Manual Title
Additional Information
be certain.
100-303-147 A
MTS Exceed™ Series 40
Product Manual
Copyright information ©2011 -2014 MTS Systems Corporation. All rights reserved.
Trademark information MTS and MTS Exceed are registered trademarks of MTS Systems Corporation
within the United States. These trademarks may be protected in other countries.
Proprietary information Software use and license is governed by MTS’ End User License Agreement
which defines all rights retained by MTS and granted to the End User. All
Software is proprietary, confidential, and owned by MTS Systems Corporation
and cannot be copied, reproduced, disassembled, decompiled, reverse
engineered, or distributed without express written consent of MTS.
Software validation and
verification
MTS software is developed using established quality practices in accordance
with the requirements detailed in the ISO 9001 standards. Because MTSauthored software is delivered in binary format, it is not user accessible. This
software will not change over time. Many releases are written to be backwards
compatible, creating another form of verification.
The status and validity of MTS’ operating software is also checked during
system verification and routine calibration of MTS hardware. These controlled
calibration processes compare the final test results after statistical analysis
against the predicted response of the calibration standards. With these established
methods, MTS assures its customers that MTS products meet MTS’ exacting
quality standards when initially installed and will continue to perform as intended
over time.
2
MTS Exceed™ Series 40 Product Manual
Contents
Technical Support 7
How to Get Technical Support 7
Before You Contact MTS Service Representative 7
If You Contact MTS by Phone 8
Preface 11
Before You Begin 11
Conventions 12
Documentation Conventions 12
Safety 13
General Safety Practices 13
Safety Practices Before System Operation 14
Safety Practices While the System Is in Operation 17
Hazard Labels 18
Introduction 21
About This Manual 21
Inappropriate Use 21
Description 22
Frame Controller 22
Software 22
Load Frame Components 24
Specifications 30
Common Specifications 31
Model Specifications 32
Dimensions 36
Installation 43
Frame Location and Ventilation 44
Leveling the Load Frame 45
MTS Exceed™ Series 40 Product Manual Contents
3
Leveling the Table-Top Load Frame 45
Leveling the Floor-Standing Load Frame 46
Controller Connections 47
Connecting the Main Power 47
Installing Cables 48
Accessory Mounting Dimensions 54
Model E42.503 Accessory Mounting Dimensions 55
Model E43 .104Accessory Mounting Dimensions 56
Model E44 Accessory Mounting Dimensions 57
Model E45.105 Accessory Mounting Dimensions 59
Model E45.305 Accessory Mounting Dimensions 62
Model E45.605 Accessory Mounting Dimensions 65
Operation 67
Main Power Switch (I/O) and Emergency-Stop 68
Setting Crosshead Travel Limits 69
Crush Zone Hazards 71
Fixture Mounting 72
Handset Control 73
Maintenance 75
Routine Maintenance Overview Checklist 75
76
Other service 76
Troubleshooting 77
Decommissioning 79
Appendix 81
Additional Digital I/O Information 81
Maintenance and Service Logs 83
8 Hours/Daily 84
40 Hours/Weekly 85
Contents
4
MTS Exceed™ Series 40 Product Manual
2000 Hours/Annual 86
PC Maintenance and System Inspection 86
2000 Hours 87
System Checks 87
2000 Hours 88
Lubrication 88
2000 Hours 89
Frame and Work Area 89
MTS Exceed™ Series 40 Product Manual Contents
5
Technical Support
How to Get Technical Support
How to Get Technical Support
Start with your
manuals
Technical support
methods
The manuals supplied by MTS provide most of the information you need to use
and maintain your equipment. If your equipment includes software, look for
online help and README files that contain additional product information.
If you cannot find answers to your technical questions from these sources, you
can use the Internet, e-mail, telephone, or fax to contact MTS for assistance.
MTS provides a full range of support services after your system is installed. If
you have any questions about a system or product, contact Technical Support in
one of the following ways.
• Website:http://www.mtschina.com
• Tel:400-888-3499
• Fax:(+86)755-26702974
Before You Contact MTS Service Representative
MTS can help you more efficiently if you have the following information
available when you contact us for support.
Know your contact
number and system
number
The contact 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 contact number, contact your sales engineer.
When you have more than one MTS system, the system model number and series
number identifies your system. You can find your these number in your order
paperwork or directly on your equipment.
Identify the problem
MTS Exceed™ Series 40 Product Manual Technical Support
Describe the problem and know the answers to the following questions:
• How long and how often has the problem occurred?
• Can you reproduce the problem?
• Were any hardware or software changes made to the system before the
problem started?
• What are the equipment model numbers?
• What is the controller model (if applicable)?
• What is the system configuration?
7
If You Contact MTS by Phone
Know relevant
computer information
Know relevant
software information
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
For software application problems, have the following information available:
• The software application’s name, version number, build number, and (if
available) software patch number. This information can typically be found
in the About selection in the Help menu.
• The names of other applications on your computer, such as:
– Anti-virus software
– Screen savers
– Keyboard enhancers
– Print spoolers
– Messaging applications
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:
• Contact 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.
Technical Support
8
MTS Exceed™ Series 40 Product Manual
If You Contact MTS by Phone
Identify system type
Be prepared to
troubleshoot
Write down relevant
information
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
Prepare to perform troubleshooting while on the phone:
• Call from a telephone close to the system so that you can implement
suggestions made over the phone.
• Have the original operating and application software media available.
• If you are not familiar with all aspects of the equipment operation, have an
experienced user nearby to assist you.
In case Technical Support must call you:
• Verify the notification number.
• Record the name of the person who helped you.
After you call
• Write down any specific instructions.
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.
MTS Exceed™ Series 40 Product Manual Technical Support
9
Preface
Before You Begin
Before You Begin
Safety first!
Other MTS manuals
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.
In addition to this manual, you may receive additional manuals in paper or
electronic form.
Manuals located on the product information CD will contain information that
pertains to your test system, such as:
• Hydraulic and mechanical accessory manuals
• Assembly drawings
• Parts lists
• Operation instructions
• Preventive maintenance tasks
Controller and application software manuals are typically included on the
software CD distribution disc(s).
MTS Exceed™ Series 40 Product Manual Preface
11
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 Refer to “Safety” on page 13 for general safety information.
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.
Special terms
Illustrations
Electronic manual
conventions
Hypertext links
Preface
12
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.
The first occurrence of special terms is shown in italics.
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.
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.
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 Exceed™ Series 40 Product Manual
Safety
General Safety Practices
This section provides information about safety issues that pertain to
electromechanical 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-performance characteristics of
MTS Exceed electromechanical systems.
MTS Exceed test systems are designed to generate motions and forces and impart
these motions and forces into a test specimen.
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
General Safety Practices
experienced, trained, or educated in the inherent dangers associated with
high-performance electromechanical machines 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 use specimens that are combustible, flammable, pressurized, or
explosive.
• Whenever possible, use tongs or similar device to handle specimens during
specimen installation.
• 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.
• Do not use the system in a test area where uncontrolled access to the test
system is allowed when the system is in operation.
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.
MTS Exceed™ Series 40 Product Manual Safety
13
Safety Practices Before System Operation
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.
