MTS 505 User Manual

4.3 (3)

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

Publication 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.

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

Model 505.60 - 505.180 SilentFlo™ HPU

How to Get Technical Support

Technical Support

How to Get Technical Support

Start with your manuals

Technical support methods

www.mts.com

E-mail

Telephone

Fax

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 software, look for online help and README files that contain additional product information.

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.

The web site provides access to our technical support staff by means of an onlineform:

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

tech.support@mts.com

MTS Call Center 800-328-2255

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

952-937-4515

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

Know your site number and system number

MTS can help you more efficiently if you have the following information available when you contact us for 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

Model 505.60 - 505.180 SilentFlo™ HPU

Technical Support

Before You Contact MTS

Know information from	If you have contacted MTS about this problem before, we can recall your file
prior technical	based on the:
assistance	•	MTS notification number
	•	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

•Amount of system memory

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

•Current status of hard-drive fragmentation

•Connection status to a corporate network

Know relevant For software application problems, have the following information available:

software information

•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 Support

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

Identify system type

Be prepared to troubleshoot

Write down relevant information

After you call

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

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

•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.

MTS logs and tracks all calls to ensure that you receive assistance for your problem or request. If you have questions about the status of your problem or have additional information to report, please contact Technical Support again and provide your original notification number.

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)

10 Technical Support

Model 505.60 - 505.180 SilentFlo™ HPU

Before You Begin

Preface

Before You Begin

Safety first!

Other MTS manuals

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.

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

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

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

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

Notes

Special terms

Illustrations

Electronic manual conventions

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 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.

The first occurrence of special terms is shown in italics.

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.

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.

12 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 13

Documentation Conventions

14 Preface

Model 505.60 - 505.180 SilentFlo™ HPU

EU Declarations

Introduction


Contents	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
	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

Models 505.60/.90 HPU

Models 505.120/.150/.180 HPU

EU Declarations

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 - 505.180 SilentFlo™ HPU

Introduction 15

Model 505.60 HPU Component Identification

Main
Electrical	Heat Exchanger and
Enclosure	Manifold Enclosure
User
Interface	Filter Assembly
Panel
Emergency	Pump
Stop Switch	Assemblies

Power

Disconnect

Switch

Level/Temperature

Switch

Level/Temperature
Transducer		Reservoir
		Reservoir
Fluid Level Gage
	Filler Cap
	Output	Commoning
	Pressure	Commoning
	Pressure	Expansion Plate
	Controls	Expansion Plate
	Controls

Component Locations (505.90 Shown)

16 Introduction

Model 505.60 - 505.180 SilentFlo™ HPU

Model 505.60 HPU Component Identification

	Component Descriptions

Component	Description

Commoning Expansion	Allows the HPU to be commoned with another HPU.
Plate

Electrical Enclosure	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.

Filler Cap	Vents the hydraulic fluid reservoir. This is where you add hydraulic fluid.

Filter	Filters particles out of the hydraulic fluid as it is returned to the HPU.

Fluid Level Gage	Indicates the reservoir hydraulic fluid level.

Heat Exchanger	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.

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

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

Manifold	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	Sets the output pressure of each pump assembly.

Power Disconnect Switch	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	Holds the hydraulic fluid and houses the pump and motor.

User Interface Panel	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 17

HPU Functional Description

Pump assemblies

Manifold

Filtering

Heat exchanger

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.

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.

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.

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

Run-on-demand option

Accumulators can be added to the hydraulic output lines to damp pressure line fluctuations. This option accommodates one pressure line accumulator.

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.

18 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 19

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).

20 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 ensures that power is removed whenever the door is opened. This device is both an ETL and TÜV-certified, lockable, main-disconnect switch.

Note The electrical schematics for the HPU are located on the following pages. The difference between the Model 505.60/.90 and Model 505.120-180 is the number of pump assemblies.

22 Introduction

Model 505.60 - 505.180 SilentFlo™ HPU