MTS 85X User Manual

be certain.

MTS 85X Damper Test System Operation

100-257-537 A

Trademark information MTS, TestStar, and TestWare are a registered trademarks of MTS Systems

Corporation within the United States. Station Manager and MTS Landmark are trademarks of MTS Systems Corporation within the United States. These trademarks may be protected in other countries.

Microsoft is a registered trademarks of Microsoft Corporation. All other trademarks or service marks are property of their respective owners.

Publication information

Manual Part Number Publication Date

100-257-537 A (Original instructions)

April 2012

Contents

Technical Support 5

How to Get Technical Support 5 Before You Contact MTS 5 If You Contact MTS by Phone 6 Problem Submittal Form in MTS Manuals 7

Preface 9

Before You Begin 9

Conventions 9

Documentation Conventions 9

Introduction 11

Other MTS Manuals 12 Typical Test System Configuration 13

Test Controller 14 Servohydraulic and Mechanical Components 15

Interlocks 16

Safety 17

General Safety Practices 17 Safety Practices Before Operating the System 19 Safety Practices While the System Is in Operation 22

Getting Started 25

System Startup 25 Test Setup 27

Operation 29

Initial Setup 30 Install the Specimen 31

Damper System Operation

Run the Test 34

793 Controller Operation Overview 35

About Running Tests 35

Understanding Files Used for Testing 35 Test Desktop 35 Monitoring Tes t Information 36

Perform a Practice Test 39

About Setting Up a Practice Test 39 Steps to Run a Test 40

Routine Maintenance 45

Decommission 51

Damper System Operation

Technical Support

How to Get Technical Support

Start with your

manuals

Technical support

methods

MTS web site

www.mts.com

E-mail techsupport@mts.com

Telephone MTS Call Center 800-328-2255

Fax 952-937-4515

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

If you cannot find answers to your technical questions from these sources, you can use the internet, e-mail, telephone, or fax to contact MTS for assistance.

MTS provides a full range of support services after your system is installed. If you have any questions about a system or product, contact MTS in one of the following ways.

The MTS web site gives you access to our technical support staff by means of a Technical Support link:

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

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

Please include “Technical Support” in the subject line.

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

Damper System Operation Technical Support

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

Example site number: 571167

When you have more than one MTS system, the system job number identifies which system you are calling about. You can find your job number in the papers sent to you when you ordered your system.

Example system number: US1.42460

Know information from

prior technical

If you have contacted MTS about this problem before, we can recall your file. You will need to tell us the:

assistance

• MTS notification number

• Name of the person who helped you

Identify the problem Describe the problem you are experiencing and know the answers to the

following questions:

• How long and how often has the problem been occurring?

• Can you reproduce the problem?

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

problem started?

• What are the model numbers of the suspect equipment?

• What model controller are you using (if applicable)?

• What test configuration are you using?

Know relevant

computer information

Know relevant

If you are experiencing a computer problem, have the following information available:

• Manufacturer’s name and model number

• Operating software type and service patch information

• Amount of system memory

• Amount of free space on the hard drive in which the application resides

• Current status of hard-drive fragmentation

• Connection status to a corporate network

For software application problems, have the following information available:

software information

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

available, software patch number. This information is displayed briefly when you launch the application, and can typically be found in the “About” selection in the “Help” menu.

• It is also helpful if the names of other non-MTS applications that are

running on your computer, such as anti-virus software, screen savers, keyboard enhancers, print spoolers, and so forth are known and available.

If You Contact MTS by Phone

Technical Support

Your call will be registered by a Call Center agent if you are calling within the United States or Canada. Before connecting you with a technical support specialist, the agent will ask you for your site number, name, company , company address, and the phone number where you can normally be reached.

If you are calling about an issue that has already been assigned a notification number, please provide that number. You will be assigned a unique notification number about any new issue.

Damper System Operation

Identify system type To assist the Call Center agent with connecting you to the most qualified

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

• Electromechanical materials test system

• Hydromechanical materials test system

• Vehicle test system

• Vehicle component test system

• Aero test system

Be prepared to

Prepare yourself for troubleshooting while on the phone:

troubleshoot

• Call from a telephone when you are close to the system so that you can try

implementing suggestions made over the phone.

• Have the original operating and application software media available.

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

experienced user nearby to assist you.

Write down relevant

Prepare yourself in case we need to call you back:

information

• Remember to ask for the notification number.

• Record the name of the person who helped you.

• Write down any specific instructions to be followed, such as data recording

or performance monitoring.

After you call MTS logs and tracks all calls to ensure that you receive assistance and that action

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

Problem Submittal Form in MTS Manuals

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

The Problem Submittal Form can be accessed:

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

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

be e-mailed to MTS)

Damper System Operation Technical Support

Technical Support

Damper System Operation

Preface

DANGER

WARNING

CAUTION

Before You Begin

Safety first! Before you attempt to use your MTS product or system, read and understand the

Conventions

safety information provided with your system. Like an automobile, your test system is very useful—but if misused, it is capable of deadly force. You should always maintain a healthy respect for it.

Improper installation, operation, or maintenance of MTS equipment in your test facility can result in hazardous conditions that can cause severe personal injury or death and damage to your equipment and specimen. Again, read and understand the safety information provided with your system before you continue. It is very important that you remain aware of hazards that apply to your system.

Documentation Conventions

The following paragraphs describe some of the conventions that are used in your MTS manuals.

Hazard conventions As necessary, hazard notices may be embedded in this manual. These notices

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

Note For general safety information, see the safety information provided with

your system.

Danger notices indicate the presence of a hazard with a high level of risk which, if ignored, will result in death, severe personal injury, or substantial property damage.

Warning notices indicate the presence of a hazard with a medium level of risk which, if ignored, can result in death, severe personal injury, or substantial property damage.

Caution notices indicate the presence of a hazard with a low level of risk which, if ignored, could cause moderate or minor personal injury, equipment damage, or endanger test integrity.

Damper System Operation Preface

Conventions

Manual formats This manual is available as an electronic document in the Portable Document

Hypertext links The electronic document has many hypertext links displayed in a blue font. All

Notes Notes provide additional information about operating your system or highlight

easily overlooked items. For example:

Note Resources that are put back on the hardware lists show up at the end of

the list.

Special terms The first occurrence of special terms is shown in italics.

Illustrations Illustrations appear in this manual to clarify text. It is important for you to be

aware that these illustrations are examples only and do not necessarily represent your actual system configuration, test application, or software.

File (PDF) format. It can be viewed on any computer that has Adobe Acrobat Reader installed. This manual can also be a file on a CD. This manual can be distributed in paper format. This manual might be available online at www.mts.com.

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.

Preface

Damper System Operation

Introduction

This manual provides operating procedures and safety practices for operation of an MTS Damper test system configured with an MTS test controller, an MTS load frame, and an MTS Hydraulic Power Unit. It also contains a general description of the typical system components.

An MTS test system can be designed for a wide variety of testing applications. To provide maximum flexibility for operation, the information in thi s ma nual is written for a typical system and should be used as a guide for general operation and not a procedure for a specific test.

Level of operator

expertise

Level of specialist

expertise

This manual is intended for a trained operator who has gotten an introduction to system operation and maintenance procedures. The operator should also be familiar with known hazards and the contents of the manuals. The operator needs to be able to perform basic controller tasks such as selecting control modes, starting and stopping hydraulic pressure, and starting and stopping tests.

