MTS 311 User Manual

be certain.

MTS Series 311 Load Frame Product Information

Model 311.11 Model 311.21 Model 311.31 Model 311.41 Model 311.51 Model 311.61 Model 311.71

011-183-705 D

Trademark information MTS is a registered trademark of MTS Systems Corporation within the United

States. This trademark may be protected in other countries. All other trademarks or service marks are property of their respective owners.

Publication information

MANUAL PART NUMBER PUBLICATION DATE

111837-05A June 1985 011-183-705 B April 2001 011-183-705 C April 2009 011-183-705 D November 2010

Contents

Technical Support 5

Preface 9

Conventions 10

Introduction 13

Component Identification 15 Functional Description 17 Specifications 19

Safety 21

Installation 33

Unpacking the Load Frame 34 Connecting Cables 38 Connecting Hydraulics 39 Removing the Shipping Collars 40

Operation 41

Lift and Lock Controls 42 Crush Point Hazards 43 Installing a Specimen 44

Maintenance 47

Routine Maintenance Overview Checklist 48 Maintenance Intervals 51 Making Daily Inspections 52 Cleaning the Columns 53 Preventing Rust 54

Checking the Accumulators’ Precharge 55 Bleeding the Hydraulic Lift Cylinders 56 Adjusting the Hydraulic Locks 59 Aligning the Force Transducer 61

Servohydraulic Load Frame Maintenance and Service Logs 67

8 Hours/Daily 68 40 Hours/Weekly 69 80 Hours/Biweekly 70 500 Hours: Crosshead and Frame 71 500 Hours: Actuator 72 500 Hours: HSM 73 500 Hours: Hoses and Cables 74 500 Hours: Overall Complete System 75 500 Hours: Grips 76 1000 Hours 77 2000 Hours: Annual Maintenance 78

Addendum 79

Technical Support

How to Get Technical Support

Start with your

manuals

Technical support

methods

MTS web site

www.mts.com

E-mail techsupport@mts.com

Telephone MTS Call Center 800-328-2255

Fax 952-937-4515

Technical support

outside the U.S.

The manuals supplied by MTS provide most of the information you need to use and maintain your equipment. If your equipment includes MTS software, look for online help and README files that contain additional product inform ation.

If you cannot find answers to your technical questions from these sources, you can use the internet, e-mail, telephone, or fax to contact MTS for assistance.

MTS provides a full range of support services after your system is installed. If you have any questions about a system or product, contact MTS in one of the following ways.

The MTS web site gives you access to our technical support staff by means of a Technical Support link:

www.mts.com > Contact MTS > Service & Technical Support

Weekdays 7:00 A.M. to 5:00 P.M., Central Time

Please include “Technical Support” in the subject line.

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 MTS > (choose your region in the right-hand column) > (choose the location closest to you)

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

Series 311 Load Frame Technical Support

The site number contains your company number and identifies your equipment type (material testing, simulation, and so forth). The number is usually written on a label on your MTS equipment before the system leaves MTS. If you do not have or do not know your MTS site number, contact your MTS sales engineer.

Example site number: 571167

When you have more than one MTS system, the system job number identifies which system you are calling about. You can find your job number in the papers sent to you when you ordered your system.

Example system number: US1.42460

Know information from

prior technical

If you have contacted MTS about this problem before, we can recall your file. You will need to tell us the:

assistance

• MTS notification number

• Name of the person who helped you

Identify the problem Describe the problem you are experiencing and know the answers to the

following questions:

• How long and how often has the problem been occurring?

• Can you reproduce the problem?

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

problem started?

• What are the model numbers of the suspect equipment?

• What model controller are you using (if applicable)?

• What test configuration are you using?

Know relevant

computer information

Know relevant

software information

If you are experiencing 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 in which the application resides

• Current status of hard-drive fragmentation

• Connection status to a corporate network

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 is displayed briefly when you launch the application, and can typically be found in the “About” selection in the “Help” menu.

• It is also helpful if the names of other non-MTS applications that are

running on your computer, such as anti-virus software, screen savers, keyboard enhancers, print spoolers, and so forth are known and available.

