MTS 311 User Manual

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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

Provide test area

guards

Specimen temperature

changes

Handle chemicals

safely

Know servohydraulic

system interlocks

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

Whenever you use or handle chemicals (for example, cleaning fluids, 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.

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. T est 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.

Ensure secure cables 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 A void 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 can 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.

Series 311 Load Frame Safety

Stay clear of moving

equipment/avoid crush

points

Stay clear of mechanical linkages, connecting cables, and hoses that move because you can 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

Do not use RF

transmitters

Hazard Icons

Icon Description

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.

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.

Following are the typical hazard icons used on MTS load units.

Moving parts; pinch points. Keep clear of areas noted with this label

Part number 57-230-011.

Safety

High pressure fluid or gasses. Do not tamper with fittings or hoses.

Part number 57-230-006.

Possible tipping hazard. The machine should only be moved by qualified riggers familiar with moving heavy, delicate equipment. Once in final operation position, the frame should be bolted to a suitable reaction mass.

Part number 572300-29.

Series 311 Load Frame

Icon Description

Do not climb on machine. Part number 57-230-037.

Read the manuals or instructions. Become familiar with safety information. Also become familiar with operating and maintenance information.

Part number 57-237-501.

Possible explosive or flying debris. Wear appropriate protection such as safety goggles and hearing protection.

Part number 57-237-506.

Lift point. Part number 572375-13.

Additional Hazard Labels

This section provides information on additional hazard labeling typically included on load units. Because of the various configurations of the 311 Load Unit, the presence or location shown in the following figures might be different on your particular load unit. Part numbers are provided should replacement labels be necessary due to damage.

Series 311 Load Frame Safety

Base Assembly

View A-A

Item Part Number Description

3 4

045-384-101 Warning. High force moving parts. Can cause severe injury or

equipment damage. Stay clear and use eye protection while test is in progress. Read instructions before operating or servicing.

037-588-901 Identification label. Includes model number, part number, serial

number, force capacity, and manufacture date. 050-275-301 Information label. No step. 050-275-201 Caution. Heavy control panel (up to 15 kg/30 lbs). Can cause

personal injury or equipment damage.

Support control panel until bolts are out. Let down slowly. 005-905-101 Warning. If lift cylinder line is opened, air may enter causing

crosshead to drop when unlocked. Bleed both cylinders before

unlocking crosshead.

Safety

Series 311 Load Frame

Cylinder Assembly

Item Part Number Description

037-588-801 Identification label. Includes model number, serial number,

assembly number, force, effective date, static stroke, dyn stroke, and hydrostatic bearing.

038-202-801 Warning. Subjecting this equipment to working pressure above

3000 psi (21 MPa) can result in component rupture and injury to personnel. See the product manual for safety precautions before operating.

Series 311 Load Frame Safety

Crush Point Hazards

Crush Zones

It is important to stay clear of any potential crush points when the system is operating. You should know where the crush points are in your system and protect yourself and others from those crush points with appropriate safety devices. The following paragraphs describe crush points and precautions to take while working around crush points.

Locations A crush point exists between the platen and crosshead on load frames where the

actuator piston rod and specimen move (both areas are shown). Another potential crush point exists where the lower end of the actuator piston rod extends below the platen and the bottom of the load frame/load frame.

Precautions Keep clear of any mechanical linkage that moves within a closed area. If the

linkage should move (when the system starts or due to mechanical failure), very high forces can be present that could pinch, cut, or crush anything in the path of linkage movement.

Safety

Never allow any part of your body to enter the path of machine movement or to touch moving machinery, linkages, hoses, cables, specimens, etc. These present serious crush points or pinch points.

Series 311 Load Frame

Installation

Contents Unpacking the Load Frame 34

Prerequisite You will need a fork lift or overhead crane capable of lifting the load frame.

This section describes how to install the Series 311 Load Frame.

Connecting Cables 38 Connecting Hydraulics 39 Removing the Shipping Collars 40

Ensure the lifting equipment can accommodate the weight of the load frame, see the following table.

Series 311 Load Fame Weights

Model Weight

311.11 900 kg (2000 lb)

311.21 2000 kg (4500 lb)

311.31 3500 kg (8000 lb)

311.41 8500 kg (19,000 lb)

311.51 16,000 kg (36,000 lb)

311.61 27,000 kg (60,000 lb)

311.71 36,000 kg (80,000 lb)

Procedure Perform the following to install the load frame.

1. Unpack the load frame. Go to “Unpacking the Load Frame” on page 34 to unpack and move the load frame.

2. Connect the cables between the load frame and controller. Go to

“Connecting Cables” on page 38 to make the various controller connections.

Return to this procedure when done.

3. Connect the hydraulic hoses between the load frame and hydraulic service manifold. Go to “Connecting Hydraulics” on page 39 to connect the load frame to your hydraulic supply system. Return to this procedure when done.

4. Remove the collars on the columns so the load frame can be used. Go to

“Removing the Shipping Collars” on page 40 to complete the installation

procedure.

Series 311 Load Frame Installation

Unpacking the Load Frame

WARNING

Wooden Pallet

Protective Wrapping

Strap

Eyebolt

Unpacking the Load Frame

Required equipment The load frame is shipped horizontally on a wooden pallet. You will need the

following equipment to unpack the load frame:

• Lifting slings—not chains—to lift the load frame from its pallet

• Lifting chains to tip the load frame upright

• Rubber mats for the load frame’s feet to rest on

• Wooden blocks for the load frame’s columns to rest on

• A knife to cut the packing straps

The load frame is extremely heavy. The weight of the load frame can seriously hurt you and damage your load

frame.

Do not allow the load frame to drop or topple.

• Ensure that your chains, slings, and crane have a working capacity greater than the load frame’s weight (see “Series 311 Load Fame Weights” on page

33).

• Ensure that the lifting eyebolts are tight.

• Ensure that the crosshead locking bolts are fully tightened.

• Lift the load frame only high enough to clear its pallet.

• Operate the crane smoothly to prevent sudden shocks to the sling.

1. Unpack the load frame from its shipping container.

Cut the packing straps and remove any bolts as needed. Make sure the lifting eyebolts are tight (two eyebolts are located on the crosshead).