Some of the information in this manual is intended for a specialist. In addition to all the requirements of an operator, the specialist should be familiar with networking protocols. The specialist should be trained on Station Manager and Station Builder and have a thorough working knowledge of MTS 793 controllers including configuration files and hardware installation files. The specialist should be trained on MPT and have a working knowledge of test design.

Assumptions This manual assumes the load frame is configured with any special fixturing (for

example the side load actuators or water cooling) before starting any operating procedure. The load frame product manual contains the information to configure the frame and its fixturing.

This manual assumes the controller has been loaded with the appropriate configuration file and HWI file by a specialist who understands controller setup and applications. This manual assumes the test to be performed has been designed and set up by a specialist and is saved for selection.

This manual assumes the system and its subcomponents are operating properly. The customer is allowed to perform preventive maintenance. However, any repair or troubleshooting of a non-functioning system or its subcomponents is to be performed by qualified MTS Service Engineers. If the system is not operating properly, call MTS Systems for assistance; contact information can be found on the back cover.

Damper System Operation Introduction

Other MTS Manuals

Because MTS systems can be configured with a variety of similar products, this operation manual covers general operation. Operation specific for a given product will be covered in its product manual. For example, you might be instructed to position the crosshead to accommodate the specimen height and grips or fixtures. For detailed information about how to position the crosshead, you would refer to your load unit or load frame product manual. Another example, during specimen installation you might be instructed to grip the specimen in the upper and lower grips. For detailed information about how to grip the specimen, you would refer your grip product manual.

These product manuals can be found on the MTS System Documentation CD. This CD contains an electronic copy of the MTS manuals that pertain to your test system. The manuals on the System Documentation CD can include hardware, hydraulic, mechanical, and electromechanical component product manuals depending on the specific products that comprise your system. In some cases, assembly drawings and parts lists might also be included. Operation, safety, and maintenance information that pertain to these products is found in the associated product manual. For 85X Damper Systems depending on system configuration, these products can include:

• Series 505G2 SilentFlo™ Hydraulic Power Unit (part number 100227352)

• Model 293.24 Hydraulic Service Manifold (part number 100046709)

• Series 111 Accumulator (part number 011553304)

• Model 850 Load Unit (part number 015203501)

• Model 852 Load Unit (part number 100254839)

• Series 252 Servovalve (part number 011182906)

• Damper Software (part number 015194700)

• MTS FlexTest® Models 40/60/100/200 Controller Hardware (part number

100187204)

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

Note When manuals are provided in electronic form, the electronic form can

be on physical media such as a pdf file on a CD or online at www.mts.com. Some manuals can also be supplied in hardcopy (paper) form.

Introduction

Damper System Operation

Typical Test System Configuration

Outlet Strip

Cables

PC Link

Line Supply

PC Workstation

MTS Documentation

Hose connections to HSM:

• Pressure

• Return

• Drain

Hydraulic Power Unit

PRD

Test Controller

Software (typical):

• TestSuite System Software

• TestSuite Applications

• TestSuite Utilities

Load Frames (typical)

Transducer ID Cable

The following illustration shows the common MTS 85X Damper System components.

Typical Test System Configuration

Damper System Operation Introduction

Typical Test System Configuration

Test Controller

The test controller can be either a FlexTest SE Basic, FlexTest SE Plus, FlexTest GT , or FlexTest 40/60/100/200.

Note Because the FlexTest 40 is the most common test controller used on the

The FlexT est 40, FlexTest SE Plus, and FlexTest SE 2-Channel are single station PC-based digital controllers. The FlexTest 60/100/200 controllers are PC-based multi-station digital controllers. In more complex testing situatio ns, the multistation controller controls many channels on a number of independent stations; with one or more of the stations being a load frame based test system. These test controllers typically consist of:

• A PC running Series 793 Software (except the FlexTest SE Basic).

• A chassis equipped with Series 493 or Series 494 electronics.

• A handset (optional) for load frame control during specimen loading and

MTS Landmark System, this manual will primarily focus on that controller.

unloading. The handset is also used for setup and can initiate tests at the load frame.

• The Station Manager application running on the PC as the primary test

interface.

• A software application (such as MultiPurpose TestWare) to provide the

command and data acquisition functions of running a test.

The FlexTest SE Basic is nonautomated and operates from the front panel controls.

Introduction

Damper System Operation

Typical Test System Configuration

Servohydraulic and Mechanical Components

The following paragraphs briefly describe the servohydraulic and mechanical components that are typical supplied with the MTS Landmark System.

Load frame There are a variety of load frames that can be supplied with the system. The load

frame is the mechanical foundation of the test system in which the load cell transducer, specimen fixturing or grips, and hydraulic actuator are mounted.

The load frame can be configured with hydraulic-controlled crosshead locks and lifts that allow convenient crosshead positioning during specimen installation. (Manual crosshead locks and lifts and manual crosshead locks and hydraulic lifts are also available.)

Hydraulic actuator The hydraulic actuator is typically mounted in the base of the load frame; some

load frames can have crosshead mounted actuators. It is the force-generating and/ or positioning device in the system. Hydraulic fluid is applied to either side of the actuator's piston to cause its piston rod to extend or retract.

Servovalve(s) The servovalve converts a control signal (from the test controller) to control the

direction and amount of fluid flow to the actuator. This regulated hydraulic fluid flow controls the displacement or force being applied to the test specimen.

Hydraulic power

supply

The hydraulic power unit (HPU) provides pressurized hydraulic fluid to the servovalve. An HPU typically includes a reservoir for the hydraulic fluid, a pump to pressurize the hydraulic fluid, a motor to run the pump, a heat exchanger to cool the hydraulic fluid, and sensors to monitor the level, pressure, and temperature of the hydraulic fluid.

Transducer(s) The load cell transducer, mounted underneath the load frame crosshead, is used

to measure the polarity and magnitude of the force that is applied to the specimen.

The extensometer is a sensor attached to a specimen that measures a dimensional change (gage length or strain) that occurs in the specimen while being tested. Extensometers use a Wheatstone bridge circuit to detect the dimensional changes. Extensometers are an option purchased separately.

The L VDT (linear variable dif ferential transformer) transducer is mounted inside the hydraulic actuator. The LVDT is used to measure the position (or displacement) of the actuator piston rod.

Specimen fixtures or

grips

Either fixtures or grips are used to hold the specimen in alignment with the force train during the test. The force train is comprised of the servohydraulic and mechanical components which receive the forces applied by the hydraulic actuator. Fixtures or grips are options purchased separately.

Test area enclosure Protective enclosures should be used when you work with hazardous test

specimens (for example, ejected fluids if a damper breaks, brittle or fragmenting materials, or materials that are internally pressurized). The enclosure is also intended to limit access during a test. Test area enclosures are an option purchased separately.

Damper System Operation Introduction

Interlocks

The test controller incorporates interlock circuitry that can automatically stop a test when a system problem, specimen failure, or an operator error could result in unwanted or unexpected actuator movement. The test controller interlock circuitry will cause one of two interlocks to occur in response to specific conditions encountered during testing. These interlocks are:

• Hydraulic Interlock – stops the program and removes hydraulic pressure

from the system.

