MTS 505G2 User Manual

be certain.

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

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