Safety Practices Before System Operation
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 can require a
complete understanding of system operation to avoid unsafe or dangerous
situations.
Locate and read hazard
placards/labels
Safety
14
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.
MTS Exceed™ Series 40 Product Manual
Safety Practices Before System Operation
Locate lockout/tagout
points
Know facility safe
procedures
Locate Emergency Stop
buttons
Know controls
Have first aid available
Know potential crush
and pinch points
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.
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.
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.
Be aware of potential crush and pinch points on your system and keep personnel
and equipment clear of these areas.
Know electrical hazards
Keep bystanders safely
away
Wear proper clothing
Remove flammable
fluids from test specimen
Check bolt ratings and
torques
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.
Keep bystanders at a safe distance from all equipment. Never allow bystanders to
touch specimens or equipment while the test is running.
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 from their containers or from components before you
install the container or component in a test system. If desired, you can replace the
flammable fluid with a non-flammable fluid to maintain the proper proportion of
weight and balance.
To ensure a reliable product, fasteners (such as bolts and tie rods) used in MTS
manufactured systems are torqued to specific requirements. Over torquing or
under torquing a fastener can create a hazardous situation due to the high forces
and pressures present in MTS test systems.
MTS Exceed™ Series 40 Product Manual Safety
15
Safety Practices Before System Operation
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.
Practice good
housekeeping
Protect hoses and
cables
Record changes
Provide test area guards
Do not disable safety
devices
Keep the floors in the work area clean. 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 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 system layout and route hoses and cables away from areas
that expose them to possible damage.
When removing hydraulic hoses for equipment repair or changing testing
components (for example, hydraulic grips), make sure to cap the hose ends to
avoid spilling hydraulic fluid.
If you change any operating procedure, write the change and the date of the
change in the appropriate manual.
Use protective guards such as cages, enclosures, and special laboratory layouts
when you work with hazardous test specimens (for example, brittle or
fragmenting materials or materials that are internally pressurized).
Your system might 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 can result in unexpected system motion.
Use appropriately sized
fuses
Provide adequate
lighting
Provide means to
access out-of-reach
components
Ensure equipment is
secure
Perodically run
consistancy checks
Safety
16
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.
Make sure the equipment is secure or provide vibration isolation. Some testing
can be performed at resonant frequencies that might cause the equipment to
vibrate and move during testing.
Pressing the Emergency-Stop button causes the system to automatically run a
consistency check. The Emergency-Stop button should be pressed occasionally
to run the constancy check.
MTS Exceed™ Series 40 Product Manual
Safety Practices While the System Is in Operation
Safety Practices While the System Is in Operation
Wear appropriate
personal protection
Provide test area guards
Expect specimen
temperature changes
Handle chemicals safely
Wear eye protection when you work with electromechanical testing machines,
breakable specimens, or when anything characteristic to the specimen could
break apart.
Wear ear protection when you work near electric motors, pumps, or other devices
that generate high noise levels. Some systems can create sound pressure levels
that exceed 70 dbA during operation.
Wear appropriate personal protection equipment (gloves, boots, suits, respirators)
whenever you work with fluids, chemicals, or powders that can irritate or harm
the skin, respiratory system, or eyes.
Use protective guards such as cages, enclosures, and special laboratory layouts
when you work with hazardous test specimens (for example, brittle or
fragmenting materials or materials that are internally pressurized).
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.
Know system interlocks
Know system limits
Do not disturb sensors
Ensure secure cables
Stay alert
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
crosshead movement regardless of the true interlock condition.
Never rely on system limits, such as mechanical limits or software limits, to
protect you or any personnel. System limits are designed to minimize the chance
of accidental damage to test specimens or to equipment. Test all limits for proper
operation immediately before a test. Always use these limits and adjust them
properly.
Do not bump, wiggle, adjust, disconnect, or otherwise disturb a sensor (such as
an accelerometer or extensometer) or its connecting cable when power is applied.
Do not change any cable connections when electrical power 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.
Avoid long periods of work without adequate rest. In addition, avoid long periods
of repetitious, unvarying, or monotonous work because these conditions can
contribute to accidents and hazardous situations. If you are too familiar with the
work environment, it is easy to overlook potential hazards that exist in that
environment.
MTS Exceed™ Series 40 Product Manual Safety
17
Hazard Labels
Stay clear of moving
equipment/avoid crush
points
Know the causes of
unexpected crosshead
motions
Do not use RF
transmitters
Hazard Labels
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 systems can be destructive and
dangerous (especially if crosshead motion is unexpected). The most likely causes
of unexpected crosshead 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 control
loop). Eliminate any condition that could cause unexpected crosshead 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.
The following hazard labels and icons are located on the test frame.
L
ABEL
D
ESCRIPTION
Lift the machine upright.
Moving parts present.
Moving parts can crush and cut.
Keep hands away from moving parts.
18
Safety
MTS Exceed™ Series 40 Product Manual
L
ABEL
D
ESCRIPTION
Flying objects.
Danger of eye injury.
Wear safety glasses.
Tip over hazard.
Use outriggers when machine is standalone.
Do not start, operate, or service machine
until you read and understand the operator’s
manual.
Hazard Labels
WEEE
Failure to do so could result in serious injury.
There are no customer-serviceable parts on
the MTS
Exceed
electromechanical frames.
The Waste Electrical and Electronic Equipment (WEEE) symbol ( ) means
that the controller and its electronic parts must not be disposed of as unsorted
municipal waste. Proper disposal is required by approved electronic waste
collection agencies. Customers in the EC region who desire to return an end-oflife controller and its electronic parts are encouraged to contact your local MTS
Systems Sales/Service Offices for instructions.
MTS Exceed™ Series 40 Product Manual Safety
19
Introduction
About This Manual
About This Manual
Purpose
Inappropriate Use
Contents
The purpose of this manual is to help you understand your testing system, its
capabilities, and operating requirements. This manual provides information for
all MTS Exceed Series Material Test System,From the lowest force model (5
kN), to the highest (600 kN). Read each section carefully and refer to the manual
whenever you need assistance.
Before you attempt to use the MTS Exceed Series 40 Material Test System, read
and understand this manual. 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.
Description 22
Load Frame Components 24
Specifications 30
MTS Exceed™ Series 40 Product Manual Introduction
21
Description
Description
Frame Controller
Every MTS
electronic frame controller, and testing software.
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 beam.
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 preloaded. This feature removes the
backlash so that position can be measured with increased accuracy over nonpreloaded ball screws.
The load frame drive is located in the frame base. The drive motor is connected
to the lower end of the ball screws by a series of belts and drive pulleys. On the
two-column machines, motor rotation causes synchronous rotation of the ball
screws, which causes the crosshead to move up or down. On the single-column
machines, motor rotation causes the rotation of the single ball screw, which
causes the crosshead to move up or down.
The frame controller is responsible for the following:
• Provides main data and signal processing power.
• Detects the activation of limit switches.
Exceed
Series 40 Material Test System is comprised of a load frame,
Software
• Provides the interface between the software (computer) and the frame.
• Provides digital servocontrol for speed and position accuracy.
• Automatically identifies accessories, including load cells and
extensometers, with the self-identify feature.
• Communicates with the handset.
• Provides programmable data acquisition rate (up to 1000 Hz maximum).