• Program Interlock – stops the current test program when certain test

parameters are not met or are exceeded.

The following table lists the possible types of interlock conditions for the test controller.

Condition Cause Type of Interlock

Emergency Stop Program Aux Hydraulic event Mechanical event End-of Count

Underpeak

Error

Upper Limit Lower Limit

* These interlocks can be set to indicate only. For further information on configuring these interlocks,

refer to the test controller documentation.

Emergency Stop or E-Stop button pressed Hydraulic Open circuit at the Prog Intlk rear panel connector Program Fault in the performance of hydraulic components Hydraulic Fault in the performance of mechanical components Hydraulic Completion of a preset number of cycles in the current test

program Selected signal fails to reach a preset minimum or maximum

level

When the control channel's DC error signal exceeds a preset maximum level

Transducer feedback signal exceeds a preset minimum or maximum level

Hydraulic or Program

Hydraulic with indicator option

Introduction

Damper System Operation

Safety

General Safety Practices

This section provides information about safety issues that pertain to servohydraulic systems in general. These issues include statements to the intended use and foreseeable misuse of the system, the hazard zone, definition for the graphical hazard labeling that is affixed to your product, and other (more general) safety information that relates to the high-pressure and highperformance characteristics of MTS servohydraulic systems.

Intended use MTS test systems are designed to generate motions and forces and impart these

motions and forces into a test specimen.

Foreseeable misuse When you prepare to operate the system and during system operation, ensure the

following:

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

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

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

• Do not apply energy levels that exceed the maximum energies and velocities

for the system design.

• Do not test a specimen that exceeds the minimum (if applicable) or

maximum allowable mass.

• Do not use specimens that are combustible, flammable, pressurized,

chemically harmful, or explosive.

• Do not exceed the performance of a test area enclosure. For example,

particles can fly up and there is no cover on the test area enclosure, or particles flying off can have higher energy than the test area enclosure shielding performance (for example when springs are tested with struts).

• Do not use humans as specimens or allow humans to ride in or on the test

specimen or the test system for any purpose unless the system is man-rated and all associated safety conditions are strictly enforced.

• 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 operate the system in an explosive atmosphere.

Damper System Operation Safety

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

system is allowed when the system is in operation

• 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.

If you have system related responsibilities (that is, if you are an operator, service engineer, or maintenance person), 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, gain an understanding of system functions by studying the other manuals supplied with your test system. Contact MTS for information about the content and dates of training classes that are offered.

It is very important that you study the following safety information to ensure that your facility procedures and the system’s operating environment do not contribute to or result in a hazardous situation. Remember, you cannot eliminate all the hazards associated with this system, so you must learn and remain aware of the hazards that apply to your system at all times. Use these safety guidelines to help learn and identify hazards so that you can establish appropriate training and operating procedures and acquire appropriate safety equipment (such as gloves, goggles, and hearing protection).

Each test system operates within a unique environment which includes the following known variables:

• Facility variables (facility variables include the structure, atmosphere, and

utilities)

• Unauthorized customer modifications to the equipment

• Operator experience and specialization

• Test specimens

Because of these variables (and the possibility of others), your system can operate under unforeseen circumstances that can result in an operating environment with unknown hazards.

Improper 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.

Hazard placards Hazard placards contain specific safety information and are affixed directly to the

system components. Each placard describes a system-related hazard. When possible, international

symbols (icons) are used to graphically indicate the type of hazard and the placard label indicates its severity. In some instances, the placard might contain text that describes the hazard, the potential result if the hazard is ignored, and general instructions about how to avoid the hazard. Refer to the product

Safety

Damper System Operation

information manuals for a description of hazard placards associated with the various products that comprise the MTS Landmark System.

Safety Practices Before Operating the System

Before you apply power to the test system, review and complete all of the safety practices that are applicable to your system. The goal, by doing this, is to improve the safety awareness of all personnel involved with the system and to maintain, through visual inspections, the integrity of specific system components.

Read all manuals Study the contents of this manual and the other manuals provided with your

system before attempting to perform any system function for the first time. Procedures that seem relatively simple or intuitively obvious may require a complete understanding of system operation to avoid unsafe or dangerous situations.

Make sure the

servovalve

configuration is

correct for the test

Locate and read

hazard placards/labels

Locate lockout/tagout

points

Know facility safe

procedures

Locate Emergency

Stop buttons

Know controls Before you operate the system for the first time, make a trial run through the

If the load frame can be configured with one of two (or more) servovalve combinations, be sure all manifold valves, solenoid valves, or other hand valves are in the appropriate position. Refer to the load frame product manual.

Find, read, and follow the hazard placard instructions located on the equipment. These placards are placed strategically on the equipment to call attention to areas such as known crush points and electrical voltage hazards.

Know where the lockout/tagout point is for all of the supply energies associated with your system. This includes the hydraulic, pneumatic, electric, and water supplies (as appropriate) for your system to ensure that the system is isolated from these energies when required.

Most facilities have internal procedures and rules regarding safe practices within the facility. Be aware of these safe practices and incorporate them into your daily operation of the system.

Know the location of all the system Emergency Stop buttons so that you can stop the system quickly in an emergency . Ensure that an Emergency Stop button is located within 2 meters (6 feet) of the operator at all times.

operating procedures with the power off. Locate all hardware and software controls and know what their functions are and what adjustments they require. If any control function or operating adjustment is not clear, review the applicable information until you understand it thoroughly.

Have first aid available Accidents can happen even when you are careful. Arrange your operator

schedules so that a properly trained person is always close by to render first aid. In addition, ensure that local emergency contact information is posted clearly and in sight of the system operator.

Know potential crush

and pinch points

Damper System Operation Safety

Be aware of potential crush and pinch points on your system and keep personnel and equipment clear of these areas. Be aware that many of the dynamic (moving) system assemblies have been painted yellow. Understand that yellow paint represents a system component that is capable of motion.

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.

Be aware of

component movement

with hydraulics off

Know electrical

hazards

Keep bystanders

safely away

A load frame crosshead can slowly drift down the columns if the locks are turned off and when hydraulic pressure is turned off. The crosshead can damage any test fixtures, grips, and specimen in its path. Unlock the crosshead only to reposition it. Always lock the crosshead after you have repositioned it and never leave the crosshead unlocked.

The actuator rod can also drift down when hydraulics are turned off hitting anything in its path. This uncommanded movement is because of oil movement between the pressure/return ports and oil blow by across the piston hub. Be aware that this can happen and clear the area around the actuator rod when hydraulics are turned off.

When the system electrical power is turned on, minimize the potential for electrical shock hazards. Wear clothing and use tools that are properly insulated for electrical work. Avoid contact with exposed wiring or switch contacts.

Whenever possible, turn off electrical power when you work on or in proximity to any electrical system component. Observe the same precautions as those given for any other high-voltage machinery.

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

Keep bystanders at a safe distance from all equipment. Never allow bystanders to touch specimens or equipment while the test is running.

Wear proper clothing Do not wear neckties, shop aprons, loose clothing or jewelry, or long hair that

could get caught in equipment and result in an injury. Remove loose clothing or jewelry and restrain long hair.

