MTS Insight Material Testing Systems User Manual
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MTS Insight™ Material Testing Systems
Product Information
1kN–300kN
100-146-666 G
Copyright information © 2006 - 2010 MTS Systems Corporation. All rights reserved.
Trademark information MTS and TestWorks are registered trademarks of MTS Systems Corporation;
MTS Insight is a trademark of MTS Systems Corporation within the United
States. These trademarks may be protected in other countries.
Publication information
MANUAL PART NUMBER PUBLICATION DATE
100-146-666 A January 2006
(build 041306)
100-146-666 B June 2006
100-146-666 C June 2006
(build 081006)
100-146-666 D December 2006
(build 051007)
100-146-666 E May 2007
100-146-666 F April 2009
100-146-666 G March 2010
Contents
Technical Support 5
How to Get Technical Support 5
Before You Contact MTS 6
If You Contact MTS by Phone 7
Problem Submittal Form in MTS Manuals 8
Preface 9
Before You Begin 9
Conventions 10
Documentation Conventions 10
Introduction 13
About This Manual 13
Description 14
Specifications 17
General Specifications 17
Model Specifications 18
Dimensions 22
Crosshead Detail 23
Baseplate Detail 24
Safety 27
General Safety Practices 27
Safety Practices Before System Operation 28
Safety Practices While the System Is in Operation 31
Hazard Labels 32
Installation 35
Moving Single-Column Frames 36
Moving Double-Column Frames 38
Machine Location and Ventilation 39
MTS Insight™ Material Testing System Contents
3
Controller Connections 40
Connecting the Main Power 40
Transformer Requirements for MTS Insight 150, 200 and 300 Machines 44
Installing Cables 46
Controller Connectors 46
Operation 53
Main Power Switch (I/O) and E-Stop 54
Travel Limit Switches (Physical Limits) 55
Crush Zone Hazards 57
Fixture Mounting 58
Load Cell Mounting 59
Handset Control 63
Maintenance 65
Routine Maintenance Overview Checklist 66
Appendix 69
Additional Digital I/O Information 69
Electromechanical Load Unit Maintenance and Service Logs 71
8 Hours/Daily 72
40 Hours/Weekly 73
2000 Hours 74
2000 Hours 75
2000 Hours 76
4
Contents
MTS Insight™ Material Testing System
Technical Support
How to Get Technical Support
Start with your
manuals
Technical support
methods
The manuals supplied by MTS provide most of the information you need to use
and maintain your equipment. If your equipment includes software, look for
online help and README files that contain additional product 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 Technical Support in
one of the following ways.
www.mts.com The web site provides access to our technical support staff by means of an
onlineform:
www.mts.com > Contact MTS > Service & Technical Support button
E-mail tech.support@mts.com
Telephone MTS Call Center 800-328-2255
Weekdays 7:00 A.M. to 5:00 P.M., Central Time
Fax 952-937-4515
Please include “Technical Support” in the subject line.
Outside the U.S. For technical support outside the United States, contact your local sales and
service office. For a list of worldwide sales and service locations and contact
information, use the Global MTS link at the MTS web site:
www.mts.com > Global MTS > (choose your region in the right-hand
column) > (choose the location closest to you)
MTS Insight™ Material Testing System Technical Support
5
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
Know information from
prior technical
The site number contains your company number and identifies your equipment
type (such as material testing or simulation). The number is typically written on a
label on your equipment before the system leaves MTS. If you do not know your
MTS site number, contact your sales engineer.
Example site number: 571167
When you have more than one MTS system, the system job number identifies
your system. You can find your job numb er in your order paperwork.
Example system number: US1.42460
If you have contacted MTS about this problem before, we can recall your file
based on the:
assistance
• MTS notification number
• Name of the person who helped you
Identify the problem Describe the problem and know the answers to the following questions:
• How long and how often has the problem occurred?
• Can you reproduce the problem?
• Were any hardware or software changes made to the system before the
problem started?
Know relevant
computer information
• What are the equipment model numbers?
• What is the controller model (if applicable)?
• What is the system configuration?