• Commands the motor.
MTS testing software has various method templates available. The method
templates in the General Testing Package provide a starting point in configuring
test methods that conform to your testing needs. The General Testing Package is
separated into four specific testing categories:
• MTS Tensile
• MTS Compression
• MTS Flex
• MTS Peel-Tear
22
Introduction
MTS Exceed™ Series 40 Product Manual
Software
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
testing software manual for additional information.
MTS Exceed™ Series 40 Product Manual Introduction
23
Load Frame Components
Limit Rod
Upper Limit Stop
Limit Switch Actuator
Lower Limit Stop
Power Switch
Power Cord
Handset
Leveling Foot
Emergency Stop
Base
Base Adapter
Mat
Adapter
Pin
Load Cell
(inside)
Crosshead
Ball Screw Cover
Top Beam
Column Cover
Controller
Load Frame Components
The following figures show the various components for the single-column and
two-column load frames. To familiarize yourself with the various components of
your frame, refer to the figure that shows your model number.
For dimensions, see the specification tables in the “Specifications” on page 30.
24
Introduction
Model E42.503 - Rated Force Capacity 5 kN
MTS Exceed™ Series 40 Product Manual
Top Beam
Ball Screw Cover
Load Cell
(inside)
Pin
Adapter
Mat
Base Adapter
Base
Crosshead
Lower Limit Stop
Controller
(back)
Power Cord
Power Switch
Handset
Emergency Stop
Limit Switch Actuator
Upper Limit Stop
Limit Rod
Column Cover
Leveling Foot
Load Frame Components
MTS Exceed™ Series 40 Product Manual Introduction
Model E43.104 - Rated Force Capacity 10 kN
25
Load Frame Components
Top Beam
Ballscrew cover
Top Beam
Load Cell
(inside)
Adapter
Ball Screw Cover
Crosshead
Adapter
Pin
Mat
Base
Lower Limit Stop
Handset
Controller
(back)
Power Cord
Power Switch
Emergency Stop
Upper Limit Stop
Limit Switch Actuator
Limit Rod
Upper Test Space
Lower Test Space
Column Cover
26
Introduction
Model E44.104 //// E44.304 - Rated Force Capacity 10 kN, 30 kN
MTS Exceed™ Series 40 Product Manual
Top Beam
Adapter
Ball Screw Cover
Crosshead
Load Cell
(inside)
Pin
Adapter
Mat
Lower Limit Stop
Handset
Controller
Power Cord
Power Switch
Upper Limit Stop
Limit Switch Actuator
Limit Rod
Base
Base Adapter
Emergency Stop
Adapter
Upper Test Space
Lower Test Space
Column Cover
Load Frame Components
Model E45.105 - Rated Force Capacity 100 kN
MTS Exceed™ Series 40 Product Manual Introduction
27
Load Frame Components
Top Beam
Ball Screw Cover
Crosshead
Load Cell
Pin
Adapter
Mat
Lower Limit Stop
Handset
Upper Limit Stop
Limit Switch Actuator
Limit Rod
Base
Base Adapter
Column Cover
Controller
Power Switch
Emergency Stop
Introduction
28
Model E45.305 - Rated Force Capacity 300kN
MTS Exceed™ Series 40 Product Manual
Connecting screw rod
(Under of crosshead)
Lower Plate
Upper Plate
Controller
Power Switch
Emergency Stop
Lower Limit
Stop
Handset
Upper Limit Stop
Limit Switch
Actuator
Limit Rod
Top Beam
Base
Adapter
Crosshead
Load Cell
Ball Screw Cover
Column Cover
Load Frame Components
Model E45.605 Rated Force Capacity 600kN
MTS Exceed™ Series 40 Product Manual Introduction
29
Specifications
Specifications
This section provides specifications for MTS Exceed Electromechanical Material
Testing System frames and accessory mounting dimensions.
Note Specifications are subject to change without notice. Contact MTS for
verification of critical specifications.
The load weighing system meets or surpasses the following standards:
• GB/T 16825.1
• ASTM E4
• BS 1610
• DIN 51221
• ISO 7500/1
• EN 10002-2
The strain measurement system meets or surpasses the following standards:
• GB/T 12160
• ASTM E 83
• BS 3864
• ISO 9513
• EN 10002-4
30
Introduction
MTS Exceed™ Series 40 Product Manual
Common Specifications
The following specifications are for all MTS Exceed frames. Specifications for
the specific models are located in the following tables.
Specifications
Accuracy Grade
Force range 0.4-100% of rated force capacity / 0.2-100% of rated force
Rated force capacity at max test speed 100%
Maximum test speed at rated force
capacity
Force indicating accuracy
Speed accuracy Set speed < 0.01 mm/min: speed accuracy is within ± 1.0% of set
Position accuracy Within ± 0.5%
Measurement range of strain 0.2 ~ 100% FS
Strain measurement accuraty Class 0.5 / Class 1
Security protection Over-Force, travel limits, over-voltage and others
Over force protection 10%
Data acquisition rate 1000 Hz
Class 0.5 / Class 1
capacity
100%
± 0.5 % of indicating / ±1% of indicating
speed
Set speed ≥ 0.01 mm/min: speed accuracy is within ± 0.2% of set
speed
Control loop rate 1000 Hz
Environmental requirements
Operating temperature
Operating humidity
Storage temperature
Maximum storage humidity
Maximum altitude
Motor and drive system
Ball screws
Position measurement Encoder
Additional DC conditioning channels 2 channels
Additional incremental encoder
conditioning channels
MTS Exceed™ Series 40 Product Manual Introduction
For indoor use only
5-40°C (41-104°F)
5-85% Noncondensing
-18-49°C (0-120°F)
90% Noncondensing
2000 m (6562 ft)
AC Servomotor
Preloaded
2 channel
31
Specifications
Model Specifications
Specifications of Model E42
Exceed model
Maximum rated force capacity 5 kN (1100 lbf)
Force capacity options 5 N, 10 N, 20 N, 50 N, 100 N, 200 N, 500 N, 1 kN, 2 kN,
Frame type table-top
Test zone Single
Maximum test speed 500 mm/min
Minimum test speed 0.001 mm/min (0.00004 in/min)
Position resolution 0.000051 mm (0.0000022 in)
Vertical test space crosshead travel
Standard length
Extended length
Clearance from loading axis to column cover 100 mm (3.94 in)
Frame height
E42.503
5 kN
(1 lbf, 2 lbf, 5 lbf, 10 lbf, 20 lbf, 45 lbf, 110 lbf, 220 lbf,
450 lbf, 1100 lbf )
(19.7 in/min)
700 mm (27.6 in)
1000 mm(39.4 in)
Standard length
Extended length
Frame width 642 mm (25.28 in)
Frame depth 582 mm (22.91 in)
Weight
Standard length
Extended length
Power Requirements 200-230 V AC
1300 mm (51.18 in)
1600 mm(63.0 in)
120 kg (265 lb)
130 kg (287 lb)
3 Amp
50/60 Hz
600 W
1 Phase
32
Introduction
MTS Exceed™ Series 40 Product Manual
Specifications of Model E43
Specifications