Remove flammable

fluids

Know compressed gas

hazards

Remove flammable fluids from their containers or from components before you install the container or component. If desired, you can replace the flammable fluid with a non-flammable fluid to maintain the proper proportion of weight and balance.

Most servohydraulic systems contain accumulators that require a high-pressure gas precharge (pressures that exceed 138 bar [2000 psi]). In addition, some systems can contain devices, such as static supports, that are pneumatically operated. High-pressure devices are potentially dangerous because a great amount of energy is available in the event of an uncontrolled expansion or rupture.

Observe the following safety practices when you work with high-pressure air or gases:

• When you charge an accumulator, follow all the charging instructions

provided in the appropriate product information manuals. When precharging accumulators, properly identify the type of gas to be used and the type of accumulator to be precharged.

Safety

Damper System Operation

• 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, th is 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.

Check bolt ratings and

torques

Practice good

housekeeping

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.

To ensure a reliable product, fasteners (such as bolts and tie rods) used in MTSmanufactured systems are torqued to specific requirements. If a fastener is loosened or the configuration of a component within the system is modified, refer to the system and component assembly drawings (located on the System Documentation CD) to determine the correct fastener, fastener rating, and torque. Overtorquing or undertorquing a fastener can create a hazardous situation due to the high forces and pressures present in MTS test systems.

On rare occasions, a fastener can fail even when it is correctly installed. Failure usually occurs during torquing, but it can occur several days later. Failure of a fastener can result in a high velocity projectile. Therefore, it is a good practice to avoid stationing personnel in line with or below assemblies that contain large or long fasteners.

Keep the floors in the work area clean. Hydraulic fluid that is spilled on any type of floor can result in a dangerous, slippery surface. Do not leave tools, fixtures, or other items not specific to the test, lying about on the floor, system, or decking.

Damper System Operation Safety

Protect hoses and

cables

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. Use a cable cover or cable tray where cables are in traffic locations. Never walk on hoses or cables or move heavy objects over them. Route hoses and cables away from areas that expose them to possible damage.

Provide proper

hydraulic fluid

filtration.

Protect accumulators

from moving objects.

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

Protect accumulators with supports or guards. Do not strike accumulators with moving objects. This could cause the accumulator(s) to separate from the manifold resulting in equipment damage and personal injury.

Record changes If you change any operating procedure, write the change and the date of the

change in the appropriate manual.

Provide test area

enclosure

Do not exceed the

Maximum Supply

Pressure

Do not disable safety

devices

Use appropriately

sized fuses

Use protective enclosures and special laboratory layouts when you work with hazardous test specimens (for example, brittle or fragmenting materials or materials that are internally pressurized). Also use protective enclosures to limit access to a running system.

Make sure that hydraulic supply pressure is limited to the maximum pressure defined by the system operating limits. Read and review “System Operating Limits” for the system.

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.

Provide adequate

lighting

Provide means to

access out-of-reach

components

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.

Safety Practices While the System Is in Operation

Wear appropriate

personal protection

Safety

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

Damper System Operation

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

W ear appropriate personal protection equipment (gloves, boots, suits, respirators) whenever you work with fluids, chemicals, or powders that can irritate or harm the skin, respiratory system, or eyes.

Provide test area

enclosure

Specimen temperature

changes

Handle chemicals

safely

Know servohydraulic

system interlocks

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

Whenever you use or handle chemicals (for example, cleaning fluids, hydraulic fluid, batteries, contaminated parts, electrical fluids, and maintenance waste), refer to the appropriate MSDS documentation for that material and determine the appropriate measures and equipment required to handle and use the chemical safely. Ensure that the chemical is disposed of appropriately.

Interlock devices should always be used and properly adjusted. Interlock devices are designed to minimize the chance of accidental damage to the test specimen or the equipment. Test all interlock devices for proper operation immediately before a test. Do not disable or bypass any interlock devices as doing so could allow hydraulic pressure to be applied regardless of the true interlock condition. The Reset/Override button is a software function that can be used to temporarily override an interlock while attempting to start the hydraulic power unit and gain control of the system.

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

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

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

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

Ensure secure cables Do not change any cable connections when electrical power or hydraulic pressure

is applied. If you attempt to change a cable connection while the system is in operation, an open control loop condition can result. An open control loop condition can cause a rapid, unexpected system response which can result in severe personal injury, death, or damage to equipment. Also, ensure that all cables are connected after you make any changes in the system configuration.

Stay alert A void long periods of work without adequate rest. In addition, avoid long periods

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

Damper System Operation Safety

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

Know the causes of

unexpected actuator

motions

Do not use RF

transmitters

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.

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.

Safety

Damper System Operation

Getting Started

System Startup

Before system startup, you should be familiar with the test fixtures, test controller or electrical console, PC workstation, hydraulic power unit, and other system components. This includes reading all of the sections in this Operation Manual and the various additional documents supplied with the system. If applicable, also read the vendor manuals supplied with the system. Observe all safety practices and operating procedures to ensure proper use of the system.

Control console The console power can be turned on after verifying that the following installation

procedures have been completed:

• cable connections are made and secured with proper strain relief,

• the power source is ready,

System Startup

• the components are properly grounded, and

• the hydraulic power unit is shut off.

PC workstation The cabling between the test controller and the computer should be checked for

proper routing and secured using attachment screws where necessary. It is important that the physical integrity of these connections be maintained to ensure safe and accurate operation of the system. When turning on power to the computer, be sure that auxiliary equipment is also turned on at the appropriate time. Refer to the test controller documentation for information regarding the rear panel connectors provided for computer-controlled operation.

Hydraulic power unit Ensure that electrical power is supplied to the HPU. Then turn on the HPU in low

pressure and check for leakage or improper operation. The cooling water supply should also be checked for leakage or improper operation. When first starting up the system or after the system has been idle for an extended period of time, run the HPU for about 30 minutes or until the hydraulic fluid is up to

operating temperature.

Actuators After checking the electrical and hydraulic power unit connections, the actuator

position control electronics (the Set Point control on the selected controller) should be checked for signal polarity and control. This is accomplished by performing the following steps:

1. Clear the area around the piston rod of obstructions.

2. Select the desired control mode (typically displacement).

3. Clear any active interlocks.

4. Apply hydraulic pressure by completing the following steps:

Damper System Operation Getting Started

System Startup

A. Press the Hydraulic Pressure Low switch to start the HPU and apply

low hydraulic pressure to the actuator (the Off indicator will extinguish and the Low indicator will light).

B. Observe the actuator for any movement caused by hydraulic fluid

pressurizing the system. Ensure that the actuator stabilizes before proceeding.

C. Press the Hydraulic Pressure High switch to apply high hydraulic

pressure to the actuator (the Low indicator will extinguish and the High indicator will light).

5. Slowly adjust the Set Point control on the controller and observe piston

movement. The direction and response should be appropriate for the system configuration. The system phase can be determined as follows:

• If the Set Point control is adjusted in a negative direction and the

actuator retracts, then the system is set for a positive phase.

• If the Set Point control is adjusted in a negative direction and the

actuator extends, then the system is set for a negative phase.

Getting Started

Damper System Operation

Test Setup

Before setting up or operating the test system, the hardware component configuration must be defined, control settings (or test parameters) should be calculated, and test setup decisions must be made. This section describes some of the factors to consider when completing these pre-operation procedures.