For 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 where the application resides
• Current status of hard-drive fragmentation
• Connection status to a corporate network
Technical Support
6
MTS Insight™ Material Testing System
Know relevant
For software application problems, have the following information available:
software information
• The software application’s name, version number, build number, and (if
available) software patch number. This information can typically be found
in the About selection in the Help menu.
• The names of other applications on your computer, such as:
– Anti-virus software
– Screen savers
– Keyboard enhancers
– Print spoolers
– Messaging applications
If You Contact MTS by Phone
A Call Center agent registers your call before connecting you with a technical
support specialist. The agent asks you for your:
• Site number
• Name
• Company name
• Company address
• Phone number where you can be reached
If your issue has a notification number, please provide that number. A new issue
will be assigned a unique notification number.
Identify system type To enable the Call Center agent to connect you with the most qualified technical
support specialist available, identify your system as one of the following types:
• Electromechanical material test system
• Hydromechanical material test system
• Vehicle test system
• Vehicle component test system
• Aero test system
Be prepared to
Prepare to perform troubleshooting while on the phone:
troubleshoot
• Call from a telephone close to the system so that you can implement
suggestions made over the phone.
• Have the original operating and application software media available.
• If you are not familiar with all aspects of the equipment operation, have an
experienced user nearby to assist you.
MTS Insight™ Material Testing System Technical Support
7
Write down relevant
In case Technical Support must call you:
information
• Verify the notification number.
• Record the name of the person who helped you.
• Write down any specific instructions.
After you call MTS logs and tracks all calls to ensure that you receive assistance for your
problem or request. If you have questions about the status of your problem or
have additional information to report, please contact Technical Support again and
provide your original notification number.
Problem Submittal Form in MTS Manuals
Use the Problem Submittal Form to communicate problems with your software,
hardware, manuals, or service that are not resolved to your satisfaction through
the technical support process. The form includes check boxes that allow you to
indicate the urgency of your problem and your expectation of an acceptable
response time. We guarantee a timely response—your feedback is important to
us.
Access the Problem Submittal Form:
• In the back of many MTS manuals (postage paid form to be mailed to MTS)
• www.mts.com > Contact Us > Problem Submittal Form button (electronic
form to be e-mailed to MTS)
Technical Support
8
MTS Insight™ Material Testing System
Preface
Before You Begin
Safety first! Before you use your MTS product or system, read and understand the Safety
manual and any other safety information provided with your system. Improper
installation, operation, or maintenance can result in hazardous conditions that can
cause severe personal injury or death, or damage to your equipment and
specimen. Again, read and understand the safety information provided with your
system before you continue. It is very important that you remain aware of
hazards that apply to your system.
Other MTS manuals In addition to this manual, you may receive additional manuals in paper or
electronic form.
You may also receive an MTS System Documentation CD. It contains an
electronic copy of the manuals that pertain to your test system, such as:
• Hydraulic and mechanical component manuals
• Assembly drawings
• Parts lists
• Operation manual
• Preventive maintenance manual
Controller and application software manuals are typically included on the
software CD distribution disc(s).
MTS Insight™ Material Testing System Preface
9
Conventions
DANGER
WARNING
CAUTION
Conventions
Documentation Conventions
The following paragraphs describe some of the conventions that are used in your
MTS manuals.
Hazard conventions Hazard notices may be embedded in this manual. These notices contain safety
information that is specific to the activity to be performed. Hazard notices
immediately precede the step or procedure that may lead to an associated hazard.
Read all hazard notices carefully and follow all directions and recommendations.
Three different levels of hazard notices may appear in your manuals. Following
are examples of all three levels.
Note For general safety information, see the safety information provided with
your system.
Danger notices indicate the presence of a hazard with a high level of risk which,
if ignored, will result in death, severe personal injury, or substantial property
damage.
Warning notices indicate the presence of a hazard with a medium level of risk
which, if ignored, can result in death, severe personal injury, or substantial
property damage.
Caution notices indicate the presence of a hazard with a low level of risk which,
if ignored, could cause moderate or minor personal injury or equipment damage,
or could endanger test integrity.
Notes Notes provide additional information about operating your system or highlight
easily overlooked items. For example:
Note Resources that are put back on the hardware lists show up at the end of
the list.
Special terms The first occurrence of special terms is shown in italics.