Exceed model
Maximum rated force capacity 10 kN (2200 lbf)
Force capacity options 5 N, 10 N, 20 N, 50 N, 100 N, 200 N, 500 N,1 kN, 2 kN, 5 kN,
Frame type Table-top
Test zone Single
Maximum test speed 500 mm/min
Minimum test speed 0.001 mm/min (0.00004 in/min)
Position resolution 0.000041 mm(0.0000016 in)
Vertical test space crosshead travel
Standard length
Extended length
Space between columns 340 mm (13.4 in)
Frame height
E43.104
10 kN
(1 lbf, 2 lbf, 5 lbf, 10 lbf, 20 lbf, 45 lbf, 110 lbf, 220 lbf, 450 lbf,
1100 lbf, 2200 lbf)
(19.7 in/min)
1000 mm (39.4 in)
1300 mm (51.2 in)
Standard length
Extended length
Frame width 681 mm (26.81 in)
Frame depth 588 mm (23.15 in)
Weight
Standard length
Extended length
Power requirements 200 -230 V AC
1617 mm (63.7 in)
1917 mm (75.5 in)
120 kg (265 lb)
130 kg (287 lb)
3 Amp
50/60 Hz
600 W
1 Phase
MTS Exceed™ Series 40 Product Manual Introduction
33
Specifications
Specifications of Model E44
Exceed model
Maximum rated force capacity 10 kN (2200 lbf) 30 kN (6600 lbf)
Force capacity options 100 N, 250 N, 500 N,1 kN, 2kN,
Frame type
Test zone Single or Dual Single or Dual
Maximum test speed 500 mm/min
Minimum test speed 0.001 mm/min (0.00004 in/min) 0.001 mm/min (0.00004 in/min)
Position resolution 0.000036 mm (0.0000014 in) 0.000040 mm (0.0000015 in)
Vertical test space crosshead travel
Standard length
Extended length
Space between columns 400 mm (15.75 in) 400 mm (15.75 in)
E44.104 E44.304
100 N, 250 N, 500 N,1 kN, 2kN,
5 kN, 10 kN
(20 lbf, 50 lbf, 110 lbf, 220 lbf,
450 lbf, 1100 lbf, 2200 lbf)
Floor-standing Floor-standing
(19.7 in/min)
1150 mm (45.28 in)
1450 mm (57.1 in)
5 kN, 10 kN, 20 kN,30 kN
(20 lbf, 50 lbf, 110 lbf, 220 lbf,
450 lbf, 1100 lbf, 2200 lbf,
4400 lbf, 6600 lbf)
500 mm/min
(19.7 in/min)
1150 mm (45.28 in)
1450 mm (57.1 in)
Frame height
Standard length
Extended length
Frame width 845 mm (33.27 in) 845 mm (33.27 in)
Frame depth 716 mm (27.19 in) 716 mm (27.19 in)
Weight
Standard length
Extended length
Power requirements 200 - 230 V AC
1862 mm (73.3 in)
2162 mm (85.1 in)
435 kg (959 lb)
450 kg (992 lb)
3 Amp
50/60 Hz
600 W
1 Phase
1862 mm (73.3 in)
2162 mm (85.1 in)
435 kg (959 lb)
450 kg (992 lb)
200 -230 V AC
6 Amp
50/60 Hz
1200 W
1 Phase
34
Introduction
MTS Exceed™ Series 40 Product Manual
Specifications of Model E45
Specifications
Exceed model
Maximum rated force capacity 100 kN (22000 lbf) 300 kN (66000 lbf) 600 kN (132000 lbf)
Force capacity options 50 kN,100 kN 200 kN, 300 kN 500 kN,,600kN
Frame type
Test zone Single or Dual Single or Dual Single or Dual
Maximum test speed 500 mm/min
Minimum test speed 0.001 mm/min
Position resolution 0.000041 mm
Vertical test space crosshead travel
Standard length
Extended length
Space between columns 600 mm (23.62 in) 580 mm (22.83 in) 750 mm (29.52 in)
E45.105 E45.305 E45.605
(11000 lbf, 22000
lbf)
Floor-standing
(19.7 in/min)
(0.00004 in/min)
(0.0000016 in)
1050 mm (41.34 in)
1350 mm (53.15 in)
(44000 lbf, 66000
lbf)
Floor-standing
250 mm/min
(9.84 in/min)
0.001 mm/min
(0.00004 in/min)
0.000017 mm
(0.0000007 in)
1100 mm (43.30 in)
1400 mm (55.12 in)
(110000 lbf, 132000 lbf)
Floor-standing
254 mm/min
(10 in/min)
0.001 mm/min (0.00004
in/min)
0.000016 mm
(0.0000006 in)
1300 mm (51.2 in)
Frame height
Standard length
Extended length
Frame width 1230 mm (48.43 in) 1215 mm (47.83 in) 1660 mm (65.35 in)
Frame depth 870 mm (34.25 in) 960 mm (37.80 in) 1272 mm (50.08in)
Weight
Standard length
Extended length
Power requirements 200 -230 V AC
2133 mm (83.98 in)
2433 mm (95.79 in)
1400 kg (3086 lb)
1450 kg(3197 lb)
10 Amp
50/60 Hz
2000 W
1 Phase
2360 mm (92.91 in)
2660 mm (104.72 in)
1700 kg (3748 lb)
1750 kg (3758 lb)
380 - 415 V AC
or 440 - 480 V AC
6.8 Amp
50/60 Hz
5000 W
3 Phase
2820 mm (111.02 in)
3500 kg (7716 lb)
380 - 415 V AC
or 440 - 480 V AC
7.2 Amp
50/60 Hz
5000 W
3 Phase
MTS Exceed™ Series 40 Product Manual Introduction
35
Specifications
178mm
(7.01 in)
100 mm
(3.94 in)
582 mm
(22.91 in)
642 mm
(25.28 in)
140 mm
(5.51 in)
278 mm
(10.94 in)
Standard height
1300 mm
(51.18 in)
Extended Length
1600 mm
(62.99 in)
Dimensions
Introduction
36
Model E42.503 - Rated Force Capacity 5 kN
MTS Exceed™ Series 40 Product Manual
Specifications
592 mm
(23.31 in)
122 mm
(4.80 in)
72 mm
(2.83 in)
Standard height
1617 mm
(63.66 in)
185 mm
(7.28 in)
588 mm
(23.15 in)
681 mm
(26.81 in)
Extended Length
1917 mm
(75.47 in)
Model E43.104 - Rated Force Capacity 10 kN
MTS Exceed™ Series 40 Product Manual Introduction
37
Specifications
85 mm
(3.35 in)
138 mm
(5.43 in)
694 mm
(27.32 in)
Standard height
1862 mm
(73.31 in)
277 mm
(10.91 in)
716 mm
(28.19 in)
845 mm
(33.27 in)
Extended Length
2162 mm
(85.12 in)
38
Introduction
Model E44.104 and E44.304 - Rated Force Capacity 10 kN, 30 kN
MTS Exceed™ Series 40 Product Manual
196 mm
(7.72 in)
1062 mm
(41.81 in)
150 mm
(5.91 in)
Standard height
2133 mm
(83.98 in)
430 mm
(16.93 in)
870 mm
(34.25 in)
1230 mm
(48.43 in)
Extended Length
2433 mm
(95.79 in)
Specifications
Model E45.105 - Rated Force Capacity 100 kN
MTS Exceed™ Series 40 Product Manual Introduction
39
1058 mm
(41.65 in)
224 mm
(8.82 in)
200 mm
(7.87 in)
Standard height
2360 mm
(92.91 in)
488 mm
(19.21 in)
960 mm
(37.80 in)
1215 mm
(47.83 in)
Extended Length
2660 mm
(104.72 in)
Model E45.305 - Rated Force Capacity 300 kN
1420 mm
(55.91 in)
278 mm
(10.94 in)
250 mm
(9.84 in)
Standard
2820 mm
(111.02 in)
625 mm
(24.61 in)
1272 mm
(50.08 in)
1660 mm
(65.35 in)
Specifications
Model E45.605 - Rated Force Capacity 600 kN
MTS Exceed™ Series 40 Product Manual Introduction
41
Specifications
42
Introduction
MTS Exceed™ Series 40 Product Manual
Installation
Contents
Frame Location and Ventilation 44
Leveling the Load Frame 45
Controller Connections 47
Accessory Mounting Dimensions 54
MTS Exceed™ Series 40 Product Manual Installation
43
Frame Location and Ventilation
Frame Location and Ventilation
To ensure proper ventilation, locate the load frame approximately 300 mm (12
inches) from adjacent walls and equipment. Allow approximately 1 m (3 feet)
behind the equipment for service access. Do not block the vent holes on the sides
or bottom of the frame.