Installation

Unpacking the Load Frame

Series 311 Load Frame

Unpacking the Load Frame

2. Inspect the load frame for shipping damage.

Look for the following:

• Scratches in the load frame or columns

• Damaged electrical connections

• Damaged hydraulic connections

• Dents and other structural damage

• Torn, kinked, or breaking hoses

Report any damage found to both the carrier and MTS. In the U.S. and Canada, call the MTS HELPLine at 1-800-328-2255. Elsewhere, contact your local MTS office.

3. Clamp the crosshead.

Normally, the crosshead is locked in place for shipping purposes. Ensure the crosshead is clamped in place; check that the shipping collars are on diagonally opposite columns directly above and below the crosshead. Refer to the following table for the torque specifications.

Shipping Collar Torque Specifications

Model Shipping Collar Torque

311.11 75 N•m (55 lbf•ft)

311.21 110 N•m (80 lbf•ft)

311.31 150 N•m (110 lbf•ft)

311.41 270 N•m (200 lbf•ft)

311.51 920 N•m (680 lbf•ft)

* Contact MTS Systems Corporation for torque specifications for the

Model 311.61 and Model 311.71 Load Frames.

4. Tip the load frame upright.

A. Attach the chains to the lifting eyebolts. Move the crane/forklift to keep

the chains as straight as possible. When attaching both eye bolts to the same point, do not exceed a 30° chain angle as shown in the following figure. Exceeding a 30° chain angle causes undesired stress or strain on the eye bolts or hoist rings.

Series 311 Load Frame Installation

Unpacking the Load Frame

Crane Travel

30° Maximum

30° maximum when connecting both eye bolts to a single point.

B. Slowly raise the load frame to its upright position. As the unit rises,

keep moving the crane to keep the chains as straight as possible.

Installation

C. When the load frame is upright, raise it slightly to clear the shipping

pallet.

5. Move the load frame to its final location.

Before you move the load frame review the following:

• The floor where the load frame will sit can bear its weight (see “Series

311 Load Fame Weights” on page 33).

• The path to the load frame’s destination is clear and uncluttered.

• The area where the load frame will sit is clean and well lit, with all

hoses and cables moved out of harm’s way.

• The eyebolts are tight.

• The crosshead shipping collars are properly torqued.

Lift the load frame only as high as necessary. Move it slowly to its installation site.

Series 311 Load Frame

Unpacking the Load Frame

Load Unit

Install Shims to Level

Floor

Isolation Pads

6. Place the load frame onto the isolation pads.

Install stock metal shims between the pads and the floor.

7. Clean the columns.

Some load frame columns are wrapped with protective paper. Remove the paper as needed. All load frame columns are covered with a protective grease. Remove the grease using a grade #1 kerosene, mineral spirits, or equivalent petroleum-based solvent. Ensure adequate ventilation when cleaning the columns, see the solvent container for additional warnings and cautions.

8. Remove the chains.

Series 311 Load Frame Installation

Connecting Cables

Your controller manual should have cabling information about the connections described in this section. Most controller manuals provide the signal pinouts of the connector and assembly numbers for standard MTS cables.

Note Many of the cables are connected to optional equipment. The following

Prerequisite You must have either a cable assembly drawing of your test system, or you must

know the system controller well enough to determine each type of cable connection.

procedure shows the most common connections. The exact connector locations vary quite a bit among the various models of the load frame.

Installation

1. The force transducer is connected to a DC conditioner in the controller.

2. The ground connection is located on the back of the control panel. This is usually connected to a chassis ground on a console or the controller chassis.

3. The load frame control panel is connected to the controller chassis. It contains the emergency stop and crosshead lock signals.

4. The servovalve is connected to a valve driver in the controller.

5. The displacement sensor (also called an linear variable displacement transducer or LVDT) is connected to an AC conditioner in the controller.

Series 311 Load Frame

Connecting Hydraulics

The procedure describes how to connect the load frame to the hydraulic power source. The load frame can be connected directly to the hydraulic power unit (also called HPU), to hydraulic plumbing in the workplace, or through a hydraulic service manifold (HSM).

Note The internal hydraulic connections from the actuator manifold and

accessories such as the hydraulic lifts and locks should already be made.

The load frame actuator usually has a manifold mounted to it. The manifold connects the ports on each end cap to the ports for a servovalve. The hydraulic connection are made at this manifold.

1. Connect the return line from the hydraulic power source to the hydraulic port on the manifold labeled “R”.

2. Connect the pressure line from the hydraulic power source to the hydraulic port on the manifold labeled “P”.

Connecting Hydraulics

3. Connect the drain line from the hydraulic power source to the hydraulic port on the manifold labeled “D”.

4. Turn on the HPU and check for any hydraulic pressure leaks.

5. Select low pressure for the load frame and check for hydraulic leaks in the load frame.

6. Select high pressure for the load frame and check for hydraulic leaks in the load frame.

7. Bleed the air out of the hydraulic lift cylinders. See “Bleeding the Hydraulic

Lift Cylinders” on page 56.

8. Return to the installation procedure.

Series 311 Load Frame Installation

Removing the Shipping Collars

CAUTION

Removing the Shipping Collars

When the load frame is shipped, the crosshead is clamped in position with shipping collars.

The collars should not be removed unless the lift cylinders have been bled, full hydraulic power has been applied to the crosshead, and the crosshead lock control is in the lock position.

Once the collars have been removed, they should be kept rather than discarded. The collars can be installed on the columns below the crosshead and used as stops to limit the crosshead travel should the crosshead fall. The collars are also used to mechanically restrain the crosshead during some maintenance procedures.

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.

Note If the shipping collars are being used as stops to limit the crosshead

travel should the crosshead fall, they should be removed before positioning the crosshead and reinstalled after the crosshead has been repositioned.

Installation

Series 311 Load Frame

Operation

Contents Lift and Lock Controls 42

This section describes how to use the Series 311 Load Frame.

Crush Point Hazards 43 Installing a Specimen 44

Series 311 Load Frame Operation

Lift and Lock Controls

Emergency Stop

Crosshead Lift / Lock Control

Emergency Stop

Locks

Crosshead Controls

Stop

Down

Unclamp Clamp

Lift and Lock Controls

The crosshead lift and lock controls for the load frame are located on the front of the load frame. Two types of control panels are used.

Series 311 Load Frame Controls

Control Description

Crosshead Lift/Lock Controls

Controls the movement and clamping of the crosshead. The left handle raises and lowers the crosshead. The right handle clamps and unclamps the crosshead to lock or unlock it. The crosshead must not be moved while it is clamped. See “Installing a Specimen” on page 44 for procedures using these controls.