Define the hardware

configuration

Define the test

parameters

Select test setup

methods

Determine the

crosshead position

Defining the test configuration involves determining how the mechanical components will be set up and what optional fixturing is necessary, These selections must be made before power is applied to the test system. This is performed by the operator.

Before defining the test parameters, the test control mode should be known and the maximum and minimum test forces or displacements should be determined. The maximum and minimum desired forces/displacements will be used in the calculation of the detector settings and program scaling. These test parameters should be defined before beginning the operating procedure. Additional information can be found in the test controller’s documentation. This is performed by a specialist.

There are steps in the operating procedure that are optional or that provide optional setup/adjustment substeps. These include zeroing transducer outputs and adjusting the servo loop controls. This information should be reviewed and any necessary setup decisions should be made before beginning the operating procedure. Usually these steps are prompted for the operator by the test program. Additional information can be found in the test controller’s documentation. This is performed by a specialist.

For balanced system operation, the load frame crosshead must be positioned so that the based-mounted actuator piston rod will be at approximately midstroke when the specimen is installed into its upper and lower fixtures/grips. This is performed by the operator.

Damper System Operation Getting Started

Test Setup

Getting Started

Damper System Operation

Operation

This section covers hardware operation for an MTS 85X Damper system. Hardware operation consists of load frame setup and specimen installation.

All other system operation is performed on the computer through the system controller software. Refer to the controller documentation for information on test definition, system tuning for the test to be performed, and hydraulic pressure operation.

This section is intended for an operator that has had an introduction to system operation, is aware of known hazards and understands the manual contents.

Damper System Operation Operation

Initial Setup

The initial setup tasks include the following:

• Determine what types of fixtures/grips will be needed to secure the

specimen into the load frame.

• Determine the position of the load frame crosshead.

• Prepare the fixtures/grips, specimen, and data acquisition transducers.

• Ensure that the load cell is properly rated for the test and that it is aligned

with the actuator.

• Ensure the appropriate servovalve configuration is set up properly.

• Ensure that the servovalve and feedback control cables are properly

connected.

Detailed information on these tasks can be found in the load frame product manual.

Operation

Damper System Operation

Install the Specimen

WARNING

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

For first time operation, it is recommended to install a dummy specimen and use it for the initial test settings. This minimizes the chance of unintentional damage to the actual test specimen.

Following is a procedure for a typical shock absorber installation. There are other possible installation configurations; see the load frame product manual for additional information.

Prerequisite You should have the necessary fixturing installed to the force transducer and

actuator. You should also have the controller set up to use the Set Point control. And, you should have a test program defined.

Install the Specimen

Be careful when working in a crush zone. The crosshead could drop suddenly cru shing hands, damaging grips, and

smashing specimens.

• Ensure you have hydraulic pressure on before unlocking the crosshead.

• The Lift Control must be in the stop “O” position before you unlock the

crosshead.

• The crosshead cannot securely clamp greasy or wet columns. Keep them

clean and dry.

• Air in the lifts will make the crosshead move roughly. If it moved roughly

when last used, bleed the lifts before unlocking the crosshead.

• Bleed the lifts before unlocking the crosshead if the sealed side of the

hydraulic supply has been opened.

You might need to prepare the specimen for installation. For example, suppose you are testing a shock absorber and the test is designed to begin with the shock at mid-displacement. You need to determine the displacement of the shock and mark the mid-displacement point of the shock’s actuator.

1. Be sure that the Lock Control is in the lock crosshead position. Be sure that the Lift Control is in the stop crosshead position.

2. Turn on system electrical power. Do no t turn on hydraulic pressure yet.

3. If necessary, reset any active interlocks at the test controller.

4. Set the Hydraulic Flow switch on the control panel to Low. This slows the actuator movement when using the Set Point control.

Damper System Operation Operation

Install the Specimen

WARNING

5. Turn on low hydraulic pressure; turn on high hydraulic pressure if low pressure is not available.

6. If there is a specimen in the load unit, remove it.

Note The actuator starting position depends on the type of test being set up.

7. Ensure the control panel Set Point control is enabled by the controller software. Adjust the Set Point control to move the actuator to its start position (usually mid-displacement).

8. This step pressurizes the lift actuators. The crosshead may have shifted position while hydraulic pressure was turned off.

Note Cap screws clamp the crosshead to the columns during shipping and

maintenance. They must be loosened before moving the crosshead.

Briefly turn the Lift Control to the lift crosshead position to apply a slight upward pressure to the crosshead. Then return the lift control to the stop position.

9. Use the Lock Control to unclamp crosshead. Wait 30 seconds for the pressure in the crosshead locks to drop to zero.

Do not leave a crosshead unlocked. It can drift slowly down when hydraulic pressure is turned off and damage

any test fixtures, grips, and specimen in its path.

Unlock the crosshead only to reposition it. Always lock the crosshead after you’ve repositioned it.

10. Use the Lift Control to move the crosshead to a point where you can install

the specimen (or specimen fixture) into the upper grip or fixture without obstruction.

11. Use the Lock Control to clamp the crosshead to its current position. The

clamped symbol is shown at the right. Wait 30 seconds for the locks to fully clamp the columns.

12. Install the specimen into the upper grip or fixture. Depending on your test requirements, zero the force transducer signal to remove the tare weight from the signal.

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

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

13. Use the Lock Control to unclamp the crosshead. Wait 30 seconds for the pressure in the crosshead locks to drop to zero.

Operation

14. Use the Lift Control to move the crosshead to a position where you can mount the lower end of the specimen (or specimen fixture) into the lower grip or fixture.

Damper System Operation

Install the Specimen

You can use the Set Point control to fine tune the alignment of the specimen and actuator positions.

15. Use the Lock Control to clamp the crosshead to its current position. The

clamped symbol is shown at the right. Wait 30 seconds for the locks to fully clamp the columns.

16. Install the specimen into the lower grip or fixture.

17. You may need to reposition the crosshead to accommodate the starting position of the specimen.

A. Use the Lock Control to unclamp the crosshead. B. Use the Lift Control to lower the crosshead until the specimen is in or

near its starting position (you can fine tune the starting position in Step D).

C. Use the Lock Control to clamp the crosshead to its current position. D. If needed, you can use the Set Point control to fine tune the starting

position of the specimen.

18. Depending on the test requirements, zero the displacement signal.

19. Set the Hydraulic Flow switch on the control panel to High. This returns the actuator flow to its normal condition.

Damper System Operation Operation

Run the Test

Note Before you can start a test, the test must be set up by a specialist. This

would include:

• The system software is started and the appropriate configuration file

and HWI file loaded.

• The test control mode is selected.

• The test program is defined.

• The forces and/or displacements to be achieved during the test are

calculated and limits defined and set.

• The signals that should be monitored during the test are defined.

Once everything is set up, you are ready to run the test.

1. Ensure the following are true:

• Interlocks are cleared.

• High hydraulic pressure is applied to the station.

• The test specimen is installed.

• Limits are set and actions are assigned.

• The test program is set up.

• The scope and meters are set up to monitor the test as desired.

2. Start the test.

On the Station Controls panel, press the Program Run button to start the test.

