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

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