Emergency Stop

Shuts down the hydraulic pressure and stops the test program. Press this button to shut down hydraulic power, and twist the switch clockwise to release it. Use the Emergency Stop button to shut down your test if something unexpected should happen.

Operation

Series 311 Load Frame

Crush Point Hazards

Crush Zones

Crush Point Hazards

Locations A crush point exists between the platen and crosshead on load frames where the

Precautions Keep clear of any mechanical linkage that moves within a closed area. If the

linkage should move (when the system starts or due to mechanical failure), very high forces can be present that could pinch, cut, or crush anything in the path of

Series 311 Load Frame Operation

linkage movement. Never allow any part of your body to enter the path of machine movement or to

touch moving machinery, linkages, hoses, cables, specimens, etc. These present serious crush points or pinch points.

Installing a Specimen

CAUTION

Installing a Specimen

The procedure to install a specimen varies due to the variety of test fixtures, grips, and the type of specimen being installed. This section should be considered a guideline. You need to modify this procedure to suit your equipmen t.

Prerequisite You must have the necessary grips and/or fixturing installed. You must also have

the controller set up to control the actuator movement, and you must have a test program defined.

Procedure 1. Set things up for specimen installation.

A. Ensure that the crosshead is locked. B. Turn on system electrical power. C. Turn on high hydraulic pressure. D. Adjust the actuator to its start position (usually mid-displacement). The

starting position of the actuator depends on the type of fixtures, grips, and the test being set up.

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.

2. Set the crosshead position.

The crosshead position depends on the length of the specimen being tested, the starting position of the actuator, and the size of the fixtures or grips being used.

A. This step pressurizes the lift actuators. The crosshead might have

shifted position while hydraulic pressure was turned off. Briefly turn the Crosshead Lift/Lock Controls to the lift

crosshead position to apply a slight upward pressure to the crosshead.

Then return the lift control to the stop position.

B. Use the Crosshead Lift/Lock Controls to unclamp the

crosshead. Wait 30 seconds for the pressure in the crosshead locks to drop to zero.

Operation

Series 311 Load Frame

Installing a Specimen

Note Always lower the crosshead to where you want it. The pressure

remaining in the lift cylinders after raising the crosshead can slightly shift its alignment. Lowering the crosshead to its final position removes this pressure and improves alignment.

C. Use the Crosshead Lift/Lock Controls to move the crosshead

to a point where you can install the specimen (or specimen fixture) into the upper grip or fixture without obstruction.

Set the control to the stop position “O” before proceeding.

D. Use the Crosshead Lift/Lock Controls to clamp the

crosshead to lock it in its current position. Wait 30 seconds for the locks to fully clamp the columns.

3. Install the specimen into the grips or fixtures.

Specimen installation will vary according to the type of grip or fixture being used. If grips are not used then the specimen is installed in a special fixture designed for a specific specimen to be installed in a specific load frame.

See the appropriate grip manual or fixture drawings for installation instructions. MTS manufactures a variety of grips:

Note Hydraulically controlled grips require a Series 685 Hydraulic Grip Supply.

• The Series 641 Hydraulic Wedge Grips (hydraulically controlled) are

specifically designed for static or fatigue testing applications. They are available with a self aligning feature.

• The Series 643.6X Tension/Compression Grips (mechanical) are used

for testing threaded-end and button-end specimens in tension, compression, or tension/compression.

• The Series 646 Hydraulic Collet Grips (hydraulically controlled) are

designed to perform in a wide variety of testing applications (for example, high and low cycle fatigue, tension, and compression).

• The Series 647 Hydraulic Wedge Grips (hydraulically controlled) are

specifically designed for static or fatigue testing applications. There are a variety of configurations of this grip.

• The Series 649 Wedge Grips are specifically designed for static or

fatigue testing applications. These are a mechanical version of the Series 647 Hydraulic Wedge Grips.

Each type of grip requires the specimen or specimen fixture to fit properly into the grip.

Series 311 Load Frame Operation

Installing a Specimen

Operation

Series 311 Load Frame

Maintenance

Contents Maintenance Intervals 51

This section describes the procedures which must be periodically performed to ensure the continued safe and effective operation of your load frame. The maintenance interval table on page 51 shows a schedule to maintain your load frame.

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

Series 311 Load Frame Maintenance

Routine Maintenance Overview Checklist

Recommended service to be performed at each running time interval noted

Calendar Time using 8 hour Running Time

Daily Weekly Biweekly Annually

rate per day

Running Time-Hours 8 40 80 500 1000 1,500 2,000

Check Actuator Platen Area to be Clean Monitor Filter Indicators X

Check hazard labels for legibility X Check Hoses/Cables/Connectors X Check Crosshead/Lifts/Supports X Check Actuator to be Dry X Check Hydraulic Service Manifold X Check Lift Seal Condition to be Dry X Check Lock Seal Condition to be Dry X Bionix Lubricate Axial/Torsional Spline

(75-100 hrs) Check Actuator X Crosshead/Load Frame

Check Crosshead/Lifts/Supports Lift Seal Condition is Dry MTS MTS MTS MTS MTS

Lock Seal Condition is Dry MTS MTS MTS MTS MTS Crosshead Columns are Clean MTS MTS MTS MTS MTS Column Abrasions are Acceptable MTS MTS MTS MTS MTS Crosshead Speed is Appropriate MTS MTS MTS MTS MTS Crosshead Unlock Causes Program

Interlock Load frame Support Airbags/Pads MTS MTS MTS MTS MTS Crosshead Movement is Smooth MTS MTS MTS MTS MTS Hydraulic Crosshead Locks are

Functioning Properly Bleed Crosshead Lift Cylinders MTS MTS Lubricate Manual Crosshead Lock Bolts MTS

†

MTS

MTS MTS MTS MTS MTS

MTS MTS MTS MTS

MTS MTS

Maintenance

Series 311 Load Frame

Routine Maintenance Overview Checklist

Recommended service to be performed at each running time interval noted

Calendar Time using 8 hour Running Time

Daily Weekly Biweekly Annually

rate per day

Running Time-Hours 8 40 80 500 1000 1,500 2,000

Actuator Cursory Check of Actuator MTS MTS MTS MTS Actuator Area is Dry MTS MTS MTS MTS Actuator Platen Area is Clean MTS MTS MTS MTS Piston Rod Wear is Acceptable MTS MTS MTS MTS Bionix Lubricate Axial/Torsional Spline

