MTS 505G2 User Manual

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Series 505G2 SilentFlo™ Hydraulic Power Unit Product Information

Model 505G2.07 Model 505G2.11

100-227-350 C

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. Molykote is a registered trademark of Dow Chemical Corporation. All other trademarks or service marks are property of their respective owners.

Publication information

Manual Part Number Publication Date

100-227-350 A July 2010

100-227-350 B February 2011

100-227-350 C December 2013

Contents

Technical Support 5

How to Get Technical Support 5 Before You Contact MTS 5 If You Contact MTS by Phone 7 Problem Submittal Form in MTS Manuals 8

Preface 9

Before You Begin 9

Conventions 10

Documentation Conventions 10

Introduction 13

EU Declarations 13 Intended Use 13 Product Information CD 14 Component Identification 15 Functional Description 17 Auto-Cooling Valve (adjustable) 18 Electrical Control 18

Safety 19

General Safety Practices: Hydraulic Power Units and Hydraulic Service Manifolds 19

Installation 27

Install the HPU 27 HPU Setup 30

Operation 35

Model 505G2.07/.11 SilentFlo™ HPU Contents

Operator’s Panel 36

Main Screen 36 Status Screen 39 Operating the HPU Locally or Remotely 41 Recovering from an Interlock 42 Changing the Water Flow 43 Resetting the Thermal Overloads and Circuit Breakers 44 Adjusting the Hydraulic Pressure 45 Adjusting the HPU Output Pressure Level 47 Adjusting the Auto-Cooling Level 47 Low/High Pressure Functionality 50

Maintenance 53

Routine Maintenance Overview Checklist 54

Checking the Hydraulic Fluid 55 Replacing the Return Line Filter 57 Sample the Hydraulic Fluid 59 Appearance of Hydraulic Fluid Sample 60 Replacing the Hydraulic Fluid 61

Accessories 63

High Pressure Filter Kit 63 Surge Suppressor Kit 65 Precharging the Surge Suppressor Accumulator 66 Lifting Kit 69 Caster Kit 71

Appendix A: HPU Maintenance and Service Logs 73

8 Hours/Daily 74 40 Hours/Weekly 75 160 Hours/Biweekly 76 500 Hours 77 1000 Hours 78 2000 Hours 79 5000 Hours 80 10,000 Hours 81

Contents

Model 505G2.07/.11 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 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.

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:

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 505G2.07/.11 SilentFlo™ HPU

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.

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.

www.mts.com > Global MTS > (choose your region in the right-hand column) > (choose the location closest to you)

Example site number: 571167

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

Model 505G2.07/.11 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 505G2.07/.11 SilentFlo™ HPU

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)

Model 505G2.07/.11 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 505G2.07/.11 SilentFlo™ HPU

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

Electronic manual

conventions

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.

Model 505G2.07/.11 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 505G2.07/.11 SilentFlo™ HPU

Documentation Conventions

Model 505G2.07/.11 SilentFlo™ HPU

Introduction

Contents Component Identification 15

EU Declarations

The MTS Model 505.07 Hydraulic Power Unit (HPU) and Model 505.11 HPU provide high-pressure hydraulic fluid for test system operation. This section contains general information about the HPU.

Functional Description 17

Auto-Cooling Valve (adjustable) 18

Electrical Control 18

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.

Intended Use

The intended use of the Hydraulic Power Unit (HPU) is:

• Hydraulic supply for servohydraulic testing systems.

• Power supply for other hydraulically operated machinery, presses, or test

Model 505G2.07/.11 SilentFlo™ HPU

systems.

Product Information CD

Drawing Number Description

A Product Information CD is supplied with the HPU (MTS part number 100-227-354). The Product Information CD includes the electrical and hydraulic schematics along with the configuration drawings. The Product Information CD also contains the product specifications and other reference documents to aid MTS qualified service personnel. These documents include:

700005313

100025526

700005263

700000263

700004937

700005213

700004942

700005293

700005263

700000264

700004965

700005214

700004966

700005294

050000536

Product Specifications

Series 505 SilentFlo™ HPU Lift and Move Instructions

505.07 Configuration Drawing

505.07 Hydraulic schematic

505.07 small PLC Electrical Schematic (200 - 480 VAC)

505.07 large PLC Electrical Schematic (200 - 480 VAC)

505.07 small PLC Electrical Schematic (575 VAC)

505.07 large PLC Electrical Schematic (575 VAC)

505.11 Configuration Drawing

505.11 Hydraulic schematic

505.11 small PLC Electrical Schematic (200 - 480 VAC)

505.11 large PLC Electrical Schematic (200 - 480 VAC)

505.11 small PLC Electrical Schematic (575 VAC)

505.11 large PLC Electrical Schematic (575 VAC)

Hydraulic Fluid Care Guide

015164000

Heat Exchanger Care Guide

Model 505G2.07/.11 SilentFlo™ HPU

Component Identification

Component Descriptions (part 1 of 2)

Item Component Description

1 Output Pressure Gage

2 Auto-Cooling Valve

Displays the hydraulic pressure being output from the HPU.

Keeps the hydraulic fluid clean and cool by circulating the fluid through the return filter and the heat exchanger while the HPU is in high pressure mode and the fluid demand by the external circuit is very low.

3 Pressure Relief Valve

4 Fluid Sample Port

Prevents the HPU from exceeding 22.4 MPa (3250 psi).

Access port for obtaining hydraulic fluid samples from the HPU. A quick disconnect port is provided. Use the optional sampling kit that includes a needle valve to regulate the flow through the sample port.

5 Electrical Enclosure

Houses the electrical and control components of the HPU. The main power lines enter the unit at the top. The power disconnect switch removes electrical power whenever the enclosure door is opened.

6 Low level/Overtemperature

Sensor

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 temperature sensor’s setting.

7 Fluid Level Gage

8 Filler Cap

Displays the level of the hydraulic fluid.

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

Model 505G2.07/.11 SilentFlo™ HPU

Component Identification

Component Descriptions (part 2 of 2)

Item Component Description

9 Reservoir

10 Hydraulic and Water

Connections

11 Water Flow Regulator

12 Drain Valve

13 High Pressure Filter

Location

14 Output Pressure Control

15 Heat Exchanger

16 Temperature Gage

17 Return Filter

18 Power Disconnect Switch

Holds the hydraulic fluid and houses the hydraulic pump and motor. The surge suppressor (optional) is mounted to the pump.

Connection points for the hydraulic fluid distribution system, water source, and return lines.

Sets the amount of water flowing through the heat exchanger. Adjust the water flow to regulate the temperature of the hydraulic fluid.

Drains the hydraulic fluid from the reservoir.

The high pressure filter is optional. If provided, it would be located where indicated in the figure.

Sets the output pressure of the HPU.

Cools the hydraulic fluid by using an oil-to-water heat exchanger. The heat exchanger removes most of the heat generated by the HPU.

Displays the temperature of the hydraulic fluid.

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

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 is in the off position). However, incoming power lines to the switch are live unless power is removed externally. The power disconnect switch is located on the front panel of the electrical enclosure (item 5).

19 Hazard placards

20 User Interface Panel

21 Nameplate

Hazard placards contain specific safety information and are affixed directly to the system so they are plainly visible. Each placard describes a product-related hazard. When possible, international symbols (icons) are used to graphically indicate the type of hazard and the placard label indicates its severity. The hazard placards are located on the front panel of the electrical enclosure (item 5).

Controls the operation of the HPU and indicates the current status of several detectors. Also used for HPU setup. The user interface panel is located on the front panel of the electrical enclosure (item 5).

Provides basic product information such as model number, serial number, and electrical information. The nameplate is located on the electrical enclosure (item 5).

Model 505G2.07/.11 SilentFlo™ HPU

Functional Description

Pump A variable volume pump draws hydraulic fluid from the reservoir and pressurizes

Pressure The start/low/high switch on the front panel of the electrical enclosure controls

Functional Description

it to the adjusted output pressure, typically 21 MPa (3000 psi). A check valve prevents hydraulic fluid from being siphoned back into the reservoir. The pressurized fluid is controlled by a control manifold that contains the high/low pressure solenoid valve and a non-adjustable relief valve set at 22.4 MPa (3250 psi).

the hydraulic pressure of the HPU. The start/low/high switch operates like an automotive ignition switch; turn and hold the switch in the start position until the motor starts running. The switch returns to the low position.

The unit automatically starts in low pressure to reduce the amperage needed for starting, which will extend pump and motor life. When operating at this setting, low-pressure fluid is available to the hydraulic circuit. Low pressure is achieved by diverting a portion of the hydraulic fluid through the high pressure solenoid and returning it to the reservoir. Selecting high pressure blocks the low pressure return path and makes all of the pressurized hydraulic fluid available to the hydraulic circuit.

The output pressure can be adjusted from about 1 MPa (145 psi) to 21 MPa (3000 psi). The HPU is designed to provide 21 MPa (3000 psi). A nonadjustable relief valve is set at 22MPa (3190 psi) to protect the hydraulic system from excessive pressure.

Filtering As hydraulic fluid returns to the reservoir, it is filtered by a 3-micron element.

This ensures that all hydraulic fluid is filtered whether it travels out through the circuit or returns by way of the unit’s control manifold under low pressure. Filter cleanliness is automatically monitored. An indicator lights on the front panel signaling when the filter needs an element change.

Heat exchanger Hydraulic fluid temperature is maintained with a heat exchanger that cools the

fluid. The water-cooled heat exchanger cools the hydraulic fluid as it passes over water-filled plates. 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.

• The typical operating temperature range of the hydraulic fluid is

43–49°C (110–120°F).

• If the hydraulic fluid temperature exceeds 55ºC (131ºF), a switch opens and

shuts down the HPU.

• When the HPU is shut off, the flow of water is also stopped by a shutoff

solenoid valve.

Note For additional information see the Heat Exchanger Care and Water

Model 505G2.07/.11 SilentFlo™ HPU

Quality Guide (part number 015-164-000).

Auto-Cooling Valve (adjustable)

The auto-cooling function is integrated into the control manifold. During periods of low flow demand from the external hydraulic circuit, this feature provides two important benefits: a re-circulating flow that ensures hydraulic fluid filtering whenever the unit is on, and safeguarding against hydraulic fluid overtemperature. It functions by opening a hydraulic flow path through the fluid conditioning circuit when external hydraulic demand for flow is low. When the external demand increases, this feature closes the path to provide the full flow of the HPU to the external demand.