3. Continue the test to completion. Some tests will run to completion and stop automatically by preset

interlocks (e.g., preset count, exceeded limit, specimen failure tripping the error detector) or by a computer-cycled stop function. If desired, the test can also be stopped periodically using the preset count feature of the test controller. To stop the test manually, press the Program Stop but ton to end the test.

Record any necessary data and, if desired, resume the test by pressing the Program Run switch. When the test is complete, ensure that the test controller is in the program stop condition (press the Program Stop switch, if necessary). Remove the test specimen and record any additional data. When no additional testing is to be performed, press the Hydraulic Pressure Off switch to turn off the HPU.

Operation

Damper System Operation

793 Controller Operation Overview

T est data file

Your Project

Station Manager application

Station Config file with Parameter set

T est design application (for example, BTW or MPT)

Test design file

Test data file

You start the test from the Station Control panel of the Station Manager application. Test Data files are generated according to the type of test design application you used to create the test design file.

The test design file, along with the generated test data, are automatically stored in the selected (or default) Project folder.

PAR

This section is intended to give you information on how to run 793 Software and help you learn how to use your system. It is not intended to provide a step-bystep procedure to perform a specific test. Specific tests are usually performed by special application software programs such as the MTS Damper Software for testing elastomers and shock absorbers (refer to MTS manual part number 015194-700). Tests can also be designed within MPT to perform custom testing on customer supplied samples or specimens.

About Running Tests

Understanding Files Used for Testing

During the testing phase, the Station Manager application controls how the parts of the system work together to maintain precision servo control. Command is typically provided by an application such as Basic TestWare or MultiPurpose TestWare.

About Running Tests

Test Desktop

Damper System Operation 793 Controller Operation Overview

With the Station Manager application window controls, you can perform the following to run tests:

• Load and reload stations

• Configure limit and error detectors

• Control hydraulic pressure to the test station

About Running Tests

Windows typically open while running a test. The windows shown here all display some element of status while a test is

in progress, and can be displayed on the desktop until the test is complete. This example shows an MPT test in progress.

Meters display the numeric value of selected signals.

The Station Manager application main window displays interlock and limit status; counters; run, stop, and hold status; and generated messages.

The Scope displays the waveforms of selected signals.

• Manage the execution of the Basic TestWare and MultiPurpose TestWare

applications

• Monitor signals on the built-in scopes and meters

Monitoring Test Information

MTS Series 793 Software includes several features for monitoring test signals and test progress.

793 Controller Operation Overview

Damper System Operation

About Running Tests

This sample procedure includes a group process labeled “Cooling Cycles,” which contains four nested processes (with indented label names, “Trigger at 75C,” and so forth.)

Name displays the assigned process label Current displays the current value of the counter Target displays the assigned number of times

the process should execute (or repeat), or the number of cycles to be executed.

MPT Counters

Run time counter The Run Time counter displays the elapsed time of the current test since the last

time it was reset.

Channel counters Channel Counters display a cumulative count of segments or cycles that have

been applied to a specific channel since the start of the test.

Sequence counters Sequence Counters display the progress of individual processes within the test.

They can be especially useful for procedures that contain nested groups, because you can configure them to show test progress within the nested structure of the procedure.

Input signals The Station Signals panel displays all of the input signals of the station with their

Damper System Operation 793 Controller Operation Overview

Meters display The Meters window can display up to 16 meters per station simultaneously. The

current values.

following data can be displayed for any defined input signal:

• Timed data

• Peak/valley data

About Running Tests

Marker delta display Marker coordinates display

Scope display The Scope window in the Station Manager application is an oscilloscope. You

• Mean/amplitude data

• Maximum/minimum values

Meters can be aligned on the desktop vertically, horizontally, or in a grid. Meter displays can be sized to your preference.

can use it to plot signals against time, frequency, and against each other. You can create up to four scopes per station, and add up to four signal pairs per scope.

Note For a description of individual controls and indicators on the Scope, see

the MTS Series 793 Control Software manual (PN 100-147-130).

You can adjust trace time and scaling in the same way you can with an oscilloscope. You can also select auto-scaling and resetting.

You can use the Program Control feature of the scope to automatically start the scope when you start the test.

You can also use the scope to plot one channel versus another, and to plot in the frequency domain rather than the time domain.

Data point display box The scope also allows you to pan trace history, and for Series 793 Software

version 4.0 or later, you can also pick and view individual data points. When you place the cursor on the trace, it becomes a crosshairs. With the

crosshairs, you can select individual data points on the trace and see their precise coordinates on the axes in the associated display box.

793 Controller Operation Overview

Damper System Operation

Perform a Practice Test

About Setting Up a Practice Test

This section includes step-by-step instructions for performing a practice test. The purpose of this procedure is simply to help you learn how to use your system.

While performing this test you will:

• Select a Project at the beginning of the test, and review test data stored in the

Project at the end of the test.

• Set limits and manually position the actuator to install the specimen.

• Apply hydraulic power to the test system.

• Adjust force tuning controls.

• Monitor test signals on the Meters and Scope.

• Create a test design file with the Basic TestWare application.

Perform a Practice Test

If MTS has set up

your controller

If you are going to set

up your controller

• Start and stop the test.

Before you can perform this test, you need to determine the setup status of your system.

MTS customers typically receive their Series 793 Controller in the following state:

• An initial Project, station configuration file, and parameter set has been

created.

• The sensors are calibrated and the servovalve is adjusted.

• The displacement tuning parameters are optimized. (The force tuning

parameters can also be optimized, but typically need to be adjusted for individual specimens, and often between tests.)

If MTS has performed these activities for your controller, you can run a practice test.

If MTS has not performed these activities for your controller, you must perform the following activities before performing the test.

If you are installing Series 793 Software on your system and setting up your controller yourself, you'll need to do the following before performing the practice test:

• Install Series 793 Software

• Set up a Project (typically performed during software installation)

• Create a station configuration file

• Calibrate the sensors

• Perform servovalve adjustments

Damper System Operation 793 Controller Operation Overview

Perform a Practice Test

WARNING

Steps to Run a Test

• Tune the system

To perform the Series 793 Software installation, see the Installation Instructions readme file on the Series 793 System Software CD, and follow the installation wizard.

To perform the remaining tasks, see the MTS Series 793 Tuning and Calibration manual.

You may also find it necessary to see the following manuals:

• MTS Series 793 Utility Software manual—To setup or edit the hardware

interface file to reflect any hardware changes to your system.

• MTS Series 793 Control Software manual—To find detailed information

about using Series 793 Software controls.

• Other MTS manuals—You can receive additional MTS manuals that

provide instructions for maintaining and operating your test system.

Improper controller setup can result in unexpected actuator movement. Unexpected actuator movement can injure personnel and damage test

equipment.

Ensure that your controller is set up properly before attempting to perform a test.

1. Power up the controller chassis and PC.

2. Start the Station Manager application and select a Project. A. From your desktop, start the Station Manager application:

Start > Programs > MTS 793 Software name (for example, FlexTest GT) > Station Manager

B. As the Station Manager application loads, you will be prompted to

select a Project. Select the existing Project that was created for your system.

3. Apply hydraulic pressure. When you power up your controller, the hydraulic interlock will be set.

Perform the following on the Station Controls panel: A. Clear system interlocks.

793 Controller Operation Overview

Click Reset. If the interlock indicator lights again, determine the cause of the interlock and correct it before proceeding.