For comfortable working conditions and proper equipment operation, heat
dissipation of the equipment must be considered in providing adequate heating or
air conditioning in the laboratory area. Heat dissipation can be approximated by
summing the heat losses going into a room (1 kVA is equivalent to 860 kcal/hr
[3,400 Btu/hr]) and the gains from other sources such as furnaces and personnel.
44
Installation
MTS Exceed™ Series 40 Product Manual
Leveling the Load Frame
Frame Base
Leveling Foot
Loosen the top nut.
Turn bottom nut to adjust level.
Leveling the Table-Top Load Frame
Level the table-top load frame immediately after you position it for installation.
This prevents the base from rocking and provides a level test surface for more
accurate test results.
Leveling the Load Frame
Equipment
Procedure
The following items are required:
• Spirit or bubble level
• Open-end wrench
To level the frame base:
1. Place a spirit or bubble level on the center of the base beam.
2. Loosen the top nut on each leveling foot.
3. Using an open-end wrench, alternately adjust the height of each leveling
foot while you monitor the spirit or bubble level reading.
4. Rotate the spirit or bubble level 90° to verify that the load frame is level side
to side and front to back.
5. When the machine is level, tighten the top nut on each leveling foot.
MTS Exceed™ Series 40 Product Manual Installation
45
Leveling the Floor-Standing Load Frame
wedge-s hape d
iron
Leveling the Floor-Standing Load Frame
Level the load frame immediately after you position it for installation. This
prevents the base from rocking and provides a level test surface for more accurate
test results. The test machine is installed on four adjustable wedge-shaped irons.
By leveling the wedge-shaped irons, you prevent the base from rocking and
provide a level test surface.
Equipment
Procedure
The following items are required (0.02/1000mm)
• Spirit or bubble level
• Hammer
To level the frame base:
1. Place a spirit level on the frame upper base plate.
2. Using the hammer, alternately adjust the height of four wedge-shaped irons
while you monitor the spirit level reading.
3. Level the load frame from front-to-back with the same procedures.
4. Repeat above procedures until the load frame is level from side-to-side and
front-to-back.
46
Installation
MTS Exceed™ Series 40 Product Manual
Controller Connections
Connecting the Main Power
Controller Connections
5 kN through 100 kN
100 kN above
Electrical disconnect
The input voltage of MTS Exceed frames rated 100 kN or less is single phase
200-230 V, 50/60 Hz.
For MTS Exceed frames equal or less than 10 kN, use 3 holes socket for power
input, specification of power wire is H05VVF,3G0.75 mm2, compatible with
standards of CCC , CE etc for certification.
For MTS Exceed frames more than 10 kN, use the Single phase 3-wires cable
that is provided for power input, and connect to the customer electrical box and
disconnect. The type of power cable is listed below:
• 10 kN~100 kN - HO7RN-F 3G2.5 mm2,or the same specifications.
compatible with standards of CCC,CE etc for certification.
Note Electrical connections must be made by qualified personnel and is their
responsibility for using the proper power disconnect that conforms to local
codes and regulations when connecting the machine to the building’s main
power.
The input voltage of MTS Exceed frames rated 100kN above is three phases
- 415 V or 440 - 480 V
The type of power cable is : JZ-602,4G4 mm2,or the same specifications.
compatible with the standards of CCC,CE etc for certification.
The customer is responsible for providing an electrical power disconnect that is
easy to operate and easy to reach. It must meet the standards of CCC,CE etc for
certification
, 50/60 Hz.
380
Recommended circuit breakers would be ones that are of the thermal magnetic
type with characteristics suitable for large inductive loads(D-type trip
characteristic).if fuses is used, it is recommended that they are of the time-delay
type with dual elements. These recommendations should be followed to avoid
nuisance tripping.
MTS Exceed™ Series 40 Product Manual Installation
47
Installing Cables
CAUTION
Installing Cables
Exercise care when connecting cables. Ensure that you are using the correct
cables and that all connections are secure. When you are finished, double-check
to ensure that all components are connected properly.
To maintain EMC compliance and help ensure optimal performance, MTS
recommends ordering all system cables from MTS. Cables should be installed so
that they are protected from conditions that could damage the cable.
There is dangerous voltage inside the machine.
Connecting cables with power applied can cause damage to the equipment.
Ensure that the power is turned off before connecting cables.
Controller connectors
J1 USB
J2 Handset
This is a standard USB 2.0 connector that accepts a USB-B cable connector and
connects to the computer. This provides a communications interface between the
testing software on the PC and the controller. This is used to allow the software to
change settings in the controller and to receive data from the controller.
This is intended to interface to the handset. Specifics for this connector are:
• 12 V output power with 200 mA current limit
• RS422 driver (differential)
• RS422 receiver (differential)
• Interlock input. Handset shorts between INTLK+ and INTLK- when it is
connected.
• 8-pin RJ-45 connector
Pin assignments are as follows:
48
Installation
MTS Exceed™ Series 40 Product Manual
PINS
IGNAL
1 Transmit+
2 Transmit-
3 +12 V
4 INTLK+
5 INTLK-
6 Analog GND
7 Receive+
8 Receive-
Installing Cables
J3 Interlock
J4 Encoder
J5 Digital I/O
This connector should be connected to the safety system (Enclosure switch). If
the safety system is not used?a pin jumper should be connected to clear the
system interlock. The enclosure switch has two NC contacts. One must be
connected between Pin 1 and Pin 4. The other should be connected between Pin 2
and Pin 5.
The J4 connector should be connected to J11 Encoder Insight connector, the
cable from J4 to J11 must be connected when using the J10 Encoder User
connector for system operation.