Illustrations Illustrations appear in this manual to clarify text. They are examples only and do
not necessarily represent your actual system configuration, test application, or
software.
Electronic manual
conventions
This manual is available as an electronic document in the Portable Document
File (PDF) format. It can be viewed on any computer that has Adobe Acrobat
Reader installed.
10
Preface
MTS Insight™ Material Testing System
Conventions
Hypertext links The electronic document has many hypertext links displayed in a blue font. All
blue words in the body text, along with all contents entries and index page
numbers, are hypertext links. When you click a hypertext link, the application
jumps to the corresponding topic.
MTS Insight™ Material Testing System Preface
11
Conventions
12
Preface
MTS Insight™ Material Testing System
Introduction
About This Manual
Purpose This manual provides detailed information about the MTS Insight Material
Summary This manual includes the following sections.
Introduction This section reviews the MTS Insight material testing system models, gives you a
Testing Systems. The information includes an overview of all the models
available, installation, operation, and maintenance.
The MTS Insight product series is the latest generation of electromechanical
material testing equipment from MTS. The purpose of this manual is to help you
understand your testing system, its capabilities, and operating requirements. This
manual provides technical information for all MTS Insight material testing
frames; from the lowest force model (1 kN), to the highest (300 kN). Read each
section carefully and refer to the manual whenever you need assistance.
description of a typical frame, and lists the environmental specifications. This
section also provides the technical frame specifications of each MTS Insight
frame model and line drawings of the crosshead and baseplate details.
Installation This section gives you specific instructions for properly moving MTS Insight
frames, cable installation, and line drawings of the basic controller.
Operation This section provides a graphic of the manual handset control and handset
functions. Other areas such as travel limit switches and fixture and load cell
mounting are reviewed.
Maintenance This section gives you a complete guide to the maintenance schedule for all MTS
Insight frames.
Inappropriate use Before you attempt to use the MTS Insight Material Testing System, read and
understand your manual that accompanies this product. Improper installation or
operation of this product can result in hazardous conditions that can cause severe
personal injury or death, and damage your equipment and specimen.
Contents Description 14
Specifications 17
Model Specifications 18
Crosshead Detail 23
Baseplate Detail 24
MTS Insight™ Material Testing System Introduction
13
Description
Low Capacity Mid-Capacity High-CapacityMultihead
Description
Every MTS Insight material testing system is comprised of a load frame,
electronic frame controller, and TestWorks software. The following figure shows
the external features of the various MTS Insight load frames.
14
Introduction
The personal computer is also an integral part of the system. It runs TestWorks
software which provides full machine control, data acquisition and management,
and advanced data analysis and presentation. MTS has minimized the amount of
custom electronics required for your system, thereby making it flexible and
reliable. This is done by connecting the frame and the computer via standard
USB 2.0 connectors.
The load frame has a rectangular shape and includes a base unit and one or two
vertical columns. The two column models have a fixed upper transverse member.
The moving crosshead is driven by precision ball screws on the load frame. The
crosshead is coupled to the ball screw(s) with high-strength, precision ball nuts
and rides on the ball bearings. This configuration is very efficient in minimizing
friction and wear. The ball screws are anti-backlash. This feature removes the
backlash so that position can be measured with increased accuracy over
nonpreloaded ball screws.
The screws are driven by a series of pulleys and belts which in turn are driven by
a precision DC servo motor on the MTS Insight 1 through MTS Insight 50
models and an AC brushless motor on the higher force models. The ball screw is
connected to an optical encoder for precise position and velocity control.
MTS Insight™ Material Testing System
Frame controller The frame controller is responsible for the following:
• Provides main data and signal processing power
• Detects the activation of limit switches
• Provides the interface between the software (computer) and the frame
• Provides digital servo control—for speed and position accuracy
• Responsible for self-ID load cell and frame
• Handset interface
• Programmable, 1000 Hz maximum, data acquisition rate
• Management of frame power
Description
MTS Insight™ Material Testing System Introduction
15
Description
Software TestWorks 4 is a versatile software program offering you a host of features that
will make the material testing process fast and easy to use. The software has
various method templates available. The method templates in the General Testing
Package provide a starting point in configuring test methods that conform with
your testing needs. The General Testing Package is separated into 4 specific
testing categories.