Technical Support

Series 311 Load Frame

If You Contact MTS by Phone

Your call will be registered by a Call Center agent if you are calling within the United States or Canada. Before connecting you with a technical support specialist, the agent will ask you for your site number, name, company , company address, and the phone number where you can normally be reached.

If you are calling about an issue that has already been assigned a notification number, please provide that number. You will be assigned a unique notification number about any new issue.

Identify system type To assist the Call Center agent with connecting you to the most qualified

technical support specialist available, identify your system as one of the following types:

• Electromechanical materials test system

• Hydromechanical materials test system

• Vehicle test system

• Vehicle component test system

• Aero test system

Be prepared to

troubleshoot

Write down relevant

information

After you call MTS logs and tracks all calls to ensure that you receive assistance and that action

Prepare yourself for troubleshooting while on the phone:

• Call from a telephone when you are close to the system so that you can try

implementing 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.

Prepare yourself in case we need to call you back:

• Remember to ask for the notification number.

• Record the name of the person who helped you.

• Write down any specific instructions to be followed, such as data recording

or performance monitoring.

is taken regarding your problem or request. If you have questions about the status of your problem or have additional information to report, please contact MTS again and provide your original notification number.

Series 311 Load Frame Technical Support

Problem Submittal Form in MTS Manuals

Use the Problem Submittal Form to communicate problems you are experiencing with your MTS software, hardware, manuals, or service which have not been resolved to your satisfaction through the technical support process. This form includes check boxes that allow you to indicate the urgency of your problem and your expectation of an acceptable response time. We guarantee a timely response—your feedback is important to us.

The Problem Submittal Form can be accessed:

• In the back of many MTS manuals (postage paid form to be mailed to MTS)

• www.mts.com > Contact Us > Problem Submittal Form (electronic form to

be e-mailed to MTS)

Technical Support

Series 311 Load Frame

Preface

Before You Begin

Safety first! Before you attempt to use your MTS product or system, read and understand the

Safety manual and any other safety information provided with your system. Improper installation, operation, or maintenance of MTS equipment in your test facility can result in hazardous conditions that can cause severe personal injury or death and damage to your equipment and specimen. Again, read and understand the safety information provided with your system before you continue. 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 MTS manuals in paper or

electronic form. If you have purchased a test system, it may include an MTS System

Documentation CD. This CD contains an electronic copy of the MTS manuals that pertain to your test system, including hydraulic and mechanical component manuals, assembly drawings and parts lists, and op eration and preventive maintenance manuals. Controller and application software manuals are typically included on the software CD distribution disc(s).

Series 311 Load Frame Preface

Conventions

DANGER

WARNING

CAUTION

Conventions

Documentation Conventions

The following paragraphs describe some of the conventions that are used in your MTS manuals.

Hazard conventions As necessary, hazard notices may be embedded in this manual. These notices

contain safety information that is specific to the task to be performed. Hazard notices immediately precede the step or procedure that may lead to an associated hazard. Read all hazard notices carefully and follow the directions that are given. Three different levels of hazard notices may appear in your manuals. Following are examples of all three levels.

Note For general safety information, see the safety information provided with

your system.

Danger notices indicate the presence of a hazard with a high level of risk which, if ignored, will result in death, severe personal injury, or substantial property damage.

Warning 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 notices indicate the presence of a hazard with a low level of risk which, if ignored, could cause moderate or minor personal injury, equipment damage, or 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 occurrence of special terms is shown in italics.

Illustrations Illustrations appear in this manual to clarify text. It is important for you to be

aware that these illustrations 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.

Preface

Series 311 Load Frame

Conventions

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 311 Load Frame Preface

Conventions

Preface

Series 311 Load Frame

Introduction

Crosshead Mounted ActuatorBase Mounted Actuator Custom T-Slot Baseplate

Contents Component Identification 15

The Series 311 Load Frames are designed to perform high-velocity tension or compression testing, high-frequency fatigue testing, as well as other tests. The load frame must be configured with optional actuators, servovalves, force transducers, grips, and other components from MTS Systems Corporation.