Digital I/O signals include three optically isolated inputs, three optically isolated
outputs, and 12 V power. Functions of each digital input or output are software
selectable. A typical example might be connecting an external switch; see
“Additional Digital I/O Information” on page 81. Only DIN1 and DOUT2 & 3
are available for external use; DIN2 & DOUT1 are used for Fault status
communicates with the software; DIN3 is used for Enclosure door switch status.
Pin assignments are as follows:.
P
IN
S
IGNAL
1 DIN1+
2 DIN2+
3 DIN3+
4 DOUT1+
5 DOUT2+
6 DOUT3+
7 No Contact
8
+12 V
9 DIN1-
10 DIN2-
MTS Exceed™ Series 40 Product Manual Installation
49
Installing Cables
11 DIN3-
12 DOUT1-
13 DOUT2-
14 DOUT3-
15 Analog GND
J6 and J7 Monitor
J8 and J9 DC
Conditioner
J10 Encoder User
Two monitor connectors are provided. There are several possible uses for analog
monitor outputs: external data acquisition, tuning, troubleshooting, and so forth.
For tuning, it is desirable to monitor command an feedback, or command and
error, simultaneously while changing the controller parameters. Therefore, two
monitor outputs are provided. Specifics for these connectors are:
• Analog +/-10.5 V
• Calibrated to +/-10 V
• 16-bit resolution minimum
• BNC connectors
The J8 connector should be connected to J14 DC Cond Insight connector, the J9
connector should be connected to J15 DC Cond Insight connector. The cable
from J8 to J14 must be connected when using the J12 DC Cond User connector
for system operation, and the cable from J9 to J15 must be connected when using
the J13 DC Cond User connector for system operation.
This connector is intended for encoder-based transducers. Specifics for this
connector are:
• Quantity: 2 encoder signal acquisition channel.
• Power: +5 V +/- 0.25 V at 100 mA max
• Signals: Quadrature A and B with index I
50
Installation
• Logic: Differential receivers (can connect single ended)
• Maximum Rate: 100,000 lines/sec = 400,000 counts/sec.
Pin assignments are as follows:
P
IN
S
IGNAL
1 TEDS+_1
2 A+_1
3 A-_1
4 +5_1
5 I+_1
6 I_1
7 Analog GND_1
MTS Exceed™ Series 40 Product Manual
8 B+_1
9 B-_1
10 TEDS-_1
11 No Contact
12 No Contact
13 No Contact
14 No Contact
15 No Contact
16 TEDS+_2
17 A+_2
18 A-_2
19 +5_2
20 I+_2
Installing Cables
J11 Encoder Insight
J12 and J13 DC
Conditioner User
21 I_2
22 Analog GND_2
23 B+_2
24 B-_2
25 TEDS-_2
The J11 connector should be connected to J4 Encoder connector,The cable from
J11 to J4 must be connected when using the J10 Encoder User connector for
system operation.
Two external DC conditioner connectors are provided. Up to two
external,transducers can be connected such as: axial or transverse extensometers,
biaxial extensometer, auxiliary load cells, pressure gages, LVDTs or strain-gaged
components.
Pin assignments are as follows:
PINS
IGNAL
1 EX+
2 EX-
3 No Contact
4 FB+
5 FB-
6 No Contact
7 No Contact
MTS Exceed™ Series 40 Product Manual Installation
51
Installing Cables
8 TEDS+
9 No Contact
10 EXS+
11 No Contact
12 RECALL(FBR+)
13 RECALL(FBR-)
14 TEDS-
15 EXS-
J14 and J15 DC Cond
Insight
The J14 connector should be connected to J8 DC Cond connector, the J15
connector should be connected to J9 DC Cond connector. The cable from J14 to
J8 must be connected when using the J12 DC Cond User connector for system
operation, and the cable from J15 to J9 must be connected when using the J13
DC Cond User connector for system operation.
52
Installation
MTS Exceed™ Series 40 Product Manual
Crosshead load cell
connector
Installing Cables
The picture above shows the load cell connection on upper test space for E44
frame. The load cell cable connects to the D-15 connector on the bellows support
of column cover.
P
IN
S
IGNAL
1 EX+
2 EX-
3 No Contact
4 FB+
5 FB-
6 No Contact
7 SHIELD
8 TEDS+
9 No Contact
10 EXS+
11 No Contact
12 RCAL1 (FBR+)
13 RCAL2 (FBR-)
14 TEDS-
15 EXS-
MTS Exceed™ Series 40 Product Manual Installation
53
Accessory Mounting Dimensions
Accessory Mounting Dimensions
You can attach numerous testing accessories and fixtures to the load frame for
specialized tests. The following figures show the standard mounting holes in
each style of load frame. Use these standard mounting holes to mount your
accessories. Avoid tapping new holes that may weaken or otherwise compromise
the integrity of the load frame. The following sections describe each style of load
frame separately. Look for the section pertaining to your specific model for the
appropriate dimensions.
Note All measurements in the following figures are shown in mm.
54
Installation
MTS Exceed™ Series 40 Product Manual
Model E42.503 Accessory Mounting Dimensions
Φ50
4-M6x12
Model E42.503 Base Beam Mounting Dimensions
Model E42.503 Crosshead Mounting Dimensions
60
+0.03
Φ12.5THRU
30
+0.03
+0.06
+0.06
vΦ25x16
Model E42.503 Accessory Mounting Dimensions
Base beam
Crosshead
MTS Exceed™ Series 40 Product Manual Installation
55
Model E43 .104Accessory Mounting Dimensions
Φ50
4-M6x15
4-M8x20
340 Horizontal Clearance
180±0.1
64±0.1
38
4-M10x20
Model E43.104 Base Beam Mounting Dimensions
Model E43.104 Crosshead Mounting Dimensions
42±0.1
50±0.1
4-M6x12
Model E43 .104Accessory Mounting Dimensions
Base beam
Crosshead
Installation
56
MTS Exceed™ Series 40 Product Manual
Model E44 Accessory Mounting Dimensions
Model E44.104/E44.304 Base Beam Mounting Dimensions
180
4
5
°
4
5
°
64
4-M8x25
Φ60±0.1
4-M8x25
140
38
4-M10x30
400
Horizontal Clearance
4
5
°
4
5
°
Φ60
4-M8x25
Model E44.104/E44.304 Topside of Crosshead Mounting Dimensions
Model E44 Accessory Mounting Dimensions
Base beam
Crosshead
MTS Exceed™ Series 40 Product Manual Installation
57
Model E44 Accessory Mounting Dimensions
70
430
2-M10x25
64
4-M12x30
Model E44.104/E44.304 Topside of Top Beam Mounting Dimensions
Top beam
Installation
58
MTS Exceed™ Series 40 Product Manual
Model E45.105 Accessory Mounting Dimensions
vΦ131x20
M24x2x25
Φ100
6-M12x25
600 Horizontal Clearance
Model E45.105 Base Beam Mounting Dimensions
8-M10x20
Φ126
40
Model E45.105 Underside of Crosshead Mounting Dimensions
Model E45.105 Accessory Mounting Dimensions
Base beam
Crosshead
MTS Exceed™ Series 40 Product Manual Installation
59
Model E45.105 Accessory Mounting Dimensions
Φ42
2-M4x12
68
Model E45.105 Topside of Crosshead Mounting Dimensions
540
2-M24x45
Model E45.105 Topside of Top Beam Mounting Dimensions
Top beam
Installation
60
MTS Exceed™ Series 40 Product Manual
Model E45.105 Accessory Mounting Dimensions
4-M8x15
180
6-M12x20
64
Φ100
Model E45.105 Underside of Top Beam Mounting Dimensions
MTS Exceed™ Series 40 Product Manual Installation
61
Model E45.305 Accessory Mounting Dimensions
8-M12x25
Φ128
vΦ156x28
580 Horizontal Clearance
Model E45.305 Base Beam Mounting Dimensions
8-M10x25
Φ116.8
Model E45.305 Underside of Crosshead Mounting Dimensions
Model E45.305 Accessory Mounting Dimensions
Base beam
Crosshead
Installation
62