• MTS Tensile
• MTS Compression
• MTS Flex
• MTS Peel-Tear
Many additional features can be purchased to meet your company’s specific
needs. Some of these features might already be part of the system you ordered, or
they can be added to your system as your requirements change. Refer to the
TestWorks manual for additional information.
16
Introduction
MTS Insight™ Material Testing System
Specifications
This section provides general specifications for the MTS Insight Material Testing
System frames and illustrations of the crosshead and baseplate threaded hole
patterns for mounting fixtures.
Note At the time of this printing, some specifications have not been tested and
General Specifications
The following specifications are for all MTS Insight frames. Specifications for
the specific models and in the following tables.
Parameter Specification
Environmental
Specifications
calculated specifications are provided in the following tables.
Consequently, specifications are subject to change without notice.
Contact MTS for verification if critical specifications.
For indoor use only
Power
Temperature
Relative humidity
Altitude
Insulation over voltage
Pollution degree
5 to 40 °C
10 to 85%, noncondensing
For use at altitudes up to 2000 m
(6500 ft)
Category II
2
MTS Insight™ Material Testing System Introduction
17
Specifications
MTS MTS
MTS
MTS
MTS MTS Insight
Insight 1 Insight 2
Insight 2
Insight 5
Insight 5
Model
High Speed
Column Configuration Single Single Double Single Double
Force Capacity 1 kN 2 kN 2 kN 5 kN 5 kN
(225 lbf) (450 lbf) (450 lbf) (1125 lbf) (1125 lbf)
Vertical T est Space
Crosshead Travel
Standard Length 750 mm 750 mm NA 750 mm 1100 mm
(29.5 in) (29.5 in) (29.5 in) (43 in)
Extended Length 1004 mm 1004 mm 1400 mm 1004 mm 1400 mm
(39.5 in) (39.5 in) (55 in) (39.5 in) (55 in)
Maximum Test Speed 1500 mm/min 1000 mm/min 2540 mm/min 500 mm/min 1000 mm/min
(59 in/min) (39 in/min) (100 in/min) (20 in/min) (39 in/min)
Minimum Test Speed 0.001 mm/min 0.001 mm/min 0.003 mm/min 0.001 mm/min 0.001 mm/min
(0.00004 in/min) (0.00004 in/min) (0.00012 in/min) (0.00004 in/min) (0.00004 in/min)
Height
Standard Length 1140 mm 1140
mm NA 1140 mm 1600 mm
(45 in) (45 in) (45 in) (63 in)
Extended Length 1394 mm 1394 mm 1900 mm 1394 mm 1900 mm
(55 in) (55 in) (74.75 in) (55 in) (74.75 in)
Width 490 mm 490 mm 650 mm 490 mm 650 mm
(19 in) (19 in) (26 in) (19 in) (26 in)
Depth 450 mm 450 mm 450 mm 450 mm 450 mm
(18 in) (18 in) (18 in) (18 in) (18 in)
Weight
Standard Length 50 kg 50
kg NA 50 kg 115 kg
(110 lb) (110 lb) (110 lb) (255 lb)
Extended Length 55 kg 55 kg 123 kg 55 kg 123 kg
(119 lb) (119 lb) (261 lb) (119 lb) (261 lb)
Clearance from Loading 100 mm 100 mm NA 100 mm N/A
Axis to Column Cover (3.9 in) (3.9 in) (3.9 in)
Space Between Columns N/A N/A 450 mm N/A 405 mm
(15.9 lb) (15.9 in)
Power Requirements
Power Supply
120 or 120
or 120 or 120 or 120 or
230 VAC 230 VAC 230 VAC 230 VAC 230 VAC
(single phase) (single phase) (single phase) (single phase) (single phase)
Model Specifications
Low Capacity
18
Introduction
MTS Insight™ Material Testing System
MTS Insight
Model
Column Configuration
Force Capacity
Vertical T est Space
Crosshead Travel
Standard Length
Extended Length