The effective operating range of the auto-cooling circuit is between system pressures of 14 MPa (2000 psi) to 21 MPa (3000 psi). In order for the AutoCooling Valve to function properly, it must be re-adjusted anytime the output pressure will be changed for longer than 10 minutes.

Note If the test condition requires a maximum pressure level less than 14 MPa

(2000 psi), consult MTS.

Electrical Control

The HPU can be controlled locally using the front panel controls, or remotely through a controller. A PLC (programmable logic controller) manages the electrical systems within the HPU. The controls included in the electrical enclosure include 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 a TÜV-certified, lockable, main-disconnect switch.

Model 505G2.07/.11 SilentFlo™ HPU

General Safety Practices: Hydraulic Power Units and

Safety

General Safety Practices: Hydraulic Power Units and Hydraulic Service Manifolds

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

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

• Do not use or allow personnel to operate the system who are not

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

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

light curtains, or proximity switches/detectors).

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

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

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

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

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

system is allowed when the system is in operation.

• For servohydraulic systems, do not operate the system unless an interlock is

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

• Mists of DTE 25 are combustible. Refer to MSDS. Customer is responsible

for fire prevention measures as per facility or building or other local regulations and codes

If you have system related responsibilities (that is, if you are an operator, service engineer, or maintenance person), you should study safety information carefully before you attempt to perform any test system procedure.

You should receive training on this system or a similar system to ensure a thorough knowledge of your equipment and the safety issues that are associated with its use. In addition, you should gain an understanding of system functions by studying the other manuals supplied with your test system. Contact MTS for information about the content and dates of training classes that are offered.

Model 505G2.07/.11 SilentFlo™ HPU

General Safety Practices: Hydraulic Power Units and

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.

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 may require a complete understanding of system operation to avoid unsafe or dangerous situations.

Locate and read

hazard placards/labels

Specimen temperature

changes

Know facility safe

procedures

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, electrical voltage, and high pressure hazards.

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

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 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.

Model 505G2.07/.11 SilentFlo™ HPU

General Safety Practices: Hydraulic Power Units and

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

component movement

with hydraulics off

Know electrical

hazards

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

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 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.

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

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

Check bolt ratings and

torques

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.

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 information in this product manual 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.

Model 505G2.07/.11 SilentFlo™ HPU

General Safety Practices: Hydraulic Power Units and

Practice good

housekeeping

Protect hoses and

cables

Provide proper

hydraulic fluid

filtration

Protect accumulators

from moving objects

Do not exceed the

Maximum Supply

Pressure

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.

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

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.

For hydraulic grips and fixtures. make sure that the hydraulic supply pressure is limited to the maximum pressure defined by the grip or fixture identification (ID) tag.

Do not disable safety

devices

Use appropriately

sized fuses

Provide adequate

lighting

Provide means to

access out-of-reach

components

Wear appropriate

personal protection

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

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.

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.

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

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

Wear 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.

Model 505G2.07/.11 SilentFlo™ HPU

General Safety Practices: Hydraulic Power Units and

Handle chemicals

safely

Know system

interlocks

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 gain control of the system.

Know system limits Never rely on system limits such as mechanical limits or software limits to

protect you or any personnel. System limits are designed to minimize the chance of accidental damage to test specimens or to equipment. Test all limits for proper operation immediately before a test. Always use these limits and adjust them properly.

Do not disturb sensors Do not bump, wiggle, adjust, disconnect, or otherwise disturb a sensor (such as

an accelerometer or extensometer) or its connecting cable when hydraulic pressure is applied.

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 Avoid long periods of work without adequate rest. In addition, avoid long periods

of repetitious, unvarying, or monotonous work because these conditions can contribute to accidents and hazardous situations. If you are too familiar with the work environment, it is easy to overlook potential hazards that exist in that environment.

Contain small leaks Do not use your fingers or hands to stop small leaks in hydraulic or pneumatic

hoses. Substantial pressures can build up, especially if the hole is small. These high pressures 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.

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.

Model 505G2.07/.11 SilentFlo™ HPU

General Safety Practices: Hydraulic Power Units and

Know the causes of

unexpected actuator

motions

Do not use RF

transmitters

Know compressed gas

hazards

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.

Some environmental chambers use liquid nitrogen or some inert gas to achieve a required test atmosphere. Typically these gasses are supplied in pressurized tanks.

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.

• Always follow the recommended bleeding procedures before you remove or

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

• Wear appropriate safety devices to protect your hearing. Escaping air or gas

can create a noise level that can damage your hearing.

• Ensure that all pressurized air or gas is bled out of a pneumatic or gas-

charged device before you start to disassemble it. A thorough understanding of the assembly and its pressurized areas is necessary before you undertake any maintenance. Refer to the appropriate product information for the correct bleeding procedure.

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

Model 505G2.07/.11 SilentFlo™ HPU

General Safety Practices: Hydraulic Power Units and

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.

The following labels and placards are typically located on the HPU.

Label Description

Hydraulic Power Unit information label.

Part # 100-263-702

Caution

To prevent equipment damage and impede performance, remove red shipping plug under filler cap before operating.

Replace with black plastic snap in strainer.

Part # 050-174-101

Model 505G2.07/.11 SilentFlo™ HPU

General Safety Practices: Hydraulic Power Units and

Label Description

Part # 100-223-270

Voltage hazard. High voltage exists in the vicinity where this icon is located. Be aware of possible electrocution when working in areas noted with this icon.

Explosion hazard; release of pressure. High pressure fluid or gasses. Do not tamper with fittings or hoses. Wear appropriate protection such as safety goggles and hearing protection. Maintain safe pressure levels.

Disconnect from

electrical power before servicing.

Read the manuals.

Wye-Delta Connections

Use for single voltage 6 lead motors suitable for wye-delta starting.

Part # 053-448-401

Model 505G2.07/.11 SilentFlo™ HPU

Installation

CAUTION

Contents Install the HPU 27

Install the HPU

This section describes how to install the Series 505 Hydraulic Power Unit (HPU).

Note The HPU is designed for indoor use. The HPU should be stored and

installed indoors.

HPU Setup 30

1. Position the hydraulic power unit.

Determine where to put the HPU. Review the following:

• The HPU can fit through a standard 1-m or 36-in door.

• The HPU can be moved by a fork lift, pallet jack, or dolly.

• Placement considerations should include proximity to the facility

electric power, water, and the hydraulic components. Positioning the HPU close to the hydraulic components can reduce the cost of hydraulic distribution.

• The HPU produces no more than 60 dB (A) of sound pressure level

fully compensated in a free field acoustic environment.

• Connect the electrical service to the HPU.

Note Local electrical codes supersede any information found here.

2. Electrical connections must be made by qualified personnel and conform to local codes and regulations. The electrical box has a power disconnect switch that must be off (O) in order to open the electrical box. An electrical service panel to provide the electrical power feed (line voltage) to the HPU is not necessary, but may be required by local electrical codes.

A. Connect the three electrical power feed wires to the input lugs of the

power disconnect in a clockwise phase orientation as indicated by the L1, L2, and L3 labels shown in the following figure (the Model 505.07/ .11 high voltage configuration is shown).

Incorrect motor rotation at high pressure for longer than 10 seconds can cause severe damage to your HPU.

It is imperative that you verify proper motor rotation to assure proper operation of the HPU and to prevent damage to the HPU.

Model 505G2.07/.11 SilentFlo™ HPU

Install the HPU

PE GND (Protective Earth Ground) Lug

Electrical Power Feed Lugs (shown labeled for clockwise phase orientation)

Ensure that lugs are secure. They should be checked periodically. See the Maintenance section.

Pressure

-12 (3/4 in)

Water In

-12 (3/4 in NPT)

Return

-12 (3/4 in)

Water Out

-12 (3/4 in NPT)

Drain

-8 (1/2 in)

Drain

-6 (3/8 in)

B. Connect the grounding wire to the lug labeled PE GND (protective

earth ground).

3. Connect the hydraulic lines.

The following figure shows the hydraulic adapter ports to the HPU.

Note Each hydraulic connection requires an O-ring face seal.

4. Connect the water lines.

Model 505G2.07/.11 SilentFlo™ HPU

Install the HPU

CAUTION

Note For hydraulic connections to air-cooled units, refer to the Air-Cooler to

SilentFlo number 100-135-073).

™

HPU Integration Product Information manual (MTS part

The HPU requires connection to a suitable water supply, equipped with an appropriate shutoff valve, to cool the hydraulic fluid. The differential pressure required between the HPU water inlet and outlet connections is

0.24 to 0.34 MPa (35 to 50 psi). The maximum allowable water inlet pressure is 0.83 MPa (120 psi).

The water supply must also be capable of maintaining water flow at a rate listed in the following table.

Water Inlet Temperature Model 505.07 Model 505.11

10.0°C (50°F) 3.8 L/m (1.0 gpm) 7.2 L/m (1.9 gpm)

15.5°C (60°F) 4.9 L/m (1.3 gpm) 9.1 L/m (2.4 gpm)

21.1°C (70°F) 6.1 L/m (1.6 gpm) 12.1 L/m (3.2 gpm)

26.7°C (80°F) 8.3 L/m (2.2 gpm) 18.9 L/m (5.0 gpm)

32.2°C (90°F) 15.9 L/m (4.2 gpm) 49.2 L/m (13.0 gpm)

A. Connect the water supply to the HPU Water In port. Connect the

Water Out port to your drain/return line.

B. A regulating valve must be adjusted according to your water

temperature.

5. Initial HPU startup.

Note The following step only applies when the HPU is first turned on after the

electrical power has been connected (see Step 2).

A. The unit is shipped with a plug in the filler cap. Remove the red filler

cap plug and install the screen in the fill port on the top of the reservoir. The screen is shipped in the electrical enclosure.

B. Rotate the power disconnect switch to the on (|) position.

Incorrect motor rotation at high pressure for longer than 10 seconds can cause severe damage to your HPU.

If the pressure, as observed on the pressure gage, does not increase within 10 seconds after High is selected, stop the unit.

C. Start the HPU by pressing the Start switch.

Model 505G2.07/.11 SilentFlo™ HPU

HPU Setup

D. Verify the motor rotation (the pump motor can start with the wrong

rotation). Press the High Pressure switch.