Functional Description 17 Specifications 19

Model 311.31 Load Frame

Series 311 Load Frame Introduction

What you

need to know

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

• Turn system electrical power on and off.

• Turn hydraulic pressure on and off.

• Manually adjust the actuator position.

• Use your grips and fixtures.

Related products The load frame includes other products. See the following product manuals for

product-specific information and maintenance procedures.

• The Series 111 Accumulator Pr oduct Information manual.

(part number 011-553-300)

• The Series 244 Actuator Product Information manual

(part number 011-551-300)

• The Series 252 Servovalve Product Information manual

(part number 011-182-900)

Introduction

Series 311 Load Frame

Component Identification

Crosshead

Locks

Crosshead

Lifts

Control

Panel

Isolation

Pads

Actuator

Lifting Rings

Force

Transducer

Manifold

Accumulator

LVDT

Servovalve

Component Identification

Series 311 Load Frame Introduction

Component Identification

Item Description

Component Descriptions

Lifting rings Crosshead

Crosshead locks

Force transducer Crosshead lifts

Actuator

Control panel

Crosshead lift control

Crosshead locks

Emergency Stop

Allows the load frame to be moved by lifting the entire load frame. Moves up and down the columns to accommodate different sized specimens

and fixtures. The crosshead is stiff and light weight; it is one end of the force train.

Clamps the crosshead to the columns. The crosshead locks are hydraulically powered.

Measures the axial forces applied to specimen. Raises and lowers the crosshead hydraulically to accommodate different

specimen sizes. The lifts are small hydraulic actuators. Applies axial forces to specimens. The actuator is a hydraulically powered

device that provides linear displacement of (or forces into) a specimen. Grips and fixtures can be mounted to the actuator.

The Emergency Stop button is standard; the other controls are optional. See

“Lift and Lock Controls” on page 42 for more information.

Controls the crosshead lifts to raise and lower the crosshead hydraulically. Clamps and unclamps the crosshead to lock it in place or to unlock it so the

crosshead can be repositioned. Removes hydraulic pressure from the load frame and issues an interlock signal

to the controller to stop the test program.

Servovalve

Manifold

Accumulators

LVDT

Isolation pads

Controls both the flow rate and the direction of fluid entering the actuators. It determines how fast the actuator extends or retracts.

Serves as the junction point between the hydraulic power unit (HPU), accumulators, servovalve, and actuator. The actuator manifold controls the hydraulic circuit that connects the hydraulic components.

Stores hydraulic fluid under pressure to increase the actuator’s response time. Accumulators also minimize line pressure fluctuations. One accumulator connects to the pressure line; the other to the return line.

Measures the displacement of the actuator’s travel. The linear variable displacement transducer (LVDT) is located inside the actuator.

Dampens the natural frequency to about 20 Hz. Optional air inflated isolators dampen the frequency to about 2 Hz.

Introduction

Series 311 Load Frame

Functional Description

The load frame is a stand alone testing structure. The following components are used with the load frame:

• Crosshead lifts and locks

• Actuator

• Servovalves

• Hydraulic manifold

• Transducers

–Force – Displacement

Load frame The load frame is the basic structure which provides the reaction mass for the

force train. The base of the load frame is one end of the reaction mass and the crosshead is the other end of the reaction mass. Installing a specimen and other fixtures or components between the load frame base and the crosshead create a force train.

Functional Description

The crosshead is mounted above the base by four columns. A control panel lets you operate the crosshead lifts, locks, and grips to assist in specimen installation procedures.

Crosshead lifts

and locks

The crosshead can be positioned anywhere along the load frame columns. It is moved along the column with hydraulic lifts. When the crosshead is in an appropriate test position, it is hydraulically clamped to that position. This lets you change the load frame to accommodate specimens of different lengths.

Actuators The actuator can be located in the middle of the load frame base or crosshead. It

is a hydraulically powered piston that applies displacement of (or force into) a specimen. It can apply equal power in tension and compression. One end of the test specimen is installed into a fixture which is mounted to the end of the actuator rod.

Servovalves A servovalves regulates the direction and flow of the hydraulic fluid to and from

a hydraulic actuator. The servovalve responds to the polarity and magnitude of the command signal generated by the controller.