Maximum Test Speed
Minimum Test Speed
Height
Standard Length
Extended
Length
Specifications
Mid-Capacity
MTS MTS
Insight 10 Insight 30
Double Double Double Double Double
10 kN 30 kN 30 kN 50 kN 50 kN
(2250 lbf) (6750 lbf) (6750 lbf) (11250 lbf) (11250 lbf)
1100 mm 1100 mm NA 1100 mm 1050 mm
(43 in) (43 in) (43 in) (41 in)
1400 mm 1400 mm 1350 mm 1400 mm NA
(55 in) (54.75 in) (53 in) (54.75 in)
1000 mm/min 500 mm/min 500 mm/min 500 mm/min 500 mm/min
(39 in/min) (20 in/min) (20 in/min) (20 in/min) (20 in/min)
0.001 mm/min 0.001 mm/min 0.001 mm/min 0.001 mm/min 0.001 mm/min
(0.00004 in/min) (0.00004 in/min) (0.00004 in/min) (0.00004 in/min) (0.00004 in/min)
1600 mm 1613 mm NA 1613 mm 1629 mm
(63 in) (64 in) (64 in) (64.1 in)
1900 mm 1394 mm 1900 mm 1394 mm NA
74.75 in) (75.75 in) (76 in) (75.75
MTS
Insight 30
Wide
MTS
Insight 50
in)
MTS
Insight 50
Wide
Width
Depth
Weight
Standard Length
Extended Length
Clearance from Loading
Axis to Column Cover
Space Between Columns
Power Requirements
Power Supply
650 mm 720 mm 1145 mm 720 mm 1145 mm
(26 in) (29 in) (45 in) (29 in) (45 in)
450 mm 500 mm 500 mm 500 mm 500 mm
(18 in) (20 in) (20 in) (20 in) (20 in)
115 kg 180 kg NA 180 kg 296 kg
(255 lb) (397 lb) (397 lb) (653 lb)
123 kg 191 kg 314 kg 191 kg NA
(261 lb) (422 lb) (692 lb) (422 lb)
N/A N/A NA N/A N/A
405 mm 405 mm 835 mm 405 mm 835 mm
(15.9 in) (15.9 in) (20 in) (15.9 in) (33 in)
120 or 120 or 120 or 120 or 120 or
230 V AC 230 VAC 230 VAC 230 VAC 230 VAC
(single phase) (single phase) (single phase) (single phase) (single phase)
MTS Insight™ Material Testing System Introduction
19
Specifications
MTS MTS MTS MTS
Insight 100 Insight 150 Insight 200 Insight 300
Double Double Double Double
100 kN 150 kN 200 kN 300 kN
(22500 lbf) (33750 lbf) (45000 lbf) (67500 lbf)
1200 mm 1200 mm 1200 mm 1150 mm
(47.3 in) (47.3 in) (47.3 in) (45.3 in)
1600 mm 1600 mm 1600 mm 1550 mm
(63 in) (63 in) (63 in) (61 in)
500 mm/min 500 mm/min 500 mm/min 500 mm/min
(20 in/min) (20 in/min) (20 in/min) (20 in/min)
0.01 mm/min 0.01 mm/min 0.01 mm/min 0.01 mm/min
(0.0004 in/min) (0.0004 in/min) (0.0004 in/min) (0.0004 in/min)
2440 mm 2440 mm 2440 mm 2440 mm
(96 in) (96 in) (96 in) (96 in)
2840 mm 2840 mm 2840 mm 2840 mm
(112 in) (112 in) (112 in) (112 in)
1133 mm 1133 mm 1133 mm 1133 mm
(44.6 in) (44.6 in) (44.6 in) (44.6 in)
685 mm 685 mm 685 mm 685 mm
(27 in) (27 in) (27 in) (27 in)
750 kg 970 kg 970 kg 1050 kg
(1655 lb) (2140 lb) (2140 lb) (2315 lb)
787 kg 1029 kg 1029 kg 1116 kg
(1735 lb) (2270 lb) (2270 lb) (2460 lb)
N/A NA N/A N/A
650 mm 650
mm 650 mm 650 mm
(25.6 in) (25.6 in) (25.6 in) (25.6 in)
230 VAC 400 VAC 400 VAC 400 VAC
(single phase) (three phase) (three phase) (three phase)
MTS Insight
Model
Column Configuration
Force Capacity
Vertical T est Space
Crosshead Travel
Standard Length
Extended Length
Maximum Test Speed
Minimum Test Speed
Height
Standard Length
Extended Length
Width
Depth
Weight
Standard Length
Extended Length
Clearance from Loading
Axis to Column Cover
Space Between Columns
Power Requirements
Power Supply
High-Capacity
Specifications MTS Insight 50 Wide
Force Capacity 50 KN (11 250 lbf)
MTS Insight 50 W Multihead
Minimum Test Speed 0.001 mm/min. (0.00004 in./min.)
