MTS 505 User Manual

be certain.

Series 505 SilentFlo™ Hydraulic Power Unit Product Information

Model 505.60 Model 505.90 Model 505.120 Model 505.150 Model 505.180

100-006-453 U

Trademark information MTS and SilentFlo are registered trademarks of MTS Systems Corporation

within the United States. These trademarks may be protected in other countries. DTE is a registered trademark of Exxon Mobil Corporation. Tellus is a registered trademark of Shell Oil Corporation. Synasol is a registered trademark of Union Carbide Corporation. Molykote is a registered trademark of Dow Chemical Corporation.

Publication information

MANUAL PART NUMBER PUBLICATION DATE

100-006-453 A October 1999 100-006-453 B January 2000 100-006-453 C September 2000 100-006-453 D January 2001 100-006-453 E April 2001 100-006-453 F September 2001 100-006-453 G January 2002 100-006-453 H July 2002

100-006-453 I June 2003

100-006-453 J May 2004 100-006-453 K September 2004 100-006-453 L August 2005 100-006-453 M June 2006 100-006-453 N August 2006 100-006-453 P September 2006 100-006-453 R February 2007 100-006-453 S March 2008 100-006-453 T April 2009 100-006-453 U March 2010

Contents

Technical Support 7

How to Get Technical Support 7 Before You Contact MTS 7 If You Contact MTS by Phone 9 Problem Submittal Form in MTS Manuals 10

Preface 11

Before You Begin 11

Conventions 12

Documentation Conventions 12

Introduction 15

EU Declarations 15 Model 505.60 HPU Component Identification 16 HPU Functional Description 18 Options Available for the HPU 18 Model 505.60/.90 HPU Hydraulic Schematic 20 Model 505.120/.150/.180 HPU Hydraulic Schematic 21 Model 505.60 HPU Electrical Control 22 Model 505.60/.90 Electrical Schematic 23 Model 505.120/.150/.180 Electrical Schematic 26

Specifications 32

Model 505.60–505.180 HPU General Specifications 32 Model 505.60 HPU Specifications 33 Model 505.90 HPU Specifications 34 Model 505.120 HPU Specifications 35 Model 505.150 HPU Specifications 36 Model 505.180 HPU Specifications 37

Safety 39

General Safety Practices: Hydraulic Power Units and Hydraulic Service Manifolds 39 Hazard Placard Placement 45

Model 505.60 - 505.180 SilentFlo™ HPU Contents

Installation 47

Model 505.60—505.180 HPU Electrical, Hydraulic, and Water Connections 47 Model 505.60 HPU Setup 52 Testing Model 505.60 HPU Operation 56 Precharging the Optional Surge Suppressor Accumulator 59

Operation 63

Model 505.60 HPU Startup Panel 64 Model 505.60 HPU Main Display 66 Model 505.60 HPU Data 68 Model 505.60 HPU Status 69 Model 505.60 HPU Setup 70 ROD Setup 72 Operating the Model 505.60 HPU Locally or Remotely 74 Recovering From an Interlock 76 Changing the Water Flow 78 Resetting the Thermal Overloads 79 Adjusting the Model 505.60 Hydraulic Pressure 81 Low/High Pressure Functionality 83 Setting Up Run-On-Demand 85

Maintenance 87

Routine Maintenance Overview Checklist 88

Models 505.60/.90/.120/.150/.180 HPU Maintenance Schedule 90 Checking the Hydraulic Fluid 92 Checking the Low Level/Temperature Detector 93 Replacing the Return-line Filter 94 Clamp-Style Housing Filter Replacement 94 Capscrew-Style Housing Filter Replacement 96 Replacing the Optional High-Pressure Filter 97 Sampling the Hydraulic Fluid 99 Replacing the Hydraulic Fluid 101 Inspecting the Heat Exchanger 103

Hydraulic Power Unit Maintenance and Service Logs 105

8 Hours/Daily 106 40 Hours/Weekly 107

Contents

Model 505.60 - 505.180 SilentFlo™ HPU

160 Hours/Biweekly 108 500 Hours 109 1000 Hours 110 2000 Hours 111 5000 Hours 112 10,000 Hours 113

Model 505.60 - 505.180 SilentFlo™ HPU Contents

Contents

Model 505.60 - 505.180 SilentFlo™ HPU

Technical Support

How to Get Technical Support

Start with your

manuals

Technical support

methods

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

www.mts.com The web site provides access to our technical support staff by means of an

onlineform:

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

E-mail tech.support@mts.com

Telephone MTS Call Center 800-328-2255

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

Fax 952-937-4515

Please include “Technical Support” in the subject line.