(75-100 hrs) Hydraulic Service Manifold Cursory Check of Hydraulic Service

Manifold Monitor Filter Indicators MTS MTS MTS MTS Manifold Hose Connections are Tight MTS MTS MTS MTS Accumulator Connections are Dry MTS MTS MTS MTS Accumulator Connections are Tight MTS MTS MTS MTS Accumulator Caps/Guards are Present MTS MTS MTS MTS Oil on the Gas Side of the Piston MTS MTS MTS MTS Check and Adjust Pressure in

Accumulator Change Filters MTS Low Pressure Adjustment (Model 294) MTS Hoses/Cables Cursory Check of Hoses/Cables/

Connectors

MTS MTS MTS MTS

Absence of Hose Abrasions, Blisters, Vulcanizing

Cable Condition and Routing is Acceptable

Check Transducer Connections MTS MTS MTS MTS Hose Connections and Crimps are Dry MTS MTS MTS MTS Complete System Overall System Condition is Acceptable

to Use Turning Parameters are Appropriate/

System Stable

Series 311 Load Frame Maintenance

MTS MTS MTS MTS

Routine Maintenance Overview Checklist

Recommended service to be performed at each running time interval noted

Calendar Time using 8 hour Running Time

Daily Weekly Biweekly Annually

rate per day

Running Time-Hours 8 40 80 500 1000 1,500 2,000

E-Stop is Working if Applicable MTS MTS MTS MTS Response to Full Stroke Waveform,

Visual and Audible Valve Balance check displacement

control Valve Dither Response MTS MTS MTS MTS Grips Cursory Check of Grips/Grip Control MTS MTS MTS MTS Grip Supply Connections are Dry MTS MTS MTS MTS Grip Seals are Dry MTS MTS MTS MTS Grip Action is Acceptable MTS MTS MTS MTS Lubricate Grip Inserts MTS MTS MTS MTS

*Symbol denotes services performed by equipment operators. Most of these procedures involve visual checks that should not interfere with test system operation. These checks are also completed by trained field service engineers on each Routine Maintenance visit.

†Symbol denotes service performed by trained field service engineers as part of an MTS Routine Maintenance plan. Some of these procedures require special service tools and/or specific service training to complete.

MTS MTS MTS MTS

Maintenance

Series 311 Load Frame

Maintenance Intervals

The following table lists the recommended interval for each of these procedures.

Maintenance Intervals

What to Do When to Do It

Making daily inspections

Cleaning the load frame columns

Preventing rust

Before the start of each day’s testing. See “Making Daily Inspections” on

When the columns become greasy or dirty.

Depends on the operating environment; more often in humid environments.

Checking the accumulators’ precharge pressures

Bleeding the hydraulic lift cylinders

At least once a month; more often as required by operating conditions.

When the crosshead begins to move roughly; if the sealed side of the hydraulic supply is opened to air.

Replacing the hydraulic lift cylinder seals

Adjusting the hydraulic locks

Replacing the hydraulic lock seals

†

When hydraulic fluid begins leaking out of the lift cylinders.

When the crosshead sticks or moves jerkily on the column.

When hydraulic fluid begins leaking from the locks.

How to Do It

page 52. See “Cleaning the Columns” on page

53. See “Preventing Rust” on page 54.

See “Checking the Accumulators’

Precharge” on page 55.

See “Bleeding the Hydraulic Lift

Cylinders” on page 56.

Contact MTS Systems Corporation to schedule service.

See “Adjusting the Hydraulic Locks” on page 59.

Contact MTS Systems Corporation to schedule service.

Aligning the force transducer

After installing the actuator or force transducer; when a better alignment

See “Aligning the Force Transducer” on page 61.

between the two is desired.

Servicing the actuator

†

When the actuator begins leaking

(see your actuator manual) hydraulic fluid or its performance becomes poor.

For maintenance items listed that do not have a corresponding procedure in this manual, call the MTS

HELPLine.

† This cannot be repaired by the customer; call the MTS HELPLine.

Series 311 Load Frame Maintenance

Making Daily Inspections

Before the start of each day’s testing, do a quick inspection of your load frame. Following are typical things that should be checked daily:

• Ensure that there are no leaks from the hydraulic lifts or locks.

• Ensure that there are no leaks from the actuator , hydraulic service manifold,

servovalve, or accumulators.

• Ensure that electrical connections are tight, with no frayed or poorly routed

cables.

• Ensure that hoses are routed properly and fittings are not leaking.

• Ensure hazard labels are legible. Replace if damaged.

Maintenance

Series 311 Load Frame

Cleaning the Columns

CAUTION

The crosshead locks can not securely clamp the crosshead to dirty or greasy columns. You will need #1 grade kerosene, mineral spirits, or equivalent petroleum-based solvent and lint-free cloths to perform this procedure.

The crosshead can slide down the columns. Crosshead cleaning takes place in a crush zone where pinched fingers and

crushed hands can occur.

Do not position yourself in a crush zone. Always lock the crosshead after moving it. Always turn off hydraulic pressure before cleaning the columns. Wait two minutes for pressure to bleed off before starting work.

1. Ensure that the crosshead is locked.

Cleaning the Columns

2. Using a clean, lint-free cloth, clean the exposed surfaces of the columns with #1 grade kerosene (or equivalent).

3. Turn on the system electrical power.

4. Apply high hydraulic pressure to the load frame.

5. If there is a specimen in the load frame, remove it.

6. Unclamp the crosshead and move it to expose the uncleaned section of the columns.

7. Clamp the crosshead.

8. Turn the hydraulic pressure to the load frame off. Wait two minutes for the pressure to bleed off before going on to the next step.

9. Clean the remaining sections of the columns.

Series 311 Load Frame Maintenance

Preventing Rust

WARNING

Unpainted surfaces: Spray with silicone, and then wipe with a clean, lint-free cloth. Or, wipe with a clean, lint-free cloth dampened with clean hydraulic fluid.

Chrome plated surfaces: For microscratches, wipe with a clean, lint-free cloth dampened with #1 kerosene. For rust discoloration, polish with a very fine emery cloth, and then wipe down.

Black oxide surfaces: Spray with silicone, and then wipe with a clean, lint-free cloth. Or, wipe with a clean, lint-free cloth dampened with clean hydraulic fluid.