• If pressure begins to increase, proceed to the next step.

• If the oil pressure value shows no pressure, press the Stop button to

shut down the unit (do not run more than 10 seconds in the wrong direction). Have a qualified electrician make a change in the electrical phase to the motor.

E. Check for unusual noises or leaks. If a problem is found, press the Stop

button. You must correct the problem(s) before you continue.

F. If there were problems in step E, restart the HPU and select high

pressure.

G. Verify the correct output pressure, as shown on the pressure gage.

H. Press the Stop button to shut down the unit.

6. Connect the controller cable (if used).

The controller cable provides a means to connect your controller to the HPU. When connected, your controller can remotely start and stop the unit and switch between the low and high pressure selections. The cable also permits the controller to monitor the low level, overtemperature, and dirty filter status.

HPU Setup

Important If a controller is not used, the installed jumper plug must be used or

the unit will not start.

Connect the controller cable to the connector located at the lower left side of the electrical enclosure.

The following procedure should only be performed at HPU installation to verify settings, when you replace the user interface panel, or if you need to change a selection.

1. Rotate the power disconnect switch to the on (|) position.

2. On the user interface Main Display, select the language.

Model 505G2.07/.11 SilentFlo™ HPU

HPU Setup

3. On the user interface Main screen ensure that the Remote Operation button is not selected (gray), indicating the HPU is in local mode.

4. On the user interface panel, press and hold the Setup button for five seconds to display the Setup HMI (human-machine interface) screen.

Model 505G2.07/.11 SilentFlo™ HPU

HPU Setup

5. The following table describes the pushbuttons and indicators on the Setup screen.

Name and Location Description

Use Buttons Below To Change Parameters

Remote Fault Normal/Remote Fault Reverse

Aux Contact: On/Off/Temp Aux Polarity Normal/Reverse

Indicator - blue-green: Provides instruction for the setup screen.

Pushbutton /Indicator. The HPU generates fault signals for remote monitoring. This button is used to define the polarity of the output signal.

Remote Fault Normal - gray: The remote fault signal is active high meaning the fault contact is closed when a fault is present.

Remote Fault Normal - black: The remote fault signal is active low meaning the fault contact is open when a fault is present.

Pushbuttons /Indicators.

Aux Contact: On/Off - gray

Aux Contact: Temp - black

Aux Polarity Normal - gray

Aux Polarity Reverse - black

One of the auxiliary contacts can be used to control an external device such as a warning lamp or a remote cooling circuit. The auxiliary contact controls whether the contact is active whenever a pump motor is running (Aux Contact: On/Off - gray) or whenever a pump motor is running and the temperature of the hydraulic fluid in the reservoir reached the trip temperature (Aux Contact: Temp - black).

– Press the Aux Contact: button to display Aux Contact:

On/Off to activate the contact when at least one pump motor is running, and to deactivate when no pump motors are running.

– Press the Aux Contact: button to display Aux Contact:

Tem p to activate the contact when at least one pump motor is running and the fluid temperature in the reservoir is above the temperature trip level and to deactivate the contact when either the temperature is lower than the temperature trip level or no pump motors are running.

– Press the Aux Polarity: button to display Aux Polarity:

Normal to cause the contact to close when it is active. MTS Controllers use normal polarity.

– Press the Aux Polarity: button to display Aux Polarity:

Reverse to cause the contact to open when it is active.

The other Aux contact is set for motor pump running only. Its function and polarity are not selectable.

Model 505G2.07/.11 SilentFlo™ HPU

Name and Location Description

HPU Setup

Mean Temp/numeric display and Deadband/numeric display

Part of the Analog Option;only displayed if the Analog Option was purchased.

Pressure Filter Not Present/Pressure Filter Present

Mean Temp (deg) - blue-green: Indicator used as a label for the pushbutton switch below it.

Deadband (deg) - blue-green: Indicator used as a label for the pushbutton switch below it.

Mean Level numeric display - pushbutton/indicator - gray: Used to set the mean level operating temperature of the hydraulic fluid. Push the button to display a numeric keypad. With the keypad displayed, use the number keys to set the desired mean level then press Enter to set the value and return to the status screen. Once value has been set on the keypad, that value is displayed.

Deadband numeric display - pushbutton/indicator - gray: Used to set the allowable deviation from the mean level operating temperature of the hydraulic fluid. Push the button to display the numeric keypad. With the keypad displayed, use the number keys to set the desired deadband level then press Enter to set the value and return to the status screen. Once value has been set on the keypad, that value is displayed.

Pushbutton /Indicator. This button is used to define if a pressure filter is present.

Pressure Filter Not Present- gray: The HPU does not have a pressure filter.

Pressure Filter Present- black: The HPU does have a pressure filter.

Temp Display In (deg)

Part of the Analog Option;only displayed if the Analog Option was purchased.

Pressure Display In (units)

Part of the Analog Option;only displayed if the Analog Option was purchased.

Screen select buttons

Pushbutton/Indicator: Used to select temperature display in either Celsius or Fahrenheit. Push to alternate between the two temperature scales.

Temp Display in

°F - gray.

°C - black.

Pushbutton/Indicator: Used to select the units for pressure displays in either psi or MPa. Push to alternate between the two pressure units.

Pressure Display in psi - gray.

Pressure Display in MPa - black.

The Main, Status, and Setup pushbuttons/indicators are described in the Main Screen section; refer to “Main Screen” on page 36.

The HMI Setup pushbutton/indicator is for MTS service personnel and used to display a screen that is used to define factory settings such as serial number and HMI software version.

Model 505G2.07/.11 SilentFlo™ HPU

HPU Setup

Model 505G2.07/.11 SilentFlo™ HPU

Operation

Contents Operator’s Panel 36

This section describes the front panel controls and indicators, and provides operating instructions for the Series 505 Hydraulic Power Unit (HPU).

Main Screen 36

Status Screen 39

Operating the HPU Locally or Remotely 41

Recovering from an Interlock 42

Changing the Water Flow 43

Resetting the Thermal Overloads and Circuit Breakers 44

Adjusting the Hydraulic Pressure 45

Adjusting the HPU Output Pressure Level 47

Adjusting the Auto-Cooling Level 47

Low/High Pressure Functionality 50

Model 505G2.07/.11 SilentFlo™ HPU

Operator’s Panel

Main Screen

The Main screen is displayed initially when the HPU is powered up. The following table describes the pushbuttons and indicators on the Main screen.

Model 505G2.07/.11 SilentFlo™ HPU

Name and Location Description

Main Screen

Faulted/Ready/Running/High Pressure/Alarm/Overtemp Bypass

Run/Stop/Bypass

Indicator. Indicate the various state of the HPU

Faulted - red: Initial condition. Also displayed when an interlock has occurred and the HPU has been shut down.

Ready - green: Indicates the interlocks are cleared and the HPU is ready to start.

Running - green: Indicates the HPU is running in low pressure.

High Pressure - green: Indicates the HPU is running in low pressure.

Alarm - yellow: Indicates something is wrong and needs attention.

Overtemp Bypass - yellow: Indicates an over temperature interlock has occurred and the HPU has been put into a bypass mode to circulate hydraulic fluid through the heat exchanger until the hydraulic fluid level reaches an acceptable temperature,

Pushbutton/Indicator. Pushbutton used to start and stop the HPU.

Run - gray. black letters: In this state, press to start the HPU

Stop - gray, red letters: In this state, press to stop the HPU

Bypass - blue, white letters: In this state, press to start the HPU in bypass mode. The Faulted state will turn to Overtemp Bypass. Bypass mode only occurs during an overtemperature condition and allows the HPU to run in low pressure to cool the hydraulic fluid.

High Pressure

Remote Operation

Pump Hours

Oil Pressure

Part of the Analog Option;only displayed if the Analog Option was purchased.

In remote operation, the run and bypass buttons are disabled.

Pushbutton/Indicator. Used to put the HPU in high pressure.

High Pressure - gray: indicates the HPU is not in high pressure.

High Pressure - green: Directs the HPU to sequence to high pressure. When the HPU is in high pressure it will be indicated on the main display.

In remote operation, the High Pressure button is disabled.

Pushbutton/Indicator. Used to put the HPU into remote operation.

Remote Operation - gray: Indicates the HPU is not in remote operation.

Remote Operation - green: Indicates the HPU is in remote operation.

In remote operation, the local Run and High Pressure buttons are disabled

Indicator/Display: Indicates total running time of the HPU.

Indicator/Display: Indicates output pressure of the HPU.

Model 505G2.07/.11 SilentFlo™ HPU

Main Screen

Name and Location Description

Oil Temp(erature)

Part of the Analog Option;only displayed if the Analog Option was purchased.

Oil Level

Part of the Analog Option;only displayed if the Analog Option was purchased.

Main

Status

Setup

Indicator/Display: Indicates the temperature of the hydraulic fluid in the reservoir.

Indicator/Display: Displays the level of the hydraulic fluid in the reservoir in 1/8 increments. The level is relative to the bottom of the sensor, not the bottom of the reservoir.

Pushbutton/Indicator. Pushbutton used to select the Main screen.

Main - gray: In this state, one of the other screens is selected; for example the Status screen.

Main - black: The Main screen is selected and displayed.

Pushbutton/Indicator. Pushbutton used to select the Status screen.

Status - gray: In this state, one of the other screens is selected; for example the Main screen.

Status - black: The Status screen is selected and displayed.

Status - blue: A blue indicator means action is required. When the status indicator is blue, press the status button to go to the status screen and resolve any condition that requires action.

Pushbutton/Indicator. Pushbutton used to select the Setup screen.

Setup - gray: In this state, one of the other screens is selected; for example the Main screen.

Setup - black: The Setup screen is selected and displayed.

Model 505G2.07/.11 SilentFlo™ HPU

Status Screen

The Status screen is displayed by pressing the Status button on the Main screen. The following table describes the pushbuttons and indicators on the Status screen.

Name and Location Description

Watchdog OK/Watchdog Fault

Indicator. Used to indicate the status of the watchdog timer.

Watchdog OK - gray: Indicates the PLC that controls the HPU is operating normally.

Watchdog Fault - red: Indicates there is a problem with the hardware watchdog timer and the PLC is not operating correctly. A watchdog fault cause the HPU to shutdown. See, “Watchdog

Fault” on page 43 to attempt to recover from this fault condition.