B. If HPU controls are present, click the (Low) and then

(High) buttons.

Damper System Operation

Perform a Practice Test

WARNING

C. If HSM controls are present, click the (Low) and then

(High) buttons.

4. Adjust force tuning.

A. From the toolbar, select an access level of Tuning (or higher). Y ou will

have to enter the password created at installation.

B. From the Application control bar, select the Function Generator. C. Select the following settings in the Function Generator.

Control Setting

Channel Control Mode Command Type Target Setpoint Amplitude Frequency Wav e Shape Compensator

Channel 1 Force Cyclic 0 kN 10% of full scale 1 Hz Ramp None

D. From the Station Manager application toolbar, select the Scope.

A crush zone exists between the actuator and any equipment in the path of its movement.

A crush zone exists between the actuator and any equipment in the path of its movement. Immediate and unexpected actuator response is possible when you apply hydraulic pressure to your system.

Stay clear of the actuators when applying hydraulic pressure. Do not place any part of your body in the path of a moving actuator.

E. Install a dummy specimen that has a compliance similar to the test

specimen.

• From the Station Controls panel toolbar, click the Manual Command

icon .

• Click to select the Enable Manual Command check box.

• Select the Displacement control mode.

Damper System Operation 793 Controller Operation Overview

Perform a Practice Test

Ringing

Overshoot

The middle waveform is the optimum waveform. In some cases the waveform will have no overshoot or ringing.

Gain (P)

Rate (D)

Low High

High

• Adjust the Manual Command slider to position the actuator while

installing the specimen.

• Switch to the Force control mode.

F. Adjust the P Gain and D Gain tuning controls.

• Start the Function Generator by clicking the Program Run control

and observe the resulting waveform on the Scope.

• From the Display menu, select Station Setup.

• From the tree view, expand Channels, then select Channel 1.

• Click the Tuning icon to displ ay the tun ing adjustment controls.

• Increase the P Gain control until you see a little overshoot and a little

ringing on the Scope.

• Slowly increase the D Gain control to reduce the overshoot and

ringing. Keep in mind that small adjustments of D can have large effects on your system.

• Repeat P Gain and D Gain adjustments until you achieve an optimum

waveform

5. Install the test specimen. A. Select the Displacement control mode for test specimen installation. B. Install the test specimen.

793 Controller Operation Overview

• Turn on the Manual Command control on the Station Contr ols panel.

Damper System Operation

Perform a Practice Test

• Adjust Manual Command to position the actuator as required.

C. Switch to the force control mode.

6. Set test limits and actions.

From the Station Controls panel, click the Detectors icon. Set upper and lower limits and associated actions to accommodate your test

as desired. For instance, you may want to adjust displacement limit detectors to limit

piston rod travel. This stops the test when the specimen is on the threshold of complete failure.

Also, you may want to adjust force limit detectors to stop the test if the piston rod applies an excessive amount of force to the specimen. This minimizes the chance of inadvertent damage to the load cell and specimen.

Finally, you may want to adjust error detectors to stop the test if the error between command and feedback becomes excessive. This stops the test when your station can no longer deliver programmed loads.

7. Set up the test monitor.

Set up the Meters and Scope as desired to monitor test signals.

8. Set up a test program.

A. From the Application control bar, select Basic TestWare. B. In the Command tab, set the following:

Note Ensure that the Target Setpoint and Amplitude values are appropriate for

your particular specimen.

Control Setting

Type Channel Control Mode Target Setpoint Amplitude Frequency Wav e Shape

Cyclic Channel 1 Force Guideline: 25% of full scale Guideline: 10% of full scale 1 Hz Sine Tapered

Compensator Start Action Done Action

None Disabled Disabled

C. In the Data Acquisition tab, set the following:

Damper System Operation 793 Controller Operation Overview

Perform a Practice Test

Control Setting

Type Signals Included Time Between

Points Buffer Size Buffer Type

Timed Channel 1 Output default

2048 Linear

D. In the Data File tab, set the following:

Control Setting

Destination File Data Header Data File Mode Data File Format

Test Default Enter “First Test” Append Plain

E. Close the Test Setup window.

9. Start the test. A. Ensure that the following are true:

• Interlocks are cleared

• High hydraulic pressure is applied to the station

• Load tuning parameters are optimized

• The test specimen is installed

• Limits are set and actions are assigned

• The test program is set up

• The scope and meters are set up to monitor the test as desired

B. On the Station Controls panel, press the Program Run button to start

the test. When desired, press the Program Stop button to end the te st.

10. Review test data.

A. Start the Project Manager application and select the current Project. B. Click on the BTW folder to view the name of the associated data file. C. Click on the data file to review its contents in the view pane.

793 Controller Operation Overview

Damper System Operation

Routine Maintenance

WARNING

High pressure fluids can be present in the test system. High-pressure hydraulic fluid can cause cuts and burns.

Ensure that you establish and follow standard lock out/tag out safety procedures and the test system is hydraulically isolated before you perform routine maintenance procedures on the test system.

Also ensure that you allow the system to rest a minimum of 20 minutes from the time the system is hydraulically isolated before you attempt to perform maintenance on hydraulic components.

Hazardous electrical current can be present in the test system. Coming in contact with high voltage electrical current can cause death or

severe burns and injury.

Overview Routine maintenance can extend the operating life of your test system by using

How to schedule

maintenance

Ensure that you establish and follow standard lockout/tagout safety procedures and that the test system is electrically isolated before you perform routine maintenance procedures on the test system.

regular inspections and simple procedures, such as filter changes, to minimize wear and component failure.

Note Y ou can adjust the time frame for performing these procedures based on

the operating requirements of your system.

This section contains a maintenance schedule table. Procedures for these maintenance requirements are found in the associated product manuals. The table includes schedules for a typically configured system. The maintenance schedule table lists the recommended routine maintenance procedures. Procedures that you can perform without special training are listed in the shaded columns of the table. Procedures that require special training are listed in the unshaded columns; you should contact MTS to perform these procedures.

The following paragraphs provide additional guidelines relating to routine maintenance.

Maintenance is scheduled based on system operating time. Use machine operating time or calendar time to help you schedule maintenance procedures, as shown in the table.

Damper System Operation Routine Maintenance

As a guideline, for a test system that operates eight hours per day, one week will equal 40 hours, and one month will equal 160 hours. For a test system that operates up to 24 hours per day, one week will equal 160 hours and one month will equal 720 hours.

When to perform

visual checks

Routine maintenance procedures that are scheduled on a daily or weekly basis usually involve visual checks only, and should not interfere with the operation of your test system. These checks will help you assess which procedures must be performed before running the next test. For example, the dirty filter indicator on the HPU signals that it is time to clean or change the filter.

You can perform these visual checks at the start of each day and incorporate them into your preparations to run a test.

Note It is highly unlikely (unless you are running an extremely long durability

type of test) that you should need to stop a test simply to perform a routine maintenance procedure.

Changing the intervals You can change the time in terval for performing maintenance checks, based on

the operating conditions for your system. Operating conditions that affect the maintenance schedule include air quality, temperature, humidity, how often you run tests, and whether you use a pump room or a hydraulic power unit to supply hydraulic fluid to the system. Keep a log to observe trends in your system, then adjust your maintenance schedule as needed. For example, you might find that you do not have to perform daily checks of the hydraulic fluid, and decide to check it once a week instead.