Painted surfaces: For small scratches, use touchup paint. For large scratches, sand, prime, and use touchup paint.

Preventing Rust

Where you operate the load frame determines how often you take rust prevention measures. Humid and corrosive environments require more prevention.

Recommended

supplies:

• 1 grade kerosene

• Silicone spray

• 000 emery cloth

• Touchup paint; MTS part numbers 011-059-854 (beige),

011-059-856 (grey), 044-587-501 (brown)

• Metal primer paint

• Lint-free cloths

The crosshead can slip if the columns are still damp with kerosene. You can be hurt and your equipment damaged.

The crosshead locks cannot securely clamp on damp columns. Wait until the columns are dry to the touch before moving and locking the crosshead.

Maintenance

Series 311 Load Frame

Checking the Accumulators’ Precharge

An accumulators’ correct precharge pressure is written on its label. Begin by checking precharge pressures at least once a month.

See the Series 111 Accumulator Product Information manual for the complete details on checking the precharge intervals and servicing the accumulators.

Record both the pressures and the room temperature in a log book. Use these readings as a basis for increasing or decreasing the interval between pressure checks.

Generally, recharging is required when there is a change of ±1.4 MPa (200 psi) in the pressure line accumulator or ±50% in the return line accumulator.

Series 311 Load Frame Maintenance

Bleeding the Hydraulic Lift Cylinders

Bleed Ports can be located at either end of the cylinder

Bleeding the Hydraulic Lift Cylinders

Bleed both hydraulic lift cylinders whenever the crosshead does not move smoothly. Also bleed them whenever the sealed side of the hydraulic system has been opened to air.

Maintenance

Location of the Bleed Ports

Series 311 Load Frame

Bleeding the Hydraulic Lift Cylinders

CAUTION

WARNING

The crosshead can slowly drift down the columns if the locks are turned off and the 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.

1. Ensure the crosshead is locked.

2. Turn on system electrical power.

3. Reset any active interlocks at the test controller.

4. Turn on high hydraulic pressure.

5. If there is a specimen in the load frame, remove it.

The lifts contain hydraulic fluid under high pressure. If the bleed port screw is unscrewed all the way, the screw can fly out of its

port at high velocity and it could hurt you or damage your equipment.

Unscrew the bleed port screw no more than 1/2 turn to vent the trapped air.

Open to Bleed

6. Use a 1/8 inch hex key (or slotted screwdriver, depending on model number) to open one of the bleed ports.

Do not unscrew the bleed port screw more than 1/2 turn.

Series 311 Load Frame Maintenance

Bleeding the Hydraulic Lift Cylinders

7. Briefly turn the lift control to lift the crosshead position so the lift cylinders

8. Shut the bleed port when bubble-free fluid begins oozing out. If necessary,

9. Repeat Step 6 through Step 8 to bleed the air out of the other lift cylinder.

pressurize. Then return it to the stop crosshead position.

Close When Bubble-Free

again pressurize the lift cylinders to force all the air out.

Note If fluid continues to leak out of a shut bleed port, turn off hydraulic

pressure to the load frame. Let the pressure in the lift cylinders return to zero. Then replace both bleed port screws (MTS part number 010-037-601).

10. Turn on high hydraulic pressure. If pressure was reduced at the hydraulic power unit, restore full pressure.

11. Briefly tu rn th e Lift Control to the lift crosshead position to pressurize the lift cylinders. Then return it to the stop crosshead position.

12. Unlock the crosshead and exercise the crosshead. Then return to the stop crosshead position. Raise and lower the crosshead to check for smooth operation. Lock the crosshead.

13. If the crosshead does not move smoothly, go back to Step 4 and continue from there.

Maintenance

Series 311 Load Frame

Adjusting the Hydraulic Locks

CAUTION

Hydraulic locks will need adjustment if the crosshead does not move smoothly after bleeding the lift cylinders. Adjustment might also be needed if the crosshead slips under full load. If adjusting the hydraulic locks does not fix these problems, contact MTS Systems Corporation.

1. Turn on electrical power at the controller. Do not turn on hydraulic pressure yet.

2. If the crosshead is already at a comfortable working level with no specimen installed, proceed to the next step.

If not, position the crosshead for a comfortable working level. Proceed as follows:

A. Turn on high hydraulic pressure. B. If there is a specimen in the load frame, remove it. C. Unclamp the crosshead.

Adjusting the Hydraulic Locks

D. Move the crosshead to a comfortable working height. E. Clamp the crosshead. F. Turn off hydraulic pressure.

The crosshead can slowly drift down the columns if the locks are turned off and the 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.

3. Install the shipping collars on diagonally opposite columns directly above and below the crosshead. See “Shipping Collar Torque Specifications” on page 35.

4. Use the Crosshead Lift/Lock Controls to the unclamp the crosshead to remove pressure from the hydraulic locks. Wait two minutes for the pressure in the locks to drop to zero before going on to the next step.

5. Use a spanner wrench to tighten the clamping piston onto the tie rod until all slack is removed and the clamping piston bottoms into the cylinder.

6. Loosen the clamping piston 1/8 turn.

7. Repeat Step 5 and Step 6 for the remaining hydraulic locks.

8. Turn on electrical power at the test controller if you have not already done so and reset any active interlocks at the test controller.

Series 311 Load Frame Maintenance

Adjusting the Hydraulic Locks

9. Turn on high hydraulic pressure.

10. Use the Crosshead Lift/Lock Controls to the clamp the crosshead in

position to pressurize the hydraulic locks.

11. Remove and reinstall the shipping collars for load frame operation. See

“Removing the Shipping Collars” on page 40.

Maintenance

Series 311 Load Frame

Aligning the Force Transducer

WARNING

This section describes how to align a force transducer with the load frame actuator.

Alignment takes place in a crush zone with hydraulic pressure on. Hands can be crushed and equipment can be damaged equipment when

hydraulics are turned on. Be careful when working in a crush zone.

To reduce the hazards in this procedure:

• Ensure that you set and enable displacement interlocks to limit the

actuator’s movement.

• Ensure that the crosshead is locked.

• Reduce the load frame’s hydraulic pressure to low.

Aligning the Force Transducer

• Keep your hands out of the crush zone except when performing the

steps needed to complete this procedure.