Hydraulic manifold A hydraulic manifold (also called an actuator manifold or hydraulic service

manifold) controls the hydraulic pressure to the load frame. The manifold includes solenoid valves that control the hydraulic pressure (off, low, or high). An actuator manifold is mounted directly to the actuator on the load frame. A hydraulic service manifold (HSM) is located near the load frame and connects to the actuator with hydraulic hoses.

Series 311 Load Frame Introduction

Functional Description

Transducers The load frame usually includes a force transducer and an LVDT (or other

displacement measurement device.

Force The force transducer (also called load cell or force sensor) measures the amount

of tension or compression and rotational torque appl ied to it. It has four strain gages that form a balanced Wheatstone bridge. When forces are applied to the bridge, it becomes unbalanced and produces an electrical signal that is proportional to the force applied to it. The force transducer is a resistive device and requires a DC conditioner to process the axial signal from the Wheatstone bridge.

LVDT The LVDT measures the linear actuator’s travel. The LVDT consists of a

transformer with one primary and two secondary coils wound on a common cylinder. The coil is stationary inside the actuator. A c ore is attached to the piston rod of the actuator. As it moves inside the coil, it produces an electrical signal that represents the position of the piston rod. The phase of the signal indicates the direction the actuator rod is moving. An LVDT requires an AC conditioner to process the signal.

Introduction

Series 311 Load Frame

Specifications

This section provides some of the specifications of the Series 311 Load Frame. Other specifications can be found on the assembly drawings specific to each load frame.

Parameter Specification

Force rating

311.11

311.21

311.31

311.41

311.51

311.61

311.71

Crosshead weight

311.11

311.21

311.31

311.41

311.51

311.61

311.71

Total weight

311.11

311.21

311.31

311.41

311.51

311.61

311.71

250 kN (55 kip) 500 kN (110 kip) 1000 kN (220 kip) 2500 kN (550 kip) 5000 kN (1100 kip) 7500 kN (1650 kip) 10,000 kN (2200 kip)

approximate weight 180 kg (400 lb)

320 kg (700 lb) 680 kg (1500 lb) 1680 kg (3700 lb) 3175 kg (7000 lb) 5450 kg (12,000 lb) 7300 kg (16,000 lb)

approximate weight 900 kg (2000 lb)

2000 kg (4500 lb) 3500 kg (8000 lb) 8500 kg (19,000 lb) 16,000 kg (36,000 lb) 27,000 kg (60,000 lb) 36,000 kg (80,000 lb)

* The weight specification is for lifting and moving purposes. The weight

includes a typical actuator, force transducer, and grips. The actual shipping weight must be determined by a scale.

Series 311 Load Frame Introduction

Specifications

Introduction

Series 311 Load Frame

Safety

General Safety Practices

This section provides information about safety issues that pertain to servohydraulic systems in general. These issues include statements to the intended use and foreseeable misuse of the system, the hazard zone, definition for the graphical hazard labeling that is affixed to your product, and other (more general) safety information that relates to the high-pressure and highperformance characteristics of MTS servohydraulic systems.

MTS test systems are designed to generate motions and forces and impart these motions and forces into a test specimen.

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

• Do not disable safety components or features (including limit detectors,

• Do not attempt to operate the system without appropriate personal safety

• Do not apply energy levels that exceed the maximum energies and velocities

• Whenever possible, use tongs or similar device to handle specimens during

• Do not test a specimen that exceeds the minimum (if applicable) or

• Do not use specimens that are combustible, flammable, pressurized, or

• Do not use humans as specimens or allow humans to ride in or on the test

• Do not modify the system or replace system components using parts that are

• Do not operate the system in an explosive atmosphere.

• Do not use the system in a test area where uncontrolled access to the test

• Do not operate the system unless an interlock is installed to monitor supply

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.

light curtains, or proximity switches/detectors).

gear (for example, hearing, hand, and eye protection).

for the system design. Refer to the system specifications.

specimen installation.

maximum allowable mass. Refer to the system specifications.

explosive.

specimen or the test system for any purpose unless the system is man-rated and all associated safety conditions are strictly enforced.

not MTS component parts or effect repairs using parts or components that are not manufactured to MTS specifications.

system is allowed when the system is in operation.

pressure into the HSM and initiate a system interlock if a low or no pressure event occurs.