MTS Exceed™ Series 40 Product Manual
Model E45.305 Accessory Mounting Dimensions
2-M3x8
Φ52
87
Model E45.305 Topside of Crosshead Mounting Dimensions
550
2-M24x40
Model E45.305 Topside of Top Beam Mounting Dimensions
Top beam
MTS Exceed™ Series 40 Product Manual Installation
63
Model E45.305 Accessory Mounting Dimensions
4-M5x15
Φ61
Φ42x30
Φ78x12
Model E45.305 Underside of Top Beam Mounting Dimensions
Installation
64
MTS Exceed™ Series 40 Product Manual
Model E45.605 Accessory Mounting Dimensions
12-M20x40
vΦ75x60
350
Φ128
10-M16x35
40
40x5=200
750 Horizontal Clearance
Model E45.605 Base Beam Mounting Dimensions
6-M12x30
Φ82 Thru
Φ190
vΦ152x94
2-Φ5.4x12
Model E45.605 Upsside of Crosshead Mounting Dimensions
Model E45.605 Accessory Mounting Dimensions
Base beam
Crosshead
MTS Exceed™ Series 40 Product Manual Installation
65
Model E45.605 Accessory Mounting Dimensions
100
2-Φ5.4x12
Φ82 Thru
Model E45.605 Underside of Crosshead Mounting Dimensions
700
2-M42x70
Φ32.5 Thru
vΦ65x60
Model E45.605 Topside of Top Beam Mounting Dimensions
2-Φ5.4x12
50
Φ32.5 Thru
Model E45.605 Underside of Top Beam Mounting Dimensions
Top beam
Installation
66
MTS Exceed™ Series 40 Product Manual
Operation
CAUTION
CAUTION
CAUTIONWARNING
This section describes the actions performed during normal, day-to-day
operation of the MTS Exceed frame. For information on using the MTS
Exceed frame in actual testing, refer to the testing software manual.
Contents
Main Power Switch (I/O) and Emergency-Stop 68
Setting Crosshead Travel Limits 69
Crush Zone Hazards 71
Fixture Mounting 72
Handset Control 73
There are rotating parts inside the machine.
Operating the machine without side covers or bellows in place can expose
the operator to rotating parts that could cause injury if contact is made.
Do not operate the MTS Exceed test frame without the side covers and bellows in
place.
Specimen debris can enter the side covers and puncture bellows causing
erratic machine operation.
Material fragments can puncture the bellows and damage the ball screw.
Damaged bellows should be replaced before operating the MTS Exceed Test
Frame. Be aware of the potential of material fragments puncturing the bellows and
damaging the ball screw, and be aware of the material properties and the hazards
generated by the materials during testing.
There are potential hazards during material testing.
Hazards generated by the materials during testing can cause injury or
death.
Ensure that only qualified, trained personnel should be allowed to operate the
machine. Keep bystanders away during machine operation.
MTS Exceed™ Series 40 Product Manual Operation
67
Main Power Switch (I/O) and Emergency-Stop
Emergency Stop
power switch
Main Power Switch (I/O) and Emergency-Stop
Main power switch
(I/O)
Emergency Stop
The main power switch and Emergency Stop is located on the front-right of the
frame base. Select position ( I )to turn the power on to the load frame and the
controller. When the power is on, the displays on the frame control panel
illuminate. Select position ( O) to turn off power to the load frame and the
controller.
The frame is also equipped with an Emergency Stop button. The EmergencyStop will cut the power to the motor and should be used for emergency purposes
only.
The Emergency-Stop should be periodically pressed when the controller is
powered but not when a test is running. The controller continously monitors the
redundant Emergency-Stop chain and will generate a fault alerting the user if any
problems are detected. Pressing Emergency-Stop allows the active state to be
checked..
To shut down the motor power and stop the test program, press the Emergency-
Stop button. Twist the switch clockwise to release it. Use the Emergency-Stop
button to shut down your test if something unexpected should happen.
68
Operation
MTS Exceed™ Series 40 Product Manual
Setting Crosshead Travel Limits
CAUTION
WARNING
There are two levels of crosshead limit stops that act to protect the crosshead
from traveling too far in either direction. The first-level stops are the upper and
lower limit stops that you manually set as described below. The second-level
limits are not user adjustable and act as a backup in case the first-level limits
malfunction.
The limit stops are not intended to be an end of test condition to end every
test.
Repeated use of the limit stops in this way may cause excessive wear,
which can result in the limit stop failing to stop the crosshead. Refer to the
Warning below for more information on unexpected crosshead motion.
Proper end of test conditions can be set from the software.
Do not use limit stops to end a test.
Setting Crosshead Travel Limits
Crosshead Limit Stops
Setting the limit stops
Unexpected crosshead motion can occur during testing.
Failure to set the limit stops could cause injury from unexpected crosshead
motion, and cause possible damage to test fixtures.
Always set the limit stops before starting a test.
Note Set the crosshead limit stops after you establish the crosshead starting
position, but before you start the test.
The travel limit stops are two adjustable blocks mounted on the limit switch rod,
which is located inside the column of the machine. Limit stops have
thumbscrews that you tighten and release by hand, and you can move them to any
position on the limit rod. Position these stops just beyond the test parameters to
prevent crosshead over-travel. When the crosshead reaches the maximum pre-set
travel, the limit switch actuator contacts one of these stops. Contact between the
limit actuator and the limit stop moves the limit switch rod and activates the limit
switches. This stops crosshead motion.
To set the limit stops:
1. Ensure that the crosshead is stationary and that the test parameters are set.
2. Set the upper limit stop at a position just above the expected maximum
crosshead travel in the upward direction when tension testing, or just above
the test starting point when compression testing. Tighten the stop securely
on the limit rod.
MTS Exceed™ Series 40 Product Manual Operation
69
Setting Crosshead Travel Limits
Crosshead
Limit Rod
Limit Switch
Actuator
Lower Limit Stop
Upper Limit Stop
3. Set the lower limit stop at a position just below the starting position when
tension testing or just below the expected maximum crosshead travel in the
down direction when compression testing. Tighten the stop securely on the
limit rod.
Moving the crosshead
When the crosshead contacts either the upper or lower limit stop, the test stops. If
this happens, there are three ways to get the crosshead moving::
• Press Motor Reset in TestSuite software. Then use the crosshead
capabilities of your software (virtual handset). Move the crosshead away
from the limit until the switch closes and the crosshead can move in both
directions again. See the TestSuite software manual for further details.