Required equipment • Torque wrench with a 5 to 135 N•m (5 to 100 lbf•ft) range

• Molykote G·n paste

• Rubber mallet

• 0.0025 mm (0.0001 in) precision dial indicator with a magnetic base

Procedure 1. Set up the load frame.

A. If grips are installed, remove them. B. Loosen the clamp rings (two rings are usually located on diagonally

opposite columns) and slide them down the column.

C. Turn on system electrical power. D. Turn on high hydraulic pressure. E. Position the actuator at midstroke. F. Set and enable the test controller’s upper and lower limit detect

interlocks to limit the actuator’s movement to 2 mm (0.10 in) in each direction.

G. Unclamp the crosshead and reposition it so there is about 450 mm (18

in) between the top of the actuator and the bottom of the force transducer.

H. Clamp the crosshead to lock it in place. I. Set the clamp rings below the crosshead and tighten them to the

columns.

Series 311 Load Frame Maintenance

Aligning the Force Transducer

J. If your load frame has an anti-rotate actuator, unscrew the four cap

screws that attach the anti-rotate plate to the bottom of the piston. The anti-rotate plate is at one end of the actuator.

2. Check the alignment.

Check the alignment between the force transducer and the actuator. A. Attach the dial indicator to the actuator.

On a low profile force transducer, adjust the indicator to take the reading along the edge of the loading surface.

On cylindrical style force transducers, adjust the indicator so that its stylus just touches the polished bottom edge of the transducer.

B. Zero the indicator.

Maintenance

Attaching and Zeroing the Indicator

Series 311 Load Frame

Aligning the Force Transducer

C. Slowly turn the actuator to rotate the indicator 360° around the force

transducer. Stop frequently to take indicator readings. Keep your hands off the

actuator and indicator when taking the readings. Compute the total indicator runout (TIR). Take the maximum dial indicator reading and subtract the minimum dial indicator reading.

TIR Tolerance

Model TIR

311.11 0.0381 mm (0.0015 in)

311.21 0.0508 mm (0.002 in)

311.31 0.0762 mm (0.003 in)

311.41 0.1016 mm (0.004 in)

311.51 0.1016 mm (0.004 in)

311.61 0.1016 mm (0.004 in)

311.71 0.1016 mm (0.004 in)

D. If the TIR is within the tolerance (as listed in the table “TIR Tolerance”

on page 63), the force transducer is accurately aligned with the actuator. Go to Step 5.

If the TIR is greater than the tolerance, the force transducer needs to be aligned with the actuator. Start over with Step 2.

3. Prepare the force transducer.

Loosen the jackbolts or setscrews in 1/4 turn steps to remove most of the tension on the force transducer. Remove and lubricate each bolt one at a time.

4. Align the force transducer.

This step describes how to align a force transducer to the crosshead. A. Lightly tap the transducer wi th the rubber mall et to change its position

until you get a TIR of 0.038 mm (0.0015 in) or less.

Series 311 Load Frame Maintenance

Aligning the Force Transducer

B. Tighten to 5% of the torque recorded on the identification plate using

the appropriate bolt torque sequence.

Bolt Torque Sequence

C. Rotate the indicator to see if the TIR is still 0.038 mm (0.0015 in) or

less. If not, loosen the nut or preloader collar and return to Step 3. (Loosen the preloader collar following the sequence shown below.)

D. Repeat Steps B and C to tighten the force transducer for the fol lowing

torque progression: 50%, 75%, and 100%.

Maintenance

Series 311 Load Frame

load cell

Aligning the Force Transducer

Cap Screw Torque Specifications

Cap Screw Size Torque

†

311.11

‡

311.11

311.21) 1-8 UNC-2A

311.31 1-8 UNC-2A

311.41

311.51 1-1/2-6 UNC-2A

* Cap screw specifications for the Model 311.61 and 311.71 Load Frames

are contained on the drawings and parts lists for the specific unit. † with a 100 kN (22 kip) force transducer ‡ with a 250 kN (55 kip) force transducer

§ with a 1500 kN (330 kip) force transducer # with a 2500 kN (550 kip) force transducer

5/8-11 5/8-11

1-1/2-6 1-1/2-6

70 N

•m (52 lb•ft)

176 N

•m (130 lb•ft)

570 N•m (420 lb•ft) 635 N•m (470 lb•ft) 1220 N

•m (900 lb•ft)

1760 N•m (1300 lb•ft) 1490 N•m (1100 lb•ft)

5. Finish the procedure.

In this step, you complete the force transducer alignment procedure. A. Remove the dial indicator. B. If you reduced pressure at the hydraulic power unit, restore full

hydraulic pressure.

C. Turn the load frame’s hydraulic pressure to off.

Series 311 Load Frame Maintenance

Aligning the Force Transducer

Maintenance

Series 311 Load Frame

Servohydraulic Load Frame Maintenance and Service Logs

Contents 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

Servohydraulic Load Frame Maintenance and Service Logs

8 Hours/Daily

8 Hours/Daily Service Interval Recommendation

Check Actuator Platen Area to be Clean

Date Performed by Performed by Performed by Notes

Monitor Filter Indicators

Check Hazard Labels for Legibility

Servohydraulic Load Frame Maintenance and Service Logs

40 Hours/Weekly

40 Hours/Weekly Service Interval Recomme ndation

Check Hoses/ Cables/ Connectors

Date Performed by Performed by Performed by Performed by Performed by Performed by Notes

Check Crosshead/ Lifts/Supports

Check Actuator Area to Be Dry

Check Hydraulic Service Manifold

Check Lift Seal Condition to be Dry

Check Lock Seal Condition to be Dry

Servohydraulic Load Frame Maintenance and Service Logs

80 Hours/Biweekly

80 Hours/Biweekly Service Interval Recommendation

Bionix Lubricate Axial/Torsional Spline (75-100 hrs)

Date Performed by Performed by Notes

Check Actuator

Servohydraulic Load Frame Maintenance and Service Logs

500 Hours: Crosshead and Frame

500 Hours Service Interval Recommendation

500 Hours: Crosshead and Frame

Check Crosshead/ Lifts/ Supports

Date Performed by Performed by Performed by Performed by Performed by Notes

Crosshead Speed is Appropriate

Lift Seal Condition is Dry

Crosshead Unlock Causes Program Interlock

Lock Seal Condition is Dry

500 Hours Service Interval Recommendation

Load Frame Support/ Airbags/Pads

Crosshead Columns are Clean

Crosshead Movement is Smooth

Column Abrasions are Acceptable

Date Performed by Performed by Performed by Performed by Notes

Servohydraulic Load Frame Maintenance and Service Logs

500 Hours: Actuator

500 Hours Service Interval Recommendation

Cursory Check of Actuator

Date Performed by Performed by Performed by Notes

Bionix Lubricate Axial/Torsional Spline (75-100 hrs)