Outside the U.S. For technical support outside the United States, contact your local sales and

service office. For a list of worldwide sales and service locations and contact information, use the Global MTS link at the MTS web site:

www.mts.com > Global 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

Model 505.60 - 505.180 SilentFlo™ HPU Technical Support

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

Example site number: 571167

When you have more than one MTS system, the system job number identifies your system. You can find your job number in your order paperwork.

Example system number: US1.42460

Before You Contact MTS

Know information from

prior technical

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

assistance

• MTS notification number

• Name of the person who helped you

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

• How long and how often has the problem occurred?

• Can you reproduce the problem?

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

problem started?

• What are the equipment model numbers?

• What is the controller model (if applicable)?

• What is the system configuration?

Know relevant

For a computer problem, have the following information available:

computer information

• Manufacturer’s name and model number

• Operating software type and service patch information

Know relevant

software information

• Amount of system memory

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

• Current status of hard-drive fragmentation

• Connection status to a corporate network

For software application problems, have the following information available:

• The software application’s name, version number, build number, and (if

available) software patch number. This information can typically be found in the About selection in the Help menu.

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

– Anti-virus software – Screen savers – Keyboard enhancers – Print spoolers – Messaging applications

Technical Supp ort

Model 505.60 - 505.180 SilentFlo™ HPU

If You Contact MTS by Phone

A Call Center agent registers your call before connecting you with a technical support specialist. The agent asks you for your:

• Site number

• Name

• Company name

• Company address

• Phone number where you can be reached

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

Identify system type To enable the Call Center agent to connect you with the most qualified technical

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

• Electromechanical material test system

• Hydromechanical material 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 for your

• Vehicle test system

• Vehicle component test system

• Aero test system

Prepare to perform troubleshooting while on the phone:

• Call from a telephone close to the system so that you can implement

suggestions made over the phone.

• Have the original operating and application software media available.

• If you are not familiar with all aspects of the equipment operation, have an

experienced user nearby to assist you.

In case Technical Support must call you:

• Verify the notification number.

• Record the name of the person who helped you.

• Write down any specific instructions.

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

Model 505.60 - 505.180 SilentFlo™ HPU Technical Support

Problem Submittal Form in MTS Manuals

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

Access the Problem Submittal Form:

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

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

form to be e-mailed to MTS)

Technical Supp ort

Model 505.60 - 505.180 SilentFlo™ HPU

Before You Begin

Preface

Before You Begin

Safety first! Before you 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 can result in hazardous conditions that can cause severe personal injury or death, or damage to your equipment and specimen. Again, read and understand the safety information provided with your system before you continue. It is very important that you remain aware of hazards that apply to your system.

Other MTS manuals In addition to this manual, you may receive additional manuals in paper or

electronic form. You may also receive an MTS System Documentation CD. It contains an

electronic copy of the manuals that pertain to your test system, such as:

• Hydraulic and mechanical component manuals

• Assembly drawings

• Parts lists

• Operation manual

• Preventive maintenance manual

Controller and application software manuals are typically included on the software CD distribution disc(s).

Model 505.60 - 505.180 SilentFlo™ HPU 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 Hazard notices may be embedded in this manual. These notices contain safety

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

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 or equipment damage, or could 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. They are examples only and do

not necessarily represent your actual system configuration, test application, or software.

Electronic manual

conventions

This manual is available as an electronic document in the Portable Document File (PDF) format. It can be viewed on any computer that has Adobe Acrobat Reader installed.

Preface

Model 505.60 - 505.180 SilentFlo™ HPU

Documentation 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.