Maximum Test Speed 500 mm/min. (19.7 in./min.)
Force Capacity
@ max. test speed
Maximum Test Speed
@rated force capacity
25 KN (5625 lbf)
250 mm/min. (9.8 in./min.)
Introduction
20
MTS Insight™ Material Testing System
MTS Insight 50 W Multihead
Crosshead Return Speed 500 mm/min. (20 in./min.)
Vertical Test Space
(crosshead travel)
Horizontal Test Space
(between baseplate adapter centerlines)
Position Resolution 0.001 mm (0.00004 in.)
Position Accuracy 0.01 mm (0.0004 in)
Speed Accuracy % of set speed
Motor Type Precision DC Servo Motor
Drive System Type DC 4 Quadrant Motor Drive
Position Measurement Optical Encoder
Ball Screw Type Anti-backlash
Guide Columns Two
Height/Width/Depth 1629 X 1145 X 500 mm
Weight 350 kg (772 lb)
Power 5/3 Amps
1016 mm (40 in.)
155.5 mm (6.125 in.)
±0.05
(64.1 X 45 X 20 in.)
120/220-240 Vac
50/60 Hz
Single phase
Specifications
MTS Insight™ Material Testing System Introduction
21
Specifications
450 mm
(18 in)
Standard
1140 mm
(45 in)
103 mm
(4.1 in)
134 mm
(5.3 in)
490 mm
(19 in)
269 mm
(10.6 in)
699 mm
(27.5 in)
Standard
1613 mm
(64 in)
155 mm
(6.1 in)
102 mm
(4 in)
500 mm
(20 in)
720 mm
(29 in)
155 mm
(6.1 in)
641 mm
(25.2 in)
Standard
1600 mm
(63 in)
155 mm
(6.1 in)
76 mm
(3 in)
450 mm
(18 in)
650 mm
(26 in)
125 mm
(4.9 in)
MTS Insight
Model 1, 2 and 5
MTS Insight
Model 5 and 10
MTS Insight
Model 30 and 50
100 mm
(3.9 in)
1130 mm
(44.5 in)
264 mm
(10.4 in)
650 mm
(25.6 in)
685 mm
(27 in)
1130 mm
(44.5 in)
650 mm
(25.6 in)
685 mm
(27 in)
1130 mm
(44.5 in)
264 mm
(10.4 in)
650 mm
(25.6 in)
685 mm
(27 in)
130 mm
(5.1 in)
140 mm
(5.5 in)
550 mm
(21.6 in)
1133 mm
(44.6 in)
2440 mm
(96 in)
152 mm
(6 in)
152 mm
(6 in)
550 mm
(21.6 in)
1133 mm
(44.6 in)
2440 mm
(96 in)
264 mm
(10.4 in)
178 mm
(7 in)
178 mm
(7 in)
550 mm
(21.6 in)
1133 mm
(44.6 in)
2440 mm
(96 in)
MTS Insight
Model 100
MTS Insight
Model 150 and 200
MTS Insight
Model 300
Extended Length
1394 mm
(55 in)
Extended Length
1900 mm
(74.75 in)
Extended Length
1913 mm
(75.75 in)
Extended Length
2840 mm
(112 in)
Extended Length
2840 mm
(112 in)
Extended Length
2840 mm
(112 in)
Dimensions
22
Introduction
MTS Insight™ Material Testing System
Crosshead Detail
Specifications
The crosshead has a single hole drilled through for mounting loadcells, alignment
fixtures, grips, and so forth.
MTS Insight™ Material Testing System Introduction
23
Specifications
Baseplate Detail
The baseplate has various patterns of threaded holes for mounting fixtures.
24
Introduction
MTS Insight™ Material Testing System
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