Actuator Area is Dry

500 Hours Service Interval Recommendation

Piston Rod Wear is Acceptable

Actuator Platen Area is Clean

Date Performed by Performed by Notes

Servohydraulic Load Frame Maintenance and Service Logs

500 Hours: HSM

500 Hours Service Interval Recommendation

Cursory Check of Hydraulic Service Manifold

Date Performed by Performed by Performed by Performed by Notes

Accumulator Connections are Tight

Monitor Filter Indicators

Accumulator Caps/Guards are Present

Manifold Hose Connections are Tight

500 Hours Service Interval Recommendation

Oil on the Gas Side of the Piston

Accumulator Connections are Dry

Check and Adjust Pressure in Accumulator

Date Performed by Performed by Performed by Performed by Notes

Servohydraulic Load Frame Maintenance and Service Logs

500 Hours: Hoses and Cables

500 Hours Service Interval Recommendation

Cursory Check of Hoses/ Cables/ Connectors

Date Performed by Performed by Performed by Performed by Performed by Notes

Absence of Hose Abrasions, Blisters, Vulcanizing

Cable Condition and Routing is Acceptable

Check Transducer Connections

Hose Connections and Crimps are Dry

Servohydraulic Load Frame Maintenance and Service Logs

500 Hours: Overall Complete System

500 Hours Service Interval Recommendation

500 Hours: Overall Complete System

Overall System Condition is Acceptable to Use

Date Performed by Performed by Performed by Performed by Notes

Valve Balance check displacement control

Tuning Parameters are Appropriate/ System Stable

Valve Dither Response

E-Stop is Working if Applicable

500 Hours Service Interval Recommendation

Response to Full Stroke Waveform, Visual and Audible

Date Performed by Performed by Notes

Servohydraulic Load Frame Maintenance and Service Logs

500 Hours: Grips

500 Hours Service Interval Recommendation

Cursory Check of Grips/Grip Control

Date Performed by Performed by Performed by Performed by Performed by Notes

Grip Supply Connections are Dry

Grip Seals are Dry

Grip Action is Acceptable

Lubricate Grip Inserts

Servohydraulic Load Frame Maintenance and Service Logs

1000 Hours

1000 Hours Service Interval Recommendation

All 500 hr Maintenance Procedures

Date Performed by Performed by Performed by Notes

Hydraulic Crosshead Locks are Functioning Properly

Bleed Crosshead Lift Cylinders

Servohydraulic Load Frame Maintenance and Service Logs

2000 Hours: Annual Maintenance

2000 Hours Service Interval Recommendation

All 1000 hr Maintenance Procedures

Date Performed by Performed by Performed by Performed by Notes

Lubricate Manual Crosshead Lock Bolts

Change Hydraulic Service Manifold Filters

Low Pressure Adjustment (Model 294 HSM)

Servohydraulic Load Frame Maintenance and Service Logs

Addendum

This addendum provides information on options not documented in the original load frame manual.

Actuator velocity limiting switch

This switch/indicator is used to control actuator speed. The switch is spring loaded left/right with a center neutral position. Momentarily turn the switch right

to the [ ] and then return the switch to the center position for high-speed, normal testing operation. The switch indicator will light, indicating the actuator rod is capable of high-speed, normal testing operation. Momentarily turn the switch left to the [ ] and then return the switch to the center position for lowspeed, specimen installation and removal. The switch indicator will extinguish, indicating the actuator rod is in a low speed condition for specimen installation.

Control Panel (Custom)

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

Crosshead lifts control Controls the crosshead lifts to raise and lower the crosshead hydraulically. Crosshead locks control Controls the crosshead locks to lock and unlock the crosshead hydraulically. Actuator velocity limiting

switch

Emergency Stop Removes hydraulic pressure from the load unit and issues an interlock signal to

Handset The handset has an encoder and buttons to help you during specimen installation

Specimen Installation

Prerequisite You must have the necessary grips and/or fixturing installed. You must also have

Controls actuator rod speed. There are two positions: one for reduced speed of the actuator rod for specimen installation and one for normal, high-speed testing operaton.

the controller to stop the test program.

and test execution. The handset also has an alphanumeric display and LEDs to provide feedback.

the controller set up to control the actuator movement, and you must have a test program defined.

Load Unit Addendum Addendum

When changing hydraulic grips, make sure you cap or plug the hydraulic

CAUTION

WARNING

hoses when removed to prevent oil spillage. Oil spillage can create an environmental concern and slippery surface that

can cause personal injury.

Promptly clean up any oil that might have spilled when hoses were removed.

The crosshead is very heavy. A dropping crosshead can crush hands, damage grips, and smash

specimens.

Be careful when working in a crush zone. T o reduce the hazards in this procedure, observe the following:

Set and enable displacement interlocks to limit the actuator’s movement. Ensure that the crosshead is locked. Ensure that the columns are clean and dry. Keep your hands out of the crush zone except when performing the steps needed

to complete this procedure.

1. Prepare the components for specimen installation. A. Ensure that the crosshead is locked. B. Turn on system electrical power. C. Apply HPU system high hydraulic pressure. Apply load unit station

low hydraulic pressure. D. If the system has a 494 based controller, enable the Gate Interlock. E. Set the actuator velocity limiting switch to (restricted flow). F. Enable the handset and use the thumbwheel to move the actuator to its

start position (usually mid-displacement). The starting position of the

actuator depends on the type of fixtures, grips, and the test being set up.

Addendum

Load Unit Addendum

For load units with hydraulic lifts and locks, the crosshead can slowly drift

CAUTION

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.

2. Set the crosshead position. The crosshead position depends on the length of the specimen being tested,

the starting position of the actuator, and the size of the fixtures or grips being used.

3. Install the specimen. Specimen installation varies according to the type of grip being used. See

the appropriate grip manual for installation instructions. Each type of grip requires the specimen or specimen fixture to fit properly into the grip. You should always review specimen installation procedures found in any grip product information manual.

Handset Control

Before testing, ensure both grips are clamped and the specimen is secure.