Reset

Pushbutton /Indicator. Used to reset interlocks.

Reset - gray: Indicates no active interlocks.

Reset - blue: Indicates one or more interlocks are active. Pressing the button in this state will clear the interlock(s) provided the cause of the interlock(s) has been remedied.

Emergency Stop OK/Emergency Stop Fault

Indicator. Used to indicate whether the safety relay is tripped.

E-Stop OK - gray: Indicates the safety relay has not tripped.

E-Stop Fault - red: Indicates the safety relay has tripped. The cause of a safety relay trip is either the main panel E-stop button, an external e-stop button, or the HPU watchdog timer.

Model 505G2.07/.11 SilentFlo™ HPU

Status Screen

Name and Location Description

Oil Level OK/Oil Level Fault

Oil Temp OK/Oil Temp Fault

Motor OK/Motor Overload

Motor Sequence OK/Motor Sequence Fault

Indicator. Used to indicate if the hydraulic fluid level is within acceptable limits.

Oil Level OK - gray: Indicates the hydraulic fluid level is within acceptable limits.

Oil Level Fault - red: Indicates the hydraulic fluid level is not within acceptable limits and an interlock is active.

Indicator. Used to indicate if the hydraulic fluid temperature is within acceptable limits.

Oil Temp OK - gray: Indicates the hydraulic fluid temperature is within acceptable limits.

Oil Temp Fault - red: Indicates the hydraulic fluid temperature is not within acceptable limits and an interlock is active.

Indicator. Used to indicate if the pump motor is in an acceptable operating condition.

Motor OK - gray: Indicates the pump motor is within an acceptable operating condition.

Motor Overload- red: Indicates the pump motor has overheated and an interlock is active.

Indicator. Used to indicate if the pump motor sequence is operating properly.

Return Filter OK/Return Filter Fault

Motor Sequence OK - gray: Indicates the motor sequence is not in a fault condition and operating properly.

Motor Sequence Fault- red: Indicates that the PLC commanded the motor contactor to close but the contactor did not close after a 10 second time period.

Indicator. Used to indicate if the return filter is within acceptable limits.

Return Filter OK - gray: Indicates the contamination in the return filter is within acceptable limits.

Return Filter Dirty - yellow: Indicates the contamination in the return filter is not within acceptable limits. This state will not generate an active interlock, but alerts the user that the filter requires maintenance.

The HPU cannot be started with an active return filter warning

Model 505G2.07/.11 SilentFlo™ HPU

Name and Location Description

Operating the HPU Locally or Remotely

Pressure Filter OK/Pressure Filter Fault

Part of the Pressure Filter Option; only displayed if the Pressure filter Option was purchased.

Indicator. Used to indicate if the pressure filter is within acceptable limits.

Press Filter OK - gray: Indicates the contamination in the pressure filter is within acceptable limits.

Press Filter Dirt y- yellow: Indicates the contamination in the pressure filter is not within acceptable limits. This state will not generate an active interlock, but alerts the user that the filter requires maintenance.

The HPU cannot be started with an active pressure filter warning.

Screen select buttons

These pushbutton/indicators are described in the Main Screen section; refer to “Main Screen” on page 36.

Operating the HPU Locally or Remotely

The HPU can be operated locally using the controls on the user interface panel or remotely using your system controller.

Local operation 1. Make a general inspection of the HPU. Ensure that all cooling water valves

are open. Ensure the Emergency Stop button is released.

2. If not already displayed, press the Main button to display the Main screen.

3. Verify that the Remote Operation button is gray. If the button is green, press the button to change it to gray (indicating local mode).

4. Press Run to start the pump. The pump starts in low pressure mode.

5. Check the HPU for leaks and unusual sounds. Stop the HPU immediately if leaks or unusual sounds are noted. Determine the cause and fix the problem before restarting the HPU.

6. Press High Pressure to turn on high hydraulic pressure.

Note If the HPU generates an interlock during operation (such as low fluid

level or high temperature), the HPU will stop. Once the cause has been corrected, press the Reset button before restarting.

7. Run the HPU for about 30 minutes or until the hydraulic fluid is up to operating temperature [typically

43–49°C (110–120°F)] before using your

test system.

8. When in high pressure mode, press the High Pressure button to return to low pressure mode.

9. To stop the HPU, press the Stop button.

Remote operation Remote operation can occur at a remote control panel or from your system

controller. The controller must be connected to the HPU.

1. Make a general inspection of the HPU. Ensure that all cooling water valves

Model 505G2.07/.11 SilentFlo™ HPU

are open. Ensure the Emergency Stop button is released.

Recovering from an Interlock

2. If not already displayed, press the Main button to display the Main screen.

3. Verify that the Remote Operation button is green. If the button is not green, press the button to change it to green (indicating remote mode).

4. Start the HPU in low pressure at your controller.

5. Check the HPU for leaks and unusual sounds. Stop the HPU immediately if leaks or unusual sounds are noted. Determine the cause and fix the problem before restarting the HPU.

6. Select high pressure at your system controller.

Note If the HPU generates an interlock during operation (low fluid level or high

temperature), the HPU will be stopped. Once the cause has been corrected, press the Reset button on the HPU user interface before restarting.

7. Run the HPU for about 30 minutes or until the hydraulic fluid is up to operating temperature [typically 43–49°C (110–120°F)] before using your test system.

8. Stop the HPU with the controller.

Recovering from an Interlock

This section describes how to reset each type of HPU interlock. If a fault occurs (Low Level, Over temperature, Dirty Filter), the HPU will not start. You must determine the source of the interlock and correct the cause before using the HPU.

If the Main screen is selected, the presence of a fault condition is evident by one of the fault or alarm indicators and a blue Status indicator. Other indicators can be lit depending on the interlock.

Click on the Status button to display the Status screen and identify the fault conditions.

Hyd fluid low level A low fluid level interlock is indicated on the Main screen by a red Faulted

indicator, a red Oil Level indicator, and a blue Stat us indicator. The interlock is generated when the hydraulic fluid falls below the setting of the low level switch mounted through the top of the reservoir. Perform the following steps to correct a low level interlock:

1. Determine the cause for the low fluid level and correct it.

2. Add hydraulic fluid to the reservoir until the sight glass on the side of the HPU indicates the proper level.

3. Verify that the hydraulic fluid level sensor is detecting the proper fluid level.

overtemperature

Hyd fluid

4. Press Reset to clear the interlock and change the unit status back to normal.

A hydraulic fluid overtemperature interlock is indicated on the Main screen by a flashing red Faulted indicator, a blue Bypass indicator, a red Oil Temp indicator, and a blue Statu s indicator. The interlock is generated when the temperature exceeds 55°C (131°F). The interlock will automatically shut down the HPU. The HPU cannot return to normal operation until the fluid has cooled. Perform the following to correct an overtemperature interlock:

Model 505G2.07/.11 SilentFlo™ HPU

Changing the Water Flow

1. Start cooling the hydraulic fluid by circulating hydraulic fluid through the heat exchanger (Overtemp Bypass mode).

A. If necessary, press the Main button to select the Main screen.

B. Ensure that Module #1 Enabled is green.

C. Press the Bypass button. Pump module #1 will start and run to circulate

the hydraulic fluid through the heat exchanger. The red flashing Faulted indicator changes to yellow Overtemp Bypass and the Bypass button changed to Stop.

2. If the there is no change in the Oil Temp reading after several minuets, determine if the hydraulic fluid is receiving adequate cooling.

• The cooling water inlet temperature affects the efficiency of cooling

the hydraulic fluid.

• Check the cooling water inlet-to-outlet pressure differential. It should

be between 0.24–0.31 MPa (35–45 psi). If necessary, adjust the water pressure at its source.

3. After the displayed fluid temperature drops below 55°C (131°F), press the Stop button.

4. Press the Reset button to clear the interlock and turn the indicator off.

Watchdog Fault The HPU Fault Status on the user interface panel displays Watchdog Fault if

the watchdog timer stops operating properly. A watchdog fault causes the HPU to shutdown. Perform the following procedure to attempt to recover from this fault.

1. Turn the power disconnect switch on the main enclosure to off.

2. Wait at least 60 seconds, then close the power disconnect switch.

3. From the Startup Screen, press the Main Display button.

4. On the Main Display screen, press the Reset button.

5. If the Watchdog Fault condition does not clear, contact MTS Systems

Dirty filter A dirty filter interlock is indicated on the Main screen by a yellow Alarm

indicator and a blue Status indicator. Press the Status button to display the Status screen and note the yellow Return Filter Dirty or Press(ure) Filter Dirty indicator(s). The interlock is generated when the filter capacity has reached a critical level. A dirty filter condition will prevent the HPU from being started, but it will not stop the HPU while it is running.

1. Replace the dirty hydraulic fluid filter. Refer to procedures for return line filter replacement and high pressure filter replacement as required.

2. Press Reset to clear the interlock and turn the indicator off.

Changing the Water Flow

The flow of water is the only way to maintain the temperature of the hydraulic fluid on a water-cooled HPU. The water-regulating valve, located on the water inlet line of the HPU, senses the hydraulic fluid temperature and automatically controls water flow to the heat exchanger.

Model 505G2.07/.11 SilentFlo™ HPU

Resetting the Thermal Overloads and Circuit Breakers

Water Regulation Valve

Adjustment

Water Solenoid Valve

Note When the HPU is turned off, a solenoid valve also shuts off the flow of

water to the heat exchanger.

The water-regulating valve is adjusted at MTS Systems Corporation to maintain the hydraulic fluid temperature at 43°C (110°F). However, the temperature of your water may require you to readjust the regulator.

To set the operating temperature of the hydraulic fluid:

1. Start the HPU and switch to high-pressure mode.

2. Observe the temperature gage as the hydraulic fluid temperature rises. Note the temperature where the hydraulic fluid stabilizes.

3. Adjust the water-regulating valve. One full turn (360°) of the adjusting screw produces a change in hydraulic fluid temperature a few degrees.

• Adjust the screw clockwise to decrease the operating temperature.

• Adjust the screw counterclockwise to increase the operating

temperature.

4. Note the effect after 15 minutes.

5. Repeat Step 3 and Step 4 until the hydraulic fluid temperature stabilizes between 43°C–49°C (110°F–120°F).

Resetting the Thermal Overloads and Circuit Breakers

The electrical power feed line for each pump motor has a circuit breaker with integrated thermal overload switch in the main electrical enclosure. If any pump motor draws too much current, its thermal overload switch trips and disconnects that pump motor from the electrical power feed.