Series 311 Load Frame Safety

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

• 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 System Operation

Before you apply hydraulic 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

Series 311 Load Frame

Locate and read

hazard placards/labels

Find, read, and follow the hazard placard instructions located on the equipment. These placards are placed strategically on the equipment to call attention to areas such as known crush points and electrical voltage hazards.

Locate Lockout/tautog

points

Know facility safe

procedures

Locate Emergency

Stop buttons

Know where the lockout/tagout point is for all 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.

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.

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 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 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.

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.

Be aware of

component movement

with hydraulics off

Know electrical

hazards

Remember, when hydraulic power is interrupted on a servohydraulic system, 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.

The crosshead can slowly drift down the columns if the locks are turned off and when hydraulic pressure is turned off. The crosshead can damage any test fixtures, grips, and specimen in its path. Unlock the crosshead only to reposition it. Always lock the crosshead after you have repositioned it and never leave the crosshead unlocked.

The actuator rod can also drift down when hydraulics are turned off hitting anything in its path. This uncommanded movement is because of oil movement between the pressure/return ports and oil blow by across the piston hub. Be aware that this can happen and clear the area around the actuator rod when hydraulics are turned off.

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.

Series 311 Load Frame Safety

Keep bystanders

safely away

Keep bystanders at a safe distance from all equipment. Never allow bystanders to touch 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

Know compressed gas

hazards

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.

Most servohydraulic systems contain accumulators that require a high-pressure gas precharge (pressures that exceed 138 bar [2000 psi]). In addition, some systems can contain devices, such as static supports, that are pneumatically operated. 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:

• 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.

Safety

• 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.

Series 311 Load Frame

• 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 might 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

Practice good

housekeeping

Protect hoses and

cables

To ensure a reliable product, fasteners (such as bolts and tie rods) used in MTSmanufactured 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. Overtorquing or undertorquing 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.

Keep the floors in the work area clean. Hydraulic fluid that is 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 electrical cables from spilled hydraulic fluid 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.

Protect all system hoses and cables from sharp or abrasive objects that can cause the hose or cable to fail. Never walk on hoses or cables or move heavy objects over them. Consider hydraulic distribution system layout and route hoses and cables away from areas that expose them to possible damage.

When removing hydraulic hoses for equipment repair or changing testing components (for example, hydraulic grips), make sure to cap the hose ends to avoid spilling hydraulic fluid.

Series 311 Load Frame Safety

Provide proper

hydraulic fluid

filtration.

If the system is equipped with a non-MTS hydraulic power unit, ensure proper filtration to the hydraulic distribution system and testing component s. Particles present in hydraulic fluid and cause erratic or poor system response.

Protect accumulators

from moving objects.

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

Do not exceed the

Maximum Supply

Pressure

Do not disable safety

devices

Use appropriately

sized fuses

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).

For standard MTS systems, ensure that hydraulic supply pressure is limited to a maximum 21 MPa (3000 psi). If you system has a custom application that requires higher pressure, make sure you limit supply pressure to that rated for the custom components.

Your system might 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 can result in unexpected system motion.

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

Provide means to

access out-of-reach

components

Ensure equipment is

secure

Ensure adequate lighting to minimize the chance of operation errors, equipment damage, and personal injury. You need to see what you are doing.

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.

Make sure the equipment is secure or provide vibration isolation. Some testing can be performed at resonant frequencies that might cause the equipment to vibrate and move during testing.

Safety Practices While the System Is in Operation

Wear appropriate

personal protection

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

W ear ear protection when you work near electric motors, pumps, or other devices that generate high noise levels. Some systems can create sound pressure levels that exceed 70 dbA during operation.

W ear appropriate personal protection equipment (gloves, boots, suits, respirators) whenever you work with fluids, chemicals, or powders that can irritate or harm the skin, respiratory system, or eyes.

Safety

Series 311 Load Frame

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