An insufficiently gripped specimen can cause specimen damage, equipment damage, and the possibility of specimen fragmentation.

4. Set up the load frame for testing. A. Set the actuator velocity limiting switch to (full flow).

B. Disable the handset and set up the controller for system operation.

5. Reset the controller interlock.

6. Apply load unit station high hydraulic pressure.

The handset has an encoder and buttons to help you during specimen installation and test execution. The handset also has an alphanumeric display and LEDs to provide feedback.

Load Unit Addendum Addendum

Handset functions The handset is intended to be used in a system for specimen loading or setup. In

LINE 1 UP TO 20 CHAR LINE 2 UP TO 20 CHAR LINE 3 UP TO 20 CHAR LINE 4 UP TO 20 CHAR

# Control/Indicator Description

some applications, it can be used to completely run a test.

Handset Controls and Indicators

1Page 2Active

Displays previous or next text in the display. Indicator. When lit, indicates the system is active (power

applied).

3 Scroll highlight

4 Thumb-wheel

5Pause

6Stop

Scrolls the highlighted selection down. Selection cycles to the top when the bottom line is highlighted and the switch is pressed.

Makes fine actuator adjustment (towards display – up; away from display – down). Only if Handset Enable is active.

Pauses the test action. This must be pressed again for the test to resume. Only if the application test software is active.

Stops the test action. Only if the application test software is

active.

Addendum

Load Unit Addendum

Handset Controls and Indicators

# Control/Indicator Description

7 Connector 8 Hydraulic off 9Start

10 Interlock reset

11 Thumbwheel enable

12 Fault 13 Handset enable

14 Select (En t er) 15 Display

Test System Modes of Operation

There are four operating modes for this test system:

RJ-45, to Controller. Shuts down the HPU. Starts the test action. Only if the application test software is

active.

Resets active interlock(s) providing the cause for the interlock(s) has been remedied.

Press to enable the thumbwheel to position the actuator. Press again to disable the thumbwheel, Indicator lights when thumbwheel is active.

Indicator. When lit, indicates an active fault or interlock. Used to enable/disable the handset. When the indicator is lit,

the handset is enabled for control of the actuator. Selects the highlighted line in the display. Four lines, 20 characters per line.

• Hydraulic Power Off

• Specimen Installation and Setup

• Run mode

• Service

Hydraulic power off Hydraulic Power is prevented from energizing the circuit via the hydraulic

service manifold. Full access to the test area is allowed in this mode.

Specimen installation

and setup

The controller provides a means for creating a specimen installation mode. This mode typically uses the Channel Limited Channel (CLC) control method. The primary control channel is Displacement (stroke) with maximum limits set on applied force. Tuning parameters unique to this mode optimize manual contro l during this mode. In addition, a maximum velocity command is set.

The handset has the ability to have a configuration specific desired response to the thumbwheel encoder on the handset for a precise level of control.

In conjunction with the controller and specimen installation mode using the handset, the load frame itself has two operation modes, full flow, and actuator velocity limiting restricted flow. A switch on the load frame control panel activates a solenoid which controls a hydraulic circuit within the load frame hydraulic service manifold. In the actuator velocity limiting mode, oil flow to the actuator is directed through an orifice which limits actuator velocity to 10 mm/ second or less.

Load Unit Addendum Addendum

During normal setup operation, the operator would follow this sequence:

1. Switch the system to the CLC manual control mode.

2. Activate the handset control.

3. Switch to velocity limiting mode on the load frame control panel.

4. Specimen setup or removal could then take place.

To resume to normal test mode , the operator would reverse the sequence:

1. Switch to full flow mode.

2. Deselect handset control.

3. Put the system into the control mode desired for the start of the test.

Run mode The system is fully operational when all of the following have been satisfied.

• Actuator velocity limiting is in full-flow state.

• The handset and manual control are yielded to the controller.

• The system is in high pressure.

Service Most normal service requirements can be met utilizing the normal three operating

modes as listed previously. However , there can be circumstances where operation in full flow mode with the Test Area Enclosure open is required. In these cases, trained service personnel can disconnect the standard enclosure cable, and temporarily replace it with a service connector. This operation is not considered typical use, and should only be used by trained individuals.

Optional interlock

logic

In addition to the actuator velocity limiting switch, some systems can include interlock switches on a Test Area Guard or interlock switch(es) on environmental products (such as a door interlock switch on an environmental chamber). Refer to the wiring assembly harness in the Load Unit/Load Frame section and the wiring diagram for other interlock switches for specific information.

Addendum

Load Unit Addendum

MTS Systems Corporation

14000 Technology Drive Eden Prairie, Minnesota 55344-2290 USA Toll Free Phone: 800-328-2255

(within the U.S. or Canada)

Phone: 952-937-4000

(outside the U.S. or Canada) Fax: 952-937-4515 E-mail: info@mts.com http://www.mts.com

ISO 9001 Certified QMS

MTS 311 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

Conventions

Documentation Conventions

Introduction

Component Identification

Functional Description

Specifications

Safety

General Safety Practices

Safety Practices Before System Operation

Safety Practices While the System Is in Operation

Hazard Icons

Additional Hazard Labels

Crush Point Hazards

Installation

Unpacking the Load Frame

Connecting Cables

Connecting Hydraulics

Removing the Shipping Collars

Operation

Lift and Lock Controls

Crush Point Hazards

Installing a Specimen

Maintenance

Routine Maintenance Overview Checklist

Maintenance Intervals

Making Daily Inspections

Cleaning the Columns

Preventing Rust

Checking the Accumulators’ Precharge

Bleeding the Hydraulic Lift Cylinders

Adjusting the Hydraulic Locks

Aligning the Force Transducer

Servohydraulic Load Frame Maintenance and Service Logs

8 Hours/Daily

40 Hours/Weekly

80 Hours/Biweekly

500 Hours: Crosshead and Frame

500 Hours: Actuator

500 Hours: HSM

500 Hours: Hoses and Cables

500 Hours: Overall Complete System

500 Hours: Grips

1000 Hours

2000 Hours: Annual Maintenance

Addendum

Actuator velocity limiting switch

Control Panel (Custom)

Specimen Installation

Handset Control

Test System Modes of Operation

• Hydraulic Power Off

• Specimen Installation and Setup

Run mode The system is fully operational when all of the following have been satisfied.

Service Most normal service requirements can be met utilizing the normal three operating