Model 505G2.07/.11 SilentFlo™ HPU

Additional protection is provided by circuit breakers. A tripped thermal overload

Output Pressure Control

Control Manifold (shown rotated)

Return Line Hose

Output Pressure Gage

Auto-Cooling Valv e

or circuit breaker indicates a potential short circuit, too much heat in the electrical box, or a component failure (mechanical or electrical). Before operating the HPU, locate and remedy the cause of the tripped thermal overload or circuit breaker.

Reset the thermal overload switches or circuit breakers as follows:

1. Turn the main disconnect switch counterclockwise to remove power from the electrical control box.

2. Loosen the bolts securing the door of the electrical enclosure and open the door.

3. Locate the tripped thermal overload or circuit breaker; labeling is provided next to each component for identification. If necessary, press Reset to clear the switch. If the thermal overload or circuit breaker switch trips again after the cause has been remedied, wait until the switch/breaker cools.

Adjusting the Hydraulic Pressure

The output pressure can be adjusted from a low pressure value of 1 MPa (145 psi) to the factory setting of 21 MPa (3000 psi). If you have a special testing requirement, you can reduce the HPU output pressure. If you do so, you should also adjust the Auto-Cooling Valve.

Adjusting the Hydraulic Pressure

To change the output pressure, see the appropriate procedure.

Model 505G2.07/.11 SilentFlo™ HPU

Control Locations

Adjusting the Hydraulic Pressure

CAUTION

Perform the procedure for adjusting the auto-cooling level if the adjusted output pressure is between 14 MPa (2000 psi) and 21 MPa (3000 psi) and the HPU will be operated in high pressure mode for an extended period of time (longer than 10 minutes).

The pump and motor are designed to operate below a specified pressure.

Setting the hydraulic pressure above 21 MPa (3000 psi) can damage the pump and its motor.

Do not adjust the output pressure higher than 21 MPa (3000 psi).

Model 505G2.07/.11 SilentFlo™ HPU

Adjusting the HPU Output Pressure Level

1. Turn on high hydraulic pressure. Ensure that there are no flow demands by the system.

2. Loosen the nut securing the output pressure control.

3. Monitor the hydraulic pressure gage located on the control manifold. Adjust the output pressure as follows until the desired pressure is displayed.

• Turn the output pressure control clockwise to increase the pressure.

• Turn the output pressure control counterclockwise to decrease the

pressure.

Note If this pressure level is to be used for longer than 10 minutes, proceed to

“Adjusting the auto-cooling level” procedure.

4. Hold the output pressure control to prevent it from moving and tighten the nut to secure it.

5. Check the hydraulic pressure gage to ensure that the desired hydraulic pressure is being maintained.

Adjusting the HPU Output Pressure Level

Adjusting the Auto-Cooling Level

Note If the test condition requires a maximum pressure level of less than 14

MPa (2000 psi), consult MTS.

An incorrect adjustment may cause one of two conditions:

• An over-temperature interlock as indicated by the front panel indicator. A

mis-adjustment of the Auto-Cooling Valve may prohibit the flow of hydraulic fluid across the heat exchanger

• Unexpectedly reduced system performance. A mis-adjustment of the Auto-

Cooling Valve may reduce the full flow of the pump to the external circuit

The Auto-Cooling Valve is factory set for an output pressure setting of 21 MPa (3,000 psi). If the HPU will be operated with a 0.2 MPa (25 psi) or larger decrease (or increase from a lower set pressure) for a period exceeding 10 minutes, an adjustment to this valve will ensure that neither of these conditions occurs. The Auto-Cooling Valve is located on the control manifold.

Model 505G2.07/.11 SilentFlo™ HPU

Adjusting the Auto-Cooling Level

Adjusting the Auto-

Cooling Valve to

correspond with a

change in HPU output

pressure

Perform the following procedure whenever the HPU will be operated with a change in output pressure for longer than 10 minutes.

The following procedure assumes that Steps 1 through 3 of “Adjusting the HPU output pressure level” have already been completed.

1. With the HPU running in high, loosen the nut on the Auto-Cooling Valve located on the control manifold (see the previous figure).

2. Adjust the Auto-Cooling Valve to shift at the desired level.

• When increasing the output pressure, adjust the Auto-Cooling Valve

clockwise to the desired shift level.

• When decreasing the output pressure, adjust the Auto-Cooling Valve

counterclockwise to the desired shift level.

Note The number of turns required to reach the transition level will depend on

the how much the output pressure is changed. For example, going from an output pressure of 21 MPa (3000 psi) to 14 MPa (2000 psi) may require as much as three full turns on the Auto-Cooling Valve before you approach the transition level.

While adjusting the Auto-Cooling Valve, listen to the pump. When the valve shifts a sudden change in pitch will be heard from the pump. Reversing the valve adjustment a number of times will aid in identifying the proper setting. Make a final counter-clockwise adjustment, an increase in pump pitch will be heard that corresponds with the opening of the valve. Stop adjusting at this point.

An alternative to listening for a change in pump pitch is to hold the return line hose at the manifold while making the valve adjustment to feel when the resultant flow stops or starts.

Important Adjustment of the Auto-Cooling Valve to a level too close to the

desired output pressure may cause an unstable condition characterized by rapid valve shifting. This condition will produce an audible flutter and can be seen as an erratic movement of the needle on the pressure gage.

Adjustment of the Auto-Cooling Valve at or above the desired output pressure may prevent the valve from shifting and result in the HPU overheating.

Adjustment of the Auto-Cooling Valve that results in the valve shifting at a level substantially below the desired output pressure may result in reduced flow to the system.

3. Confirm the Auto-Cooling Valve setting by slowly cycling the HPU Output Pressure Control. Decrease the HPU output pressure and note a decrease in

pump pitch when the valve closes. At the point when the valve closes, the pressure on the gage will momentarily hesitate during the adjustment. Increase the pump output pressure to the desired pressure setting and note an increase in pump pitch when the valve opens. Once again the pressure gage will show a momentary hesitation when the valve opens.

4. If necessary, repeat Steps 2 and 3 until the Auto-Cooling Valve is stable and the HPU cools properly.

Model 505G2.07/.11 SilentFlo™ HPU

Adjusting the Auto-Cooling Level

5. After the final adjustment tighten the nut to secure the setting.

6. Hold the HPU Output Pressure Control to prevent it from turning while tightening the nut.

7. Verify that the output pressure remained at the desired level and tighten the nut to secure the setting.

A. Hold the Auto-Cooling Valve stem to prevent it from turning while

tightening the nut.

Adjusting the Auto-

Cooling Valve if the

HPU shuts down due to an over-temperature condition or if the HPU

fails to deliver the full

flow to the external

circuit.

Adjust the Auto-Cooling Valve if:

• The HPU shuts down due to an overtemperature condition that has been

determined to not be caused by a fault in the heat exchanger circuit or

• If the HPU fails to deliver the full flow of the HPU to the external circuit.

1. With the HPU running in high and the HPU set for the desired output pressure, loosen the nut on the Auto-Cooling Valve located on the control manifold.

2. Adjust the Auto-Cooling Valve setting by slowly turning the valve clockwise. If the valve shifts, a sudden change in pitch will be heard from the pump. Reversing the valve adjustment a number of times will aid in identifying the proper setting. Make a final counter-clockwise adjustment. An increase in pump pitch will be heard that corresponds with the opening of the valve. Stop adjusting at this point. If no valve shift is audibly or visually detected and the valve has been fully closed go to step 3.

Important Adjustment of the Auto-Cooling Valve to a level too close to the

Adjustment of the Auto-Cooling Valve at or above the desired output pressure may prevent the valve from shifting and result in the HPU overheating.

3. Adjust the Auto-Cooling Valve by slowly turning the valve counter

4. Confirm the Auto-Cooling Valve setting by slowly cycling the HPU Output

Model 505G2.07/.11 SilentFlo™ HPU

Adjustment of the Auto-Cooling Valve that results in the valve shifting at a level substantially below the desired output pressure may result in reduced flow to the system.

clockwise. When the valve shifts a sudden change in pitch will be heard from the pump. Reversing the valve adjustment a number of times will aid in identifying the proper setting. Make a final counter-clockwise adjustment, an increase in pump pitch will be heard that corresponds with the opening of the valve. Stop adjusting at this point.

Pressure Control. Decrease the HPU output pressure and note a decrease in pump pitch when the valve closes. At the point when the valve closes the pressure on the gage will momentarily hesitate during the adjustment. Increase the pump output pressure to the desired pressure setting and note an increase in pump pitch when the valve opens. Once again the pressure gage will show a momentary hesitation when the valve opens.

Low/High Pressure Functionality

High Pressure Flow to External System

Return Flow from System

Auto-cooling

HPU Manifold

Low Pressure Flow

Heat Exchanger Filter

Reservoir

5. If necessary, repeat steps 2 and 3 until the Auto-Cooling Valve is stable and the HPU cools properly.

6. After the final adjustment, hold the HPU Output Pressure Control to prevent it from moving while tightening the nut to secure the setting.

7. Verify the output pressure remained at the desired level and the nut to secure the setting.

A. Hold the Auto-Cooling Valve stem to prevent it from turning while

tightening the nut.

Low/High Pressure Functionality

This section clarifies the low and high pressure functionality of the HPU. There are certain cases where it is advantageous to use the HPU in low pressure versus high pressure. Low/High functionality is illustrated in the block diagram below:

Low pressure Series 505 HPUs are started in low pressure to reduce the amount of current

inrush at motor startup. A solenoid valve that opens a direct flow path to the return line commands the pressure setting. Because this direct path offers little resistance to the full flow, minimal system pressure is developed (low pressure). Low pressure operation of a Series 505 HPU provides several useful functions when high pressure is not required by the external system.

System commissioning Best practices for system commissioning include flushing the hard line and

related equipment. This process “conditions” the hydraulic fluid to a cleanliness level that supports high performance servovalve systems. (Refer to the Hydraulic Fluid Care Guide (part number 050-000-536) for information on fluid cleanliness.)

Model 505G2.07/.11 SilentFlo™ HPU

Low/High Pressure Functionality

A logical progression of fluid conditioning that begins at the HPU is required to minimize problems when commissioning a system.

