MTS Multi-Pump Control Manager User Manual

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Multi-Pump Control Manager (MPCM) Product Information

Supervisor and Basic Connection Interface (BCI)

100-249-603 A

Trademark information MTS and SilentFlo are registered trademarks of MTS Systems Corporation

within the United States. These trademarks may be protected in other countries. All other trademarks or service marks are property of their respective owners.

Publication information

Manual Part Number Publication Date

100-249-603 A November 2011

Contents

Introduction 5

Intended Use 6 Specifications 7

Safety 9

General Safety Practices 9

Installation 15

Placement of Components 15 Mount the BCI 15 Spacing Requirements 16 Cabling 16 Lifting Instructions 16 AC Power Disconnect Requirements 16 External Device Connections 16

Operation 17

Set HPU to Remote Operation for use with the MPCM Supervisor 17 Setup 18 Startup and Main Screen 19 System 20 Unit 23 Status Screen 27 Setup 31 Station 32 Operating the HPU Locally or Remotely 33 How to Clean the MPCM 34

Appendix 35

Setting Up System Run On Demand (ROD) 35 Run On Demand Detailed Example 36

Multi-Pump Control Manager Contents

Contents

Multi-Pump Control Manager

Introduction

The Multi-Pump Control Manager (MPCM) product family consists of a Basic Connection Interface (BCI) and typically the optional dedicated PC running the Supervisor software, with remote E-Stops, Station Flow Managers (SFM), and/or light stacks as options. Together, these components allow you to remotely run multiple HPUs similar to operation at the main HPU HMI panel.

This manual assumes you are familiar with local operation of the HPU. That is, the descriptions of the controls and indicators that are similar to the controls and indicators on the HPU will be abbreviated in this manual, and it is assumed that you understand the full description provided in the HPU manual.

Note The Multi-Pump Control Manager and associated components can only

be used on the G2 HPU models. It will not work with the older HPU models. Contact MTS for additional information.

In a typical configuration, there is one BCI, one Supervisor running on a dedicated PC, up to eight large HPUs, and a combination of up to eight remote E-Stops and SFMs. One or more optional light stack(s) can be included for HPU status away from the control room.

Multi-Pump Control Manager Introduction

Intended Use

Note MTS can provide the BCI without the Supervisor and dedicated PC. In

this case, the BCI commons the signals required for the HPU(s) to work as a system controlling the cooling solenoids, bypass solenoids, and E-Stop chain (which includes external E-Stops). In this case, all control of the HPUs is accomplished at the HPU HMIs.

Intended Use

HPU #1

HPU #2

HPU #8

SUPERVISOR PC

SUPERVISOR E-STOP

LIGHT STACK(S)

(DAISY CHAIN MULTIPLE LIGHT BARS,2 AMPS PER CHANNEL NOT TO EXCEED 6 AMPS TOTAL)

The intended use is to provide remote operation and status information for one or more HPUs. Before you attempt to use your MTS product, read and understand the manuals that accompany this product. Improper installation or operation of this product can result in hazardous conditions that can cause severe personal injury or death, and damage to your equipment and test specimen.

BCI

E-STOP #1

SFM #8

E-STOP #2

SFM #7

E-STOP #8

SFM #1

Introduction

Multi-Pump Control Manager

Specifications

25.56

MTG. HOLES

28.50 MTG. HOLES

29.94 MTG. KIT DIMENSION

30.00 ECLOSURE DIMENSION

27.06

MTG. KIT

DIMENSION

9.04

ENCLOSURE

24.00

8.76

DIMENSION

8.00 ENCLOSURE

Specifications

Parameter Specification

Temperature 5ºC–40ºC (41ºF–104ºF) Humidity 5–85%, non-condensing Altitude 2000 m (6,561 ft) maximum IP rating IP40 Pollution Degree 2 Weight 41 kg (90 lb) Dimensions See illustration

Multi-Pump Control Manager Introduction

Specifications

Note Electrical connections must be made by qualified personnel and conform

to local codes and regulations. Local electrical codes supersede any information found here.

Parameter Specification

100–240 V AC (single phase)

Input Voltage

Input Frequency 50–60 Hz

Input Current

power factor corrected universal input

4 A at 100 V AC

2 A at 240 V AC

Facility Power Requirements

Input Surge <50 A Over Voltage Category II

Mark for Canada

Provide a dedicated circuit for the chassis, computer, and monitor.

This product has been tested to the requirements of CAN/CSA-C22.2 No. 610101, 2nd Edition, including Amendment 1, or a later version of the same standard incorporating the same level of testing requirements.

Introduction

Multi-Pump Control Manager

Safety

General Safety Practices

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

General Safety Practices

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

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

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

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

light curtains, or proximity switches/detectors).

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

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

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

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

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

system is allowed when the system is in operation.

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

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

• Mists of DTE 25 are combustible. Refer to MSDS. You are responsible for

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

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

Multi-Pump Control Manager Safety

General Safety Practices

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

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

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

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

utilities)

• Unauthorized customer modifications to the equipment

• Operator experience and specialization

• Test specimens

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

Improper installation, operation, or maintenance of your system can result in hazardous conditions that can cause death, personal injury, or damage to the equipment or to the specimen. Common sense and a thorough knowledge of the system’s operating capabilities can help to determine an appropriate and safe approach to its operation.

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

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

Locate and read

hazard placards/labels

Know facility safe

procedures

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

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

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

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

Safety

Multi-Pump Control Manager

General Safety Practices

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

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

Know potential crush

and pinch points

Be aware of

component movement

with hydraulics off

Know electrical

hazards

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

Remember, when hydraulic power is interrupted on a servohydraulic system, it is likely that stored accumulator pressure will persist for some time within the system. In addition, it is likely that as stored energy dissipates, gravity will cause portions of the system to move.

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

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

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

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

Keep bystanders

safely away

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

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

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

Practice good

housekeeping

Protect hoses and

cables

Do not disable safety

devices

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

Protect electrical cables from spilled hydraulic fluid and from excessive temperatures that can cause the cables to harden and eventually fail. Ensure that all cables have appropriate strain relief devices installed at the cable and near the connector plug. Do not use the connector plug as a strain relief.

Protect all system hoses and cables from sharp or abrasive objects that can cause the hose or cable to fail. Never walk on hoses or cables or move heavy objects over them. Consider hydraulic distribution system layout and route hoses and cables away from areas that expose them to possible damage.

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.

Multi-Pump Control Manager Safety

General Safety Practices

Use appropriately

sized fuses

Provide adequate

lighting

Provide means to

access out-of-reach

components

Wear appropriate

personal protection

Handle chemicals

safely

Whenever you replace fuses for the system or supply, ensure that you use a fuse that is appropriately sized and correctly installed. Undersized or oversized fuses can result in cables that overheat and fuses that explode. Either instance creates a fire hazard.

Ensure adequate lighting to minimize the chance of operation errors, equipment damage, and personal injury. You need to see what you are doing.

Make sure you can access system components that might be out of reach while standing on the floor. For example, ladders or scaffolding might be required to reach load cell connectors on tall load units.

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

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.

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.

Know system

interlocks

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

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.

Safety

Multi-Pump Control Manager

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