Model 505.60 - 505.180 SilentFlo™ HPU Preface

Documentation Conventions

Preface

Model 505.60 - 505.180 SilentFlo™ HPU

Introduction

Models 505.60/.90 HPU

Models 505.120/.150/.180 HPU

Contents Model 505.60 HPU Component Identification 16

EU Declarations

HPU Functional Description 18 Options Available for the HPU 18 Model 505.60/.90 HPU Hydraulic Schematic 20 Model 505.120/.150/.180 HPU Hydraulic Schematic 21 Model 505.60 HPU Electrical Control 22 Model 505.60/.90 Electrical Schematic 23 Model 505.120/.150/.180 Electrical Schematic 26 Model 505.60–505.180 HPU General Specifications 32 Model 505.60 HPU Specifications 33 Model 505.90 HPU Specifications 34

EU Declarations

Model 505.120 HPU Specifications 35 Model 505.150 HPU Specifications 36 Model 505.180 HPU Specifications 37

Model 505.60 - 505.180 SilentFlo™ HPU Introduction

EC Declaration of

Conformity (Machinery

Directive 2006/42/EC

Annex II 1A)

If applicable, a Declaration of Conformity is supplied with the machinery; an example of the Declaration of Conformity is provided at the end of this manual.

Model 505.60 HPU Component Identification

Heat Exchanger and Manifold Enclosure

Filter Assembly

Pump

Assemblies

Reservoir

Output

Pressure

Controls

Filler Cap

Fluid Level Gage

Level/Temperature Transducer

Level/Temperature

Switch

Power

Disconnect

Switch

Emergency Stop Switch

User Interface Panel

Main Electrical Enclosure

Commoning

Expansion Plate

Model 505.60 HPU Component Identification

Introduction

Component Locations (505.90 Shown)

Model 505.60 - 505.180 SilentFlo™ HPU

Model 505.60 HPU Component Identification

Component Descriptions

Component Description

Commoning Expansion Plate

Electrical Enclosure

Filler Cap Filter Fluid Level Gage Heat Exchanger

Level/Temperature Transducer

Low Level/Temperature Switch

Manifold

Allows the HPU to be commoned with another HPU.

Houses the HPU’s electrical and control components. The wye-delta starters for the Model 505.60/.90 HPUs are located in the electrical enclosure. The wye-delta starters for the Model 505.120/.150/.180 HPUs are located in the pump assemblies. The main power lines enter the electrical enclosure at its top. The power disconnect switch removes electrical power whenever the enclosure’s door is opened.

Vents the hydraulic fluid reservoir. This is where you add hydraulic fluid. Filters particles out of the hydraulic fluid as it is returned to the HPU. Indicates the reservoir hydraulic fluid level. Cools the hydraulic fluid using a highly efficient, stainless steel oil-to-water

heat exchanger. The heat exchanger removes most of the heat generated by the HPU.

Senses the hydraulic fluid level and temperature, and produces an analog signal for display purposes.

Senses the hydraulic fluid level and temperature. Control interlocks automatically shut the HPU down if the fluid level drops too low or the hydraulic fluid temperature rises above the sensor’s setting.

Combines the output of the individual pumps to deliver the full output of the HPU through a single port. The manifold provides solenoid control of the high/ low pressure output from the individual pumps. It also contains relief valves for each pump circuit and a bypass circuit to maintain the hydraulic temperature during low flow conditions.

Output Pressure Controls Power Disconnect Switch

Sets the output pressure of each pump assembly . Disconnects the incoming power from the HPU. The switch is a lockable,

mechanical latch. Power is removed whenever the door to the electrical enclosure is open. The switch will not allow the door to be opened when in the ON (|) position. Incoming power lines to the switch are live unless power is removed externally.

Pump Assemblies

Produces the pressurized hydraulic fluid for system use. Each pump assembly includes a motor, pump, and electrical enclosure for connecting with the main starter.

Reservoir User Interface Panel

Holds the hydraulic fluid and houses the pump and motor. Configures and controls the operation of the hydraulic power unit and indicates

the current status of several sensors.

Model 505.60 - 505.180 SilentFlo™ HPU Introduction

HPU Functional Description

Pump assemblies Pump assemblies draw hydraulic fluid from the reservoir and pressurize it to a

maximum preset pressure. Each pump assembly contains a variable volume pump, a motor, and an electrical enclosure. Each pump assembly has a flow capacity that contributes to the total hydraulic flow capacity of the HPU.