• With the HPU running in low pressure, acceptable particle counts are

obtained in a relatively short time.

• Keeping the HPU in low pressure effectively isolates the external or system

flow because the relative back pressure is normally much higher in the external system circuit.

• Running the HPU in low pressure maximizes fluid flow, allowing the HPU

to circulate the reservoir contents across the filter more times per hour.

• Starting the commissioning process with an isolated HPU reduces the

possible number of problems encountered during startup.

Once the HPU has cleaned the reservoir hydraulic fluid, sections of the system should be isolated and sequentially cleaned. Flushing of hard line sections takes place in high pressure mode. If the HPU is run in low pressure, flow losses in the system will minimize the external flow and reduce the effectiveness of the system flushing and fluid conditioning.

System cooling A Series 505 HPU running in low pressure maximizes the cooling efficiency of

the unit:

• Because the motor is not working to pressurize the fluid, it runs at a low

power level, producing less waste heat.

• Flow rates are high in low pressure mode, providing an ample volume of

coolant (hydraulic fluid) with a lower BTU per gallon heat content to the heat exchanger. The heat exchanger operates with greater efficiency when flows are near the designed flow rate as boundary layers are minimized.

Energy consumption All Series 505 HPUs have variable volume pumps. Switching from high to low

pressure operation when external demands are absent will conserve energy and water:

• Leaving an HPU idling in high pressure mode uses roughly 40% more

electrical power than idling in low pressure mode.

• When the hydraulic fluid is pressurized, cooling water usage is higher.

When operating in low pressure, the motor consumes less energy and less heat needs to be removed by the heat exchanger.

Hydraulic fluid

replacement

Overtemperature

recovery

New fluid right out of the barrel is the dirtiest the fluid will ever be in a properly maintained system. Particle counts are well beyond safe limits for servohydraulic components. Use the system commissioning methodology (filter new fluid first when possible) to condition the fluid when introducing new fluid into a system.

Cooling tower, chiller failures, or shut-off valves cause a large number of overtemperature interlock conditions in the field. Low pressure mode is the fastest way to get the tank temperature back to normal. Each HPU has an override feature to force the unit into low pressure for fast over temperature recovery.

Model 505G2.07/.11 SilentFlo™ HPU

Low/High Pressure Functionality

High pressure When the Series 505 HPUs are running in high pressure, a considerable amount

Auto-cooling The Auto-Cooling Valve is adjusted such that the shift between valve closed and

of heat is generated. During normal testing, this heat is dissipated by running the hydraulic fluid through the system from the return line to the heat exchanger. During periods of low system demand, this heat is dissipated by running the hydraulic fluid through the auto-cooling circuit to the heat exchanger.

valve opened occurs just below the output pressure level. Whenever system pressure is above the shift level of the Auto-Cooling Valve (indicating low system demand), the valve opens to port hydraulic fluid through the return filter to the heat exchanger. When system pressure drops below the shift level (indicating an increase in system demand), the valve closes and full flow is available to the system.

Note If the test condition requires a maximum pressure level less than 14 MPa

(2000 psi), consult MTS.

Model 505G2.07/.11 SilentFlo™ HPU

Maintenance

This section describes preventive maintenance requirements and their recommended intervals for the HPU.

Routine Maintenance Overview Checklist 54

Checking the Hydraulic Fluid 55

Replacing the Return Line Filter 57

Sample the Hydraulic Fluid 59

Appearance of Hydraulic Fluid Sample 60

Replacing the Hydraulic Fluid 61

Spare parts Parts that are specified in the maintenance procedures of this section can be

obtained from MTS Systems Corporation.

Lockout/tagout For your safety, follow all appropriate lockout/tagout procedures while

performing HPU maintenance.

Operating the HPU When running the HPU, become familiar with the sounds and smells of the HPU.

Changes in the sounds and smells of the HPU might indicate that maintenance or service is needed.

Model 505G2.07/.11 SilentFlo™ HPU

Routine Maintenance Overview Checklist

Recommended service to be performed at each running time interval noted

Calendar Time using 8 hour

Daily Weekly Monthly Annually

Running Time rate per day

Running Time-Hours 8 40 160 500 1000 1,500 2,000 5,000 10,000

Check electronic enclosure ventilation

Check dirty filter indicators X

Check for leaks X

Check oil level X

Check pressure X

Check fluid color and odor X

Check interlock devices X

Check cables and connectors X

Check console air filter

Check all accumulators for proper precharge pressure and oil

Check condition of all electrical cables and cable connections

†

MTS

MTS MTS MTS MTS

Check HPU hydraulic fluid color and odor

Check HPU operating pressure and temperature

Clean control cabinet air filter, replace if required

Inspect heat exchanger for leaks or “flow (when off)”

Inspect pump hoses for leaks MTS MTS MTS MTS

Lubricate-grease motor bearings (non 505)

Verify dirty filter indicators status

Verify HPU hydraulic fluid level MTS MTS MTS MTS

Verify warning and interlock devices

MTS MTS MTS MTS

Model 505G2.07/.11 SilentFlo™ HPU

Checking the Hydraulic Fluid

Recommended service to be performed at each running time interval noted

Calendar Time using 8 hour

Daily Weekly Monthly Annually

Running Time rate per day

Running Time-Hours 8 40 160 500 1000 1,500 2,000 5,000 10,000

Replace all filters MTS MTS

Verify operation and settings of psi control and relief valves

Check pump/motor coupling for wear and debris

Check pump voltage and current

Check case drain flow MTS

Recommend MTS Hydraulix oil sample

Recommend replacement or rebuild of heat exchanger

Recommend replacement of hoses

Inspect motor bearings

Determine if replacement or

rebuild of pump required

Determine if replacement or

rewind of motor is required

Recommend hydraulic fluid change & clean pump inlet strainer

‡

MTS MTS MTS MTS

MTS MTS

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.

‡ Generally, an inspection would be done every 10,000 hours. Replacement/repair is typically done at

30,000 hours.

Checking the Hydraulic Fluid

Hydraulic fluid contamination and deterioration normally occur in most hydraulic systems. Failure to keep your fluid sufficiently free of contaminants or to change the fluid before severe fluid breakdown occurs will cause poor system performance and may lead to expensive system cleanups. Servovalves are especially susceptible to damage from dirty hydraulic fluid.

Model 505G2.07/.11 SilentFlo™ HPU

Checking the Hydraulic Fluid

Procedure Perform the following checks of the hydraulic fluid weekly. If you suspect

To avoid these problems, you must maintain a clean hydraulic system. Regularly test samples of your hydraulic fluid and follow the recommended maintenance procedures described here. For more information on hydraulic fluid care, refer to the Hydraulic Fluid Care Guide (part number 050-000-536).

Important To prevent problems with inconsistent and inferior fluids, MTS

recommends only ExxonMobil DTE 25 or Shell Tellus 46 to its customers.

contamination of the hydraulic fluid, take a sample and have it analyzed.

1. Check the fluid level in the HPU sight gage to verify the fluid level is correct.

• A low level can indicate a leak. If necessary, add enough fluid to bring

the reservoir level up to the proper operating level.

• A high level can indicate water contamination from the heat exchanger.

2. Check the hydraulic fluid color. Clean hydraulic fluid is amber in color.

Keep a sample of brand-new hydraulic fluid in a clean glass container for comparison. A change in color can mean that the fluid is contaminated or that it has broken down chemically. Refer to the table, “Appearance of Hydraulic Fluid Sample,” if the hydraulic fluid appears different than the clean sample.

3. Check the smell of the hydraulic fluid. Burnt-smelling hydraulic fluid can indicate a chemical breakdown.

If you detect a distinct change in the smell of hydraulic fluid, have it chemically analyzed by the manufacturer.

4. Keep records of the maximum reservoir temperature.

High operating temperatures can cause the fluid to break down. If your records indicate a pattern of overheating, consult your MTS Field Service Engineer to determine if changes or adjustments to your hydraulic system are required.

5. Check and adjust the hydraulic fluid delivery system so that:

• Hydraulic fluid temperature stabilizes within acceptable limits when

the HPU is operating at high pressure.

• Pressure line reading is maintained at 21 MPa (3000 psi) maximum

static value.

• Maximum drain line back pressure is limited to 0.1 MPa (15 psi).

If you need to adjust the water-regulating valve, overtemperature switch or pressure control valves, see the procedure for Changing the Water Flow.

Model 505G2.07/.11 SilentFlo™ HPU

Replacing the Return Line Filter

Output Pressure Gage

Filter Assembly

The filter element of the HPU should be replaced for the following reasons:

• When the dirty-filter indicator lights

• Whenever the hydraulic fluid is changed

• The maximum interval recommended by the filter manufacturer has passed

(1000 hours or 6 months)

Prerequisite You will need a filter element (MTS part number 100-009-495) or a filter kit

(MTS part number 100-030-195).

Procedure To change the filter element:

Note The dirty-filter indicator may light when the HPU is first started due to low

hydraulic fluid temperature. When the HPU is at normal operating temperature, recheck the indicator to determine if the element actually needs replacement.

1. Turn off the HPU.

Replacing the Return Line Filter

2. Open the top of the HPU with an 8-mm (5/16-inch) allen wrench.

Return Line Filter Component Identification

3. Check the output pressure gage. Ensure that the pressure is at zero before proceeding.

4. Unscrew the filter cover. The filter element, bypass assembly, and filter bowl can be removed as one assembly. Be careful not to spill any hydraulic fluid.

5. Remove the disposable element from the bowl. Discard any fluid contained

Model 505G2.07/.11 SilentFlo™ HPU

in the filter bowl.

Replacing the Return Line Filter

Align the 90° elbow outlet at the bottom of the assembly such that it directs hydraulic fluid flow in the direction of the arrow in the graphic above.

6. Wipe out any remaining sludge in the filter housing with a lint-free cloth.

7. Inspect the O-rings in the manifold for any sign of deterioration. If necessary, replace the defective O-ring(s).

8. Insert a new filter element into the bowl and reinstall the bowl assembly. Align the 90° elbow outlet at the bottom of the assembly such that it directs hydraulic fluid flow towards the side of the reservoir as shown in the following illustration. Screw the filter cover back on.