Additional

maintenance

Because of the variations in system configurations, the maintenance schedule table lists the typical procedures for the associated products. Additional maintenance procedures might be required depending on the specific product model. Refer to the product manuals for complete maintenance information.

Additional maintenance procedures can be required whenever you notice decreased system performance. An example of this type of maintenance is servovalve filter replacement. Many of these procedures require additional training and should be performed by MTS service personnel.

Information about analyzing hydraulic fluid is contained in the MTS Fluid Care Guide that accompanies each hydraulic power unit, and in the appendices of maintenance manuals

Routine Maintenance

Damper System Operation

Calendar time

Daily 1

week1month2months3months6months1year2year

5 + years

Running time - Hours 8 40 160 320 500 1000 2,000 4,000 10,000

Hazard labels

Inspect for legibility

Replace as required

Hydraulic Hoses

Inspect for leaks and wear

Replace MTS

Hydraulic Fluid

Sensory Check

Particle count MTS

Analyze for contamination

Load Frame

Set initial accumulator check interval

Check accumulator N

Clean actuator rod and columns

Inspect actuator for leakage

Adjust Servovalve mechanical null

Change servovalve filter.

MTS

precharge

After the valve balancing procedure (electrical compensation) has been completed and the results are judged unsatisfactory.

When servovalve performance has deteriorated.

Damper System Operation Routine Maintenance

Calendar time Daily 1

week1month2months3months6months1year2year

5 + years

Running time - Hours 8 40 160 320 500 1000 2,000 4,000 10,000

Maintain airmount pressures

Check HSM filters (replace as required)

Series 505 Hydraulic Power Unit

Check functionality of warning and interlock devices

Conduct external inspection of the heat exchanger

Replace fluid filter

Inspect incoming power lines for loose connections or defects

When the load frame sits unevenly .

X MTS

MTS

Check autocooling circuit functionality

Check water hoses

Replace PLC battery

Routine Maintenance

MTS

Damper System Operation

Calendar time Daily 1

week1month2months3months6months1year2year

5 + years

Running time - Hours 8 40 160 320 500 1000 2,000 4,000 10,000

Controller

Check cooling Perform shunt

calibration Verify

controller calibration

Verify Safety Circuits

Check E-Stops X Check limits X Check test

area guard interlocks

Check actuator speed control (if applicable)

MTS

Damper System Operation Routine Maintenance

Routine Maintenance

Damper System Operation

Decommission

The decommissioning process is performed when the system is going to be moved or taken out of service. Disassembly is required when performing either of these tasks.

1. Remove specimen(s) and fixtures. Large grips should be removed if the load

2. Move the actuator piston rod down to its lowest position, fully into that

3. If the unit has hydraulic lifts move the crosshead to its lowest position and

4. If there are hydraulic grips on the unit, ensure that the hydraulic pressure is

frame is going to be tipped over.

cushion.

torque the manual crosshead locking bolts. However, if the unit is going to be moved, the crosshead might need to be locked at a higher position to accommodate moving the unit.

If the unit has manual locks select a crosshead position that will accommodate moving the unit and torque the manual locking bolts.

relieved from the grip and release ports and hoses on both grips. On large grips, position the wedge chambers to the lowest positions, similar

to the unit’s piston rod as noted above. If the unit has a remote 685 grip supply, cycle the grip/release handles while

reducing the pressure setting to release all pressure from the grips and hoses. Turn off the 685 grip control and disconnect electrical power. Remove the hoses.

If the unit has an integrated grip control (318 and Landmark) on the frame control panel move the grip/release handle to the null position and release the pressure using the pressure release valves on the grip manifold under the control panel.

5. Turn off the HSM.

6. Turn off the HPU or shut off valves if the unit is connected to a hard line distribution system. Allow time for pressure to bleed off before closing the return shut off valve.

7. Remove the accumulator charging pressure from all accumulators.

8. Hydraulic locks can retain stored pressure. Manually bleed them if the unit is going to be stored or disassembled.

9. Isolate the system hydraulically . To isolate the system from hydraulic power requires that the hydraulic

supply valve or control is closed. Depending on your system’s configuration, there is either a manual valve that must be moved to its Off position or an electronically controlled supply valve that must be turned off. Electronically controlled valves are either turned off using local controls or the system software interface controls.

Damper System Operation Decommission

10. Isolate the system from electrical power. When the system electronics, control software, and the system PC are

powered down, turn off the system’s main electrical supply and disconnect all cables.

Residual hydraulic pressure can produce a high pressure spray. You could be cut by this spray or hydraulic fluid could be forced into your

skin.

Do not start this procedure unless the system has been isolated from hydraulic pressure for at least 20 minutes. Always be cautious when you loosen any hydraulic connection or remove bolts or screws from any hydraulic component. Always allow fluid pressure to dissipate slowly until completely vented before continuing to loosen. Always wear gloves and appropriate eye protection.

11. Remove all accessible hydraulic hoses. The system does not have hydraulic reservoirs that must be drained.

However, each hose and hard line will potentially have trapped oil in it. When removing the hydraulic components, ensure that you have drain pans and towels available that are sufficient to handle the drain volume of the item you are disconnecting. Use safe practices when removing hydraulic components and allow any trapped or latent pressure to dissipate safely through a loosened connection before removing the component. Cap each hose, port, and hardline component.

12. Dispose of all hydraulic fluid in accordance with all local codes regarding hazardous materials handling and disposal.

13. Disconnect all cables from the controller.

14. There are two configurations for the controller: contained in an upright console (perform step A) or floorstanding (perform step B).

A. Upright consoles are lifted by an overhead lifting devise using supplied

lift rings. If necessary, install lift rings in the threaded bores at the top of the control cabinet. If not already installed, the lift rings are typically stored inside the cabinet or in receptacles at the rear of the cabinet. Rig and lift the cabinet and set aside.

B. Floorstanding controllers can be lifted onto a suitable cart and moved

to a desired location.

Decommission

Damper System Operation

Electrical components and parts can contain hazardous chemicals and compounds.

Improper disposal of hazardous chemicals and compounds can cause injury and death to people, animals, and plants. In addition, it can cause contamination of the soil, air, and water.

Always refer to local codes that govern the disposal of potentially hazardous materials and follow these codes for the proper handling and disposal of these materials.

Damper System Operation Decommission

Decommission

Damper System Operation

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 Internet: www.mts.com

ISO 9001 Certified QMS

MTS 85X User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Technical Support

How to Get Technical Support

Before You Contact MTS

If You Contact MTS by Phone

Problem Submittal Form in MTS Manuals

Preface

Before You Begin

Conventions

Documentation Conventions

Introduction

Other MTS Manuals

Typical Test System Configuration

Test Controller

Servohydraulic and Mechanical Components

Interlocks

Safety

General Safety Practices

Safety Practices Before Operating the System

Safety Practices While the System Is in Operation

Getting Started

System Startup

Test Setup

Operation

Initial Setup

Install the Specimen

Run the Test

793 Controller Operation Overview

About Running Tests

Understanding Files Used for Testing

Test Desktop

Monitoring Test Information

Perform a Practice Test

About Setting Up a Practice Test

Steps to Run a Test

Routine Maintenance

Decommission