Manifold The manifold combines the pressurized hydraulic output of the discrete pump

assemblies, and provides the hydraulic connection to your hydraulic system. The manifold contains the high/low pressure solenoid valve and a nonadjustable relief valve. Check valves are located within the manifold to prevent pressurized hydraulic fluid from being forced back through the pumps.

The hydraulic power unit uses solenoid-operated valves to control when highpressure is available to the hydraulic circuit. Start/low/high control settings are selected at the operator interface on the electrical enclosure’s front panel.

The HPU is designed to start in low pressure to reduce the amperage needed for starting, which will extend the life of the pump and motor. When operating at this setting, low-pressure hydraulic fluid circulates back to the reservoir through the manifold. The direct fluid path back to the reservoir limits pressure and flow available out to the external hydraulic circuit. When high pressure is selected, the unit forces pressurized hydraulic fluid out to the hydraulic circuit.

Filtering As hydraulic fluid returns to the reservoir, it is filtered by a full flow element.

This ensures that all hydraulic fluid is filtered, whether it travels out through the circuit or returns by way of the unit’s manifold under low pressure. Filter cleanliness is automatically monitored. A warning registered on the unit’s operator interface signals when the filter needs to be changed.

Heat exchanger Hydraulic fluid temperature is maintained with a high–efficiency stainless steel

heat exchanger that cools the fluid. A regulating valve monitors the temperature of the hydraulic fluid and adjusts the flow of water through the plates. The flow of cooling water regulates the temperature of the hydraulic fluid. If the hydraulic fluid temperature exceeds the maximum preset temperature, a switch opens and shuts down the HPU. When the HPU is shut off, the flow of water is automatically stopped by a shutoff solenoid valve.

Options Available for the HPU

Accumulator option Accumulators can be added to the hydraulic output lines to damp pressure line

fluctuations. This option accommodates one pressure line accumulator.

Run-on-demand option The run-on-demand (ROD) option will turn individual pumps on and off as

needed to accommodate the system’s demand for hydraulic fluid. The PLC monitors the fluid flow; when flow changes beyond preset limits for a preset time, a pump will be turned on or off as needed.

Introduction

Model 505.60 - 505.180 SilentFlo™ HPU

Options Available for the HPU

The ROD option allows the HPU to turn individual pump motors on and off as your system flow demand changes. A minimum flow reserve is maintained and pump usage is equalized by sequentially turning on pumps starting with the pump with the least amount of run time, and turning the pumps off in reverse order. The cycling of these pumps is controlled by a PLC that takes into account various system parameters such as system hydraulic fluid flow (both real time and trends), the number of pumps currently running, and user configurable on/off delay settings.

Model 505.60 - 505.180 SilentFlo™ HPU Introduction

Model 505.60/.90 HPU Hydraulic Schematic

The hydraulic schematic shows the functional layout of HPU models with two or three pump assemblies (505.60/.90).

Introduction

Model 505.60 - 505.180 SilentFlo™ HPU

Model 505.120/.150/.180 HPU Hydraulic Schematic

The hydraulic schematic shows the functional layout of HPU models with four to six pump assemblies (505.120/.150/.180).

Model 505.60 - 505.180 SilentFlo™ HPU Introduction

Model 505.60 HPU Electrical Control

The HPU can be controlled locally using the front panel controls, or remotely through a controller via the J1 connector . A PLC (programmable logic controller) manages the electrical systems within the HPU. The electrical system includes the following:

• A user interface panel that contains a touch screen to program preferences

and operational settings. The screens on the user interface panel provide quick indication of the unit’s condition, including motors status, running time displays for each motor, hydraulic fluid level and temperature, and filter condition.

• Wye-delta starting reduces the initial current rush when the motor starters

are engaged.

• Thermal overloads protect the individual HPU motors from excessive

current draw .

• A latchable Emergency Stop button prevents inadvertent starts.

• Interlocks protect the HPU against low hydraulic fluid level,

overtemperature, and dirty filters.

• A Reset button brings the unit back into operation after a fault has been

detected and corrected.

• A dirty filter signal will not shut the unit down, but will prevent the unit

from starting.

• The power disconnect switch on the door of the main electrical enclosure