Model 505.07 HPU Top View

9. Turn on the HPU and switch to high-pressure mode. Inspect the seal between the housing and the manifold for any signs of leakage. If leakage occurs, repeat this procedure (without replacing the filter element). If leakage persists, contact MTS Systems Corporation.

10. If you are changing the filter because the dirty filter indicator tripped, run the HPU for two to four hours to remove contaminants. Then take a fluid sample and have it analyzed.

Continue to clean the fluid if it does not meet an ISO cleanliness level of 13/ 9 or better.

11. Press the Reset button on the HPU control panel to reset any interlocks and turn off the Dirty Filter indicator.

Model 505G2.07/.11 SilentFlo™ HPU

Sample the Hydraulic Fluid

Bypass Valve

Hose Valve Assembly

Needle Valve

Sample Port

This section describes how to check the quality of the hydraulic fluid. Review the following hints before obtaining your sample:

• Avoid contamination.

• For additional information on hydraulic fluid care, see the Hydraulic Fluid

• Hold the hose valve assembly still when taking a sample.

• Do not let the hose sample assembly line touch the mouth of the bottle or go

Sample the Hydraulic Fluid

– Keep the sample bottle in the storage box of the hydraulic fluid

sampling kit until it is needed.

– Do not remove the cap from the bottle until immediately before taking

the sample.

– Do not set the cap down on a dirty surface or in an area where airborne

dust can settle.

Care Guide (part number 050-000-536) found in the documentation package inside the electrical control box.

into the bottle.

Prerequisite You will need a hydraulic fluid sampling kit (part number 055-589-601).

Procedure Take a fluid sample from the reservoir to get a visual indication of the fluid level

and relative contamination. Clean hydraulic fluid is clear and has an amber color. If the composition of the fluid appears to have changed, obtain a sample of the hydraulic fluid from the sample port and check the fluid qualities.

Model 505G2.07/.11 SilentFlo™ HPU

Control Manifold

Appearance of Hydraulic Fluid Sample

1. Operate the HPU until the hydraulic fluid is at normal operating temperature

2. Close the needle valve. Connect the hose valve assembly to the sample port

3. Open the needle valve on the hose valve assembly and flush 1 liter (1 quart)

4. Obtain a sample of the hydraulic fluid after flushing the valve hose

5. Check the fluid qualities of the sample by comparing it to a small jar of

(about 30 minutes).

located on the hydraulic manifold on top of the HPU. (See illustration.)

of hydraulic fluid though the sampling assembly. This fluid can be directed to a waste container or back into the HPU reservoir.

assembly.

A. Without closing the valve, quickly place the sample bottle into the fluid

stream (keep the sample bottle sealed until the sample is to be taken).

B. Fill the sample bottle (175 mL/6 oz) with fluid.

C. Close the valve on the hose valve assembly and cap the sample bottle.

clean hydraulic fluid. Clean hydraulic fluid has an amber color.

See the table, “Appearance of Hydraulic Fluid Sample,” for unacceptable fluid qualities.

6. If there still is any uncertainty regarding fluid quality, obtain another sample of the fluid and have it analyzed. The fluid tests should include chemical analysis, particle count, and viscosity checks. Most oil companies have facilities for performing these tests, or consult MTS Systems Corporation.

7. Close the needle valve and remove the hose and valve assembly. Open the needle valve.

Appearance of Hydraulic Fluid Sample

Fluid Properties Problem What to Do

Dark colored fluid

Burnt odor

Indicates chemical breakdown or the hydraulic fluid has been allowed to rise above the maximum recommended temperature (severe overheating)

Analyze the fluid and replace as required by the analysis.

If the cause was overheating, flush the entire system to remove varnish or residue. Consult your MTS Field Service Engineer to determine if changes or adjustments to your hydraulic system are required.

Analyze the fluid and replace as required by the analysis.

Model 505G2.07/.11 SilentFlo™ HPU

Fluid Properties Problem What to Do

CAUTION

Replacing the Hydraulic Fluid

Opaque fluid

Milky appearance

Indicates chemical breakdown Replace the fluid

Indicates water is present in the fluid

Sediment at the bottom of the sample container (after sample has stood overnight)

Indicates collapsed, ruptured, or clogged filter(s)

Replacing the Hydraulic Fluid

Replace the hydraulic fluid in the HPU reservoir whenever you have determined that the hydraulic fluid is no longer suitable for use.

Recommended

equipment

• A transfer pump with a 10-micron filter (such as the Model 590.01 Fluid

Transfer Pump)

Check the heat exchanger for damage.

Look for other water sources if the water does not appear to be coming from the heat exchanger.

Identify and correct the source of the water leakage and replace the fluid if necessary.

Analyze the fluid and replace all filter elements.

Clean the fluid or replace it as required by the analysis.

• ethanol or a similar cleaning solvent

• Lint-free cloths or manufactured rags

• A container for the used hydraulic oil and a small drain pan that will fit

underneath the drain plug

• A hydraulic fluid sampling kit (MTS part number 055-589-601).

• A new filter—see “Replacing the Return Line Filter”

Prerequisite Perform the procedure “Sampling the Hydraulic Fluid” to determine if the

hydraulic fluid should be replaced.

Identify and correct any sources of contamination.

Mixing different brands of hydraulic fluid can contaminate your system.

Contaminated hydraulic fluid can cause premature wear of the hydraulic components in your system.

Do not mix different brands of hydraulic fluid. MTS Systems Corporation recommends using ExxonMobil DTE-25 or Shell Tellus 46 AW hydraulic fluid.

Model 505G2.07/.11 SilentFlo™ HPU

Replacing the Hydraulic Fluid

Procedure See “Component Identification” to identify the components called out in the

following procedure.

1. Prepare the HPU.

A. Press the Stop button to turn off the HPU.

B. Remove the electrical power to the HPU via a circuit breaker at the

power source.

C. Use an 8-mm (5/16-inch) allen wrench to unlatch the HPU cover.

D. Remove the filler cap.

E. Remove the reservoir cover.

2. Remove the hydraulic fluid.

A. Use the transfer pump to remove the old hydraulic fluid from the

reservoir and into an appropriate container.

B. Open the fluid drain to remove any remaining fluid.

C. Drain the hydraulic fluid from hoses and accumulators in the system.

3. Clean the inside of the reservoir using clean cloths dampened with ethanol. Clean the pump, motor, and bottom of the cover plate as well.

4. Use a dry cloth to wipe away the solvent.

5. Install the reservoir cover.

6. Replace the HPU filter element—see “Replacing the Return Line Filter”.

7. Add new hydraulic fluid to the reservoir.

A. Close the fluid drain.

B. Replace the filter in the transfer pump and transfer fresh hydraulic fluid

(filtered to 10 microns) into the reservoir. Stop when the fluid level is full.

C. Reinstall the strainer assembly of the filter cap.

8. Run the HPU.

A. Press the Start switch.

B. Run the HPU in low pressure for three hours to clean the new hydraulic

fluid.

C. Run the HPU in high pressure to check for leaks.

D. Press the Stop button.

E. Check the dirty filter indicator. Replace the filter element as needed.

Model 505G2.07/.11 SilentFlo™ HPU

Accessories

Contents High Pressure Filter Kit 63

High Pressure Filter Kit

Surge Suppressor Kit 65

Precharging the Surge Suppressor Accumulator 66

Lifting Kit 69

Caster Kit 71

This section describes how to install the high pressure filter kit (part number 100008-737).

To install the high pressure filter kit:

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

2. Remove the hose assembly connecting the high pressure port on the manifold assembly to the high pressure output port.

Model 505G2.07/.11 SilentFlo™ HPU

High Pressure Filter Kit

High Pressure Port

Elbow

High Pressure Hose

High Pressure Output Port

Control Manifold

Filter Assembly

Check Valve

Free Flow

3. Connect the elbow to the input of the filter assembly. Connect the straight tube to the output of the filter assembly.

Replacing the Filter

Element

High Pressure Filter Components

4. Connect the elbow of the filter assembly to the high pressure port on the manifold assembly.

5. Connect the high pressure hose between the filter assembly and the high pressure output port.

6. Turn on the hydraulic pressure and check for leaks.

The high pressure filter should be changed every 1000 hours or six months, or when the Dirty Filter indicator is lit. You will need a filter element (MTS part number 100-030-007) or a filter kit (MTS part number 100-030-194).

To replace the filter:

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

2. Unscrew the filter bowl and remove the filter element.

3. Lift the filter element out of the filter bowl. Be careful to catch any hydraulic fluid dripping from the filter element with a rag or drip pan.

4. Insert the replacement filter into the filter assembly.

Model 505G2.07/.11 SilentFlo™ HPU

Surge Suppressor Kit

Remote Charging adapter

Surge Suppressor Kit

5. Screw the filter bowl back onto the filter assembly. Torque the filter bowl to

27.1 N•m (20 lbf-ft).

6. Press the Reset button on the HPU control panel to reset any interlocks and turn off the Dirty Filter indicator.

The surge suppressor kit smooths out the ripple caused by the pulsing action of the pump as it pressurizes the hydraulic fluid. The surge suppressor is a cylinder that has an outer sleeve that is pressurized with nitrogen. The gas pressurized sleeve dampens the pressure pulses.

The surge suppressor is mounted to the output of the hydraulic pump inside the reservoir.

Required equipment You will need the following to install the Surge Supressor kit:

• A Model 505.07 Surge Suppressor kit (part number 100-008-667) or a

Model 505.11 Surge Suppressor kit (part number 100-008-665).

• Optional Remote Charging kit (part number 100-056-912)

• A transfer pump with a 10-micron filter (such as the Model 590.01 Fluid

Transfer Pump).

• A cleaning solvent such as ethanol.

• A charging kit (part number 037-698-601).

Installation procedure To install the Surge Suppressor Kit.

Model 505G2.07/.11 SilentFlo™ HPU

Precharging the Surge Suppressor Accumulator

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

2. Remove the electrical power to the HPU via a circuit breaker at the power source.

3. Open the top cover of the HPU. Use a 8-mm (5/16-inch) allen wrench to unlatch the cover.

4. Remove the filler cap and reservoir cover.

5. Remove the hydraulic fluid.

Use the transfer pump to remove the old hydraulic fluid out of the reservoir and into an appropriate container. Open the fluid drain to remove any remaining fluid.

Note Every part to be installed must be cleaned and wiped dry.

