure to determine the suitability of a Model 244.31 Actuator with a 6 in. stroke (S) for a specific test. The numbered steps of this example correspond to the numbered steps of the preceding procedure.

1. The following test conditions are determined by the setup configuration and test parameters:

F = 3000 lbf

P = 500 lbf

B = 3.00 in

C = 3.50 in

S = 6.00 in

2. Calculate the actuator bearing load (L).

3. Divide the actuator bearing load (L) by the bearing area constant (E) and ensure that the value is less than 950 psi.

62 Series 244 Actuators Product Information

The result, 149.49 psi, is less than (950 psi).

4. Calculate the piston bending stress and ensure that the value is less than 40,000 psi.

The result, 2283.67 psi, is less than 40,000 psi.

Where:

(PRS) = piston rod stress

Operation

5. The maximum allowable piston rod velocity is given by the following equation:

Where:

(MAPRV) = maximum allowable piston rod velocity

6. The minimum cyclical sideload frequency is determined by the following equation:

Where:

(MSF) = minimum sideload frequency

Series 244 Actuators Product Information 63

Maintenance

Topics:

•

Maintenance Recommendations...........................................................................................................66

Series 244 Actuators Product Information 65

Maintenance

Maintenance Recommendations

The Series 244 Actuator is designed for extended periods of operation without extensive maintenance requirements.

Warning:

Changing the servovalve/actuator configuration will impact the actuator’s maximum attached mass for cushion design limit.

Operating an actuator outside of its design limit can result in injury to personnel or damage to the equipment.

Do not alter the given servovalve/actuator configuration.

The routine maintenance procedures are 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.

Monthly

Inspect actuator piston rod and seals for excessive wear or leakage. Small scratches in the axial direction of the piston rod or polishing of the rod surface is considered normal operating wear.

Yearly

Change actuator seals if necessary. Actuator assemblies may require more or less frequent seal changes depending on usage. External oil leakage or decreased performance are indicators of seal wear.

66 Series 244 Actuators Product Information

011-551-304 G

MTS 244 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Technical Support

How to Get Technical Support

Before You Contact MTS

If You Contact MTS by Phone

Problem Submittal Form in MTS Manuals

Preface

Before You Begin

Documentation Conventions

Introduction

About the 244 Series Actuator

What You Need to Know

Component Identification

Functional Description

About Actuator Mounting

Actuator Operation

LVDT Operation

Specifications

Force Ratings

Environmental and Hydraulic Fluid Recommendations

Dimensions

LVDT Housing Specifications

Pedestal Base Specifications

Safety

General Safety Practices: Hydraulic Power Units and Hydraulic Service Manifolds

Safety Practices Before Operating the System

Safety Practices While Operating the System

Hazard Placard Placement

Labels And Icons

Warning Label

Warning Label

Caution Label

Attached Mass Warning Label

Hydraulic Actuator ID Tag

Hydraulic Actuator ID Tag

Pressure Icon Label

Pressure Rating Label

Lift Hole Thread Size

Installation

About Installation

Load Units

Installing a Fixture to the Actuator

Mounting Bolt Specifications

Spiral Washers

Installing Fixtures with Spiral Washers

Multiple Fixtures With Different Ratings

Removing Fixtures with Spiral Washers

Multiple Fixtures With Different Ratings

LVDT Cable Connection

Hydraulic Connections

Operation

About Operation

Actuator ID

Operating Considerations

Sideload Forces

Sideload Calculation Procedure

Sample Calculation

Maintenance

Maintenance Recommendations