6. Remove the hose from the pump output port to the bottom of the control manifold.

7. Install the elbow (and reducer for the 505.11) to the surge suppressor cylinder. Torque the fixtures to 33.9 N•m (25 lbf-ft).

8. Remove manifold from the reservior.

9. Install fittings inot the manifold inlet port.

10. Install the surge suppressor assembly into the manifold inlet port.

11. Reinstall the hose between the surge suppressor assembly and the pump outlet.

12. Install the remote charging line and bulhead fitting.

13. Precharge the surge suppressor.

14. Add new hydraulic fluid to the reservoir.

Pump hydraulic fluid (filtered to 10 microns) into the reservoir. Stop when the fluid level is full. Reinstall the strainer assembly of the filter cap. Change the filter.

15. Run the HPU and check for leaks.

A. Press the Start switch.

B. Run the HPU at low pressure for about three hours to filter the new

hydraulic fluid.

C. Run the HPU in high pressure to check for leaks.

D. Press the Stop button.

Precharging the Surge Suppressor Accumulator

It is normal for a small amount of surge suppressor precharge loss to occur during operation. Because of this gradual reduction in precharge pressure, the pressure should be checked and recharged (if necessary) at regular intervals.

Model 505G2.07/.11 SilentFlo™ HPU

Precharging the Surge Suppressor Accumulator

Low Pressure Gage

High Pressure Gage 0–21 MPa (0–3000 psi)

Gage Protector (factory set to limit pressure to the gage to

Extensi

Bleed

Input Check

Nitrogen Supply Hose

Regulator Output Pressure

Nitrogen Bottle Pressure

Core-Type Valve To Open and Close Use Chuck

Nitrogen Bottle

Regulator

Regulator Shut-Off

You must supply these

Check

Lockn

Val v e Stem

Open

Clos

Poppet-Type Valve To Open and Close Use Chuck Valve

Clos

Val ve

Open

Ope

Clos

Determining a

pressure check

interval

Checking precharge

pressure

The precharge pressure checking intervals of your surge suppressor depends on how your system is used. Vigorous use causes more rapid pressure loss and thus requires checking and recharging more often.

Initially, check the surge suppressor precharge pressure every month or 160 operating hours. If the precharge pressure changes more than 200 psi during this time period, recharge the surge suppressor and check the pressure twice as often in the future. If the precharge pressure changes less than 200 psi, check the pressure half as often.

When you have established a regular interval for checking the precharge pressure, note the amount of pressure loss that occurs each time the pressure is checked. An increase in pressure loss during the period between checks may indicate that the surge suppressor seals or bladder require replacement.

The nitrogen precharge should be about 50–60% of the output pressure. Monitor the pressure gage. If the pressure reading is outside the range of 10.3–12.5 MPa (1500–1800 psi), perform the procedure “Changing the precharge pressure.”

Changing the

precharge pressure

Decreasing pressure To decrease the precharge pressure:

Model 505G2.07/.11 SilentFlo™ HPU

The nitrogen precharge should be within the range of 10.3–12.5 MPa (1500– 1800 psi) which is 50–60% of the output pressure (21 MPa or 3000 psi). Perform one of the following procedures to change the precharge pressure.

Charging Kit

Precharging the Surge Suppressor Accumulator

WARNING

CAUTION

1. Slowly open the bleed valve on the charging kit until gas begins to escape. When the pressure reading on the appropriate pressure gage drops to the level required, close the bleed valve.

2. Close the locknut. Open the bleed valve on the accumulator charging kit and remove the chuck valve from the accumulator.

3. Install the valve stem cap and protective cover.

Increasing pressure To increase the precharge pressure:

1. Close the locknut on the surge suppressor.

2. Open the bleed valve two turns.

Mixing gases can produce unpredictable results.

Do not use another gas to precharge a surge suppressor.

Use only dry nitrogen gas to precharge surge suppressors.

3. Connect the nitrogen supply hose from the supply bottle pressure regulator output to the input check valve on the charging kit.

4. Open the nitrogen bottle valve. Check the nitrogen bottle pressure gage on the regulator. (The bottle must contain sufficient pressure to provide an adequate gas volume.)

5. Monitor the regulator output pressure gage and adjust the regulator output pressure valve to the required level.

Avoid rapid and extreme pressure transitions.

Rapid flow rates with pressure differentials of more than 2.1 MPa (300 psi) across the input check valve can damage the valve seal(s).

Do not allow rapid flow rates. Open the regulator shut-off valve only far enough to permit a gradual transfer of gas.

6. Slowly open the regulator shut-off valve until gas is heard escaping from the accumulator charging kit bleed valve.

A. Allow gas to slowly escape for approximately ten seconds, and then

close the bleed valve.

B. Immediately close the regulator shut-off valve before the pressure

reading on either the high or low charging kit pressure gage exceeds the pressure level of the accumulator.

Model 505G2.07/.11 SilentFlo™ HPU

Lifting Kit

CAUTION

Lifting Kit

7. Open the locknut. Slowly open the regulator shut-off valve until the pressure indicator on either the high or low charging kit pressure gage begins to rise. When the pressure is at the required pressure level, close the regulator shutoff valve.

8. Close the locknut.

9. Open the bleed valve on the charging kit and remove the chuck valve from the accumulator.

10. Install the valve stem cap and protective cover. Close the valve on the nitrogen bottle.

The balance of the load unit can become unsettled.

The weight of the HPU can injure you or damage the HPU if it should become unbalanced and fall off the lift.

Before moving the HPU, test the balance of the lift by raising the HPU a short distance off the ground.

The lifting kit (part number 100-036-287) includes support brackets, slings, chain connectors, eyebolts, and hardware to allow the hydraulic power unit to be lifted and moved by an overhead device (such as an overhead crane). The support brackets and slings help distribute the weight of the HPU so it is balanced when it is lifted.

Model 505G2.07/.11 SilentFlo™ HPU

Lifting Kit

Slings

Brackets

Bracket

The slings and brackets should be positioned as shown.

Lifting Support Brackets and Slings

Model 505G2.07/.11 SilentFlo™ HPU

Caster Kit

The caster kit (part number 100-025-327) is a couple of channel supports with casters (two rigid, two locking swivel) connected by support angle brackets. The caster kit allows the hydraulic power unit to be easily moved. The caster kit is designed to hold the Model 505.07 or Model 505.11.

Model Approximate Wieght (with fluid)

505.07 451 kg (992 lb)

505.11 474 kg (1042 lb)

Model 505G2.07/.11 SilentFlo™ HPU

Caster Kit

Model 505G2.07/.11 SilentFlo™ HPU

Appendix A: HPU Maintenance and Service Logs

Contents 8 Hours/Daily 74

40 Hours/Weekly 75

160 Hours/Biweekly 76

500 Hours 77

1000 Hours 78

2000 Hours 79

5000 Hours 80

10,000 Hours 81

8 Hours/Daily

8 Hours/Daily Service Interval Recommendation

Check Console Verification

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

Check Dirty Filter Indicators

Check for Leaks

Check oil Level Check

Pressure

40 Hours/Weekly

40 Hours/Weekly Service Interval Recommendation

Check Fluid Color and Odor

Date Performed by Performed by Notes

Check Interlock Devices

160 Hours/Biweekly

160 Hours/Monthly Service Interval Recommendation

Check Cables and Connectors

Date Performed by Performed by Notes

Check Console Air Filter

500 Hours

500 Hours Service Interval Recommendation

Check All Accumulators for Proper Precharge Pressure and Oil

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

Inspect Pump Hoses for Leaks

Check Condition of All Electrical Cables and Cable Connections

LubricateGrease motor Bearings (non-

505)

Check HPU Hydraulic Fluid Color, and Odor

500 Hours Service Interval Recommendation

Verify Dirty Filter Indicators Status

Check HPU Operating Pressure and Temperature

Verify HPU Hydraulic Fluid Level

Clean Control Cabinet Air Filter, Replace if Required

Verify Warning and Interlock Devices

Inspect Heat Exchanger for Leaks or “flow (when off)”

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

1000 Hours

1000 Hours Service Interval Recommendation

All 500 hr Maintenance Procedures

Date Performed by Performed by Performed by Notes

Replace All Filters

Verify Operation and Settings of psi Control and Relief Valves

2000 Hours

2000 Hours Service Interval Recommendation

All 1000 hr Maintenance Procedures

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

Check Pump/ Motor Coupling for Wear and Debris

Check Pump Voltage and Current

Check Case Drain Flow

Recommend MTS Hydraulix Oil Sample

5000 Hours

Recommend R/R Heat Exchanger

Date Performed by Notes

5000 Hours Service Interval Recommendation

10,000 Hours

10,000 Hours Service Interval Recommendation

Recommend R/R Heat Exchanger

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

Recommend Replacement of Hoses

Inspect Motor Bearings

Determine if Replacement or Rebuild of Pump needed

Determine if Replacement or Rebuild of Motor needed

Recommend Hydraulic Fluid Change & Clean Pump Inlet

10,000 Hours

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 505G2 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

Before You Begin

Preface

Conventions

Documentation Conventions

Introduction

EU Declarations

Intended Use

Product Information CD

Component Identification

Functional Description

Auto-Cooling Valve (adjustable)

Electrical Control

Safety

General Safety Practices: Hydraulic Power Units and Hydraulic Service Manifolds

Installation

Install the HPU

HPU Setup

Operation

Operator’s Panel

Main Screen

Status Screen

Operating the HPU Locally or Remotely

Recovering from an Interlock

Changing the Water Flow

Resetting the Thermal Overloads and Circuit Breakers

Adjusting the Hydraulic Pressure

Adjusting the HPU Output Pressure Level

Adjusting the Auto-Cooling Level

Low/High Pressure Functionality

Maintenance

Routine Maintenance Overview Checklist

Checking the Hydraulic Fluid

Replacing the Return Line Filter

Sample the Hydraulic Fluid

Appearance of Hydraulic Fluid Sample

Replacing the Hydraulic Fluid

Accessories

High Pressure Filter Kit

Surge Suppressor Kit

Precharging the Surge Suppressor Accumulator

Lifting Kit

Caster Kit

Appendix A: HPU Maintenance and Service Logs

8 Hours/Daily

40 Hours/Weekly

160 Hours/Biweekly

500 Hours

1000 Hours

2000 Hours

5000 Hours

10,000 Hours