• Manually move the adjustable limit along the range of travel away from the
crosshead until the limit switch is no longer active. Then press Motor Amp
Reset in TestSuite software or Handset Enable on the handset.
• If TestSuite software is not active, press Handset Enable on the handset.
Then use the manual handset control to move the crosshead until the limit
switch is no longer active.
Operation
70
MTS Exceed™ Series 40 Product Manual
Crush Zone Hazards
Crush Zone
Crush Zones
It is important to stay clear of any potential crush zones when the system is
operating. Know where the crush zones are in your system and protect yourself
and others from those crush zones with appropriate safety devices. The following
paragraphs describe crush zones and precautions to take while working around
crush zones.
Crush Zone Hazards
Locations
Precautions
A crush zone exists between the platen and crosshead on load units where the
crosshead and specimen move (both areas are shown).
Keep clear of any mechanical linkage that moves within a closed area. If the
linkage should move (when the system starts or due to mechanical failure), very
high forces can be present that could pinch, cut, or crush anything in the path of
linkage movement.
Never allow any part of your body to enter the path of machine movement or to
touch moving machinery, linkages, hoses, cables, specimens, and so forth. These
present serious crush points or pinch points.
MTS Exceed™ Series 40 Product Manual Operation
71
Fixture Mounting
Locking
Collar
Mounting Pin
(Clevis Pin
Load Frame-
Adapter
Mounting Dowel
(Pin)
Fixture Mounting
MTS offers a wide variety of fixtures. Mounting these fixtures typically involves
installing the fixture or load cell onto a mounting (clevis pin) adapter and
securing it with a mounting dowel (pin). To further secure a fixture, some
configurations also include locking collars. A typical mounting configuration is
shown in the following figure.
72
Operation
MTS Exceed™ Series 40 Product Manual
Handset Control
The handset has an encoder and buttons to help you during specimen installation
and test execution. The handset also has an alphanumeric display and LEDs to
provide feedback.
Handset Control
Handset functions
# C
1 Page
2 Active
3 F1 and F2
4 Thumb-wheel
5 Pause
6 Stop
MTS Exceed™ Series 40 Product Manual Operation
ONTROL/INDICATOR
The handset is intended to be used for specimen loading or setup. In some
applications, it can be used to completely run a test.
Handset Controls and Indicators (part 1 of 2)
D
ESCRIPTION
Displays the next four lines of text in the display.
When lit, indicates the system is active (motion is possible).
Programmable functions that are set up in the software as
digital inputs. This allows you to define the test function (that is,
start test, pause, hold position, and so forth).
Makes fine crosshead adjustment (towards display – up; away
from display – down. Only if Handset Enable is active.
Pauses the test action. This must be pressed again for the test
to resume. Only if the testing software is active.
Stops motion.
73
Handset Control
Handset Controls and Indicators (part 2 of 2)
7 Connector
8 Crosshead Return
9 Start
10 Crosshead Down
11 Crosshead Up
12 Fault
13 Handset enable
14 Display
RJ-45, to Controller.
Returns the crosshead to the original position (zero point).
Starts the test action. Only if the testing software is active.
Moves the crosshead in the downward direction while
depressed. Only if Handset Enable is active.
Moves the crosshead in the upward direction while depressed.
Only if Handset Enable is active.
When lit, indicates an active fault or interlock.
Pressing with an interlock active attemps to clear the interlock.
Pressing when there are no active interlocks enables the
handset for local control.
When the indicator is lit, the handset is enabled for control of the
crosshead.
Four lines, 20 characters per line.
74
Operation
MTS Exceed™ Series 40 Product Manual
Maintenance
Routine Maintenance Overview Checklist
Recommended Service
C
ALENDAR TIME USING
R
ATE PER DAY
R
UNNING TIME-HOURS
8 H
OURS RUNNING TIME
D
AILY
W
8 40 2000
Routine Maintenance Overview Checklist
EEKLY
A
NNUALLY
Check shunt calibration
Clean work area/machine surface X
Activate and reset limits and Emergency-Stop X
Inspect cable/connections X
PC Maintenance
Back up testing software files (*.reg/.cal files)
Hard drive defragment MTS
System Inspection
Check/adjust drive belt tension (refer to table) MTS
Inspect drive belts for excessive wear MTS
Inspect cable connections MTS
System Checks
Check Emergency-Stop MTS
Check upper limit MTS
Check lower limit MTS
Check load cal/shunt cal MTS
Lubrication
*
X
MTS
†
Crosshead/ball screw (#2 white lithium grease) MTS
Drivetrain bearings (if applicable) MTS
Frame and Work Area
Clean off frame and work area MTS
* Denotes services performed by equipment operators. Most of these procedures involve visual checks
that should not interfere with testing system operation. These checks are also completed by trained
field service engineers on each Routine Maintenance visit.
† Denotes service performed by trained field service engineers as part of an MTS Routine Maintenance
plan. Some of these procedures require special service tools and/or specific service training to
complete.
MTS Exceed™ Series 40 Product Manual Maintenance
75
There are no customer serviceable components on the MTS Exceed frames.
WARNING
CAUTION
Maintenance consists of keeping the frame and work area clean, general
inspection, checking interlocks, and scheduled frame calibration.
Be careful not to spill and cleaning liquid on the frame.
Inadvertent electrical component contamination with detergents or cleaning
fluids can cause circuits to short resulting in equipment damage.
Disconnect the power cord from the wall outlet before cleaning or inspecting any
part of the test frame.
Observe all manufacturers recommendations and cautions when using any
cleaning solution.
Cleaning solution can cause damage to injury.
To avoid hazardous conditions, always follow the manufacturers’
recommendations and cautions.
General Cleaning
Monthly Maintenance
Semiannual
Maintenance
Removing Mats
Other service
Clean the frame as often as needed. Use a damp, lint-free rag to clean the side
covers, base, and crosshead. If necessary, mild detergent or cleaning fluid can be
used.
Verify that the Emergency Stop button is functioning properly.
Test the limit switches by manually moving the adjustable limits-a limit switch
fault should be indicated on the computer screen.
Verify the speed and position accuracy of the frame. This requires standards and
other equipment typically not available for routine maintenance. Contact your
MTS field service engineer for assistance.
Some installation and maintenance situations may require you to remove the load
frame mat covers in order to access components within the base of machine.
Regular inspection and service of the drive motor system and crosshead
positioning components are needed to prolong the life of your frame and keep it
performing optimally. This type of service is typically preformed by MTS field
service engineers or MTS authorized service representative. Contact your MTS
authorized representative for additional information.
Note MTS offers annual maintenance and calibration plans. Contact your
sales representative for more information.
76
Maintenance
MTS Exceed™ Series 40 Product Manual
Troubleshooting
S
YMPTOMS
S
OLUTIONS
Basic Troubleshooting
Failure in Windows system
Testing software failure
Communication trouble
between hardware and
software
Power OK light not on when
power switch is on
Turn off the computer and start again.
Check to see if the failure is gone; if the failure still exist, ask your IT
Department to check into the problem. If your IT Department can’t solve
the issue, delete the current windows system and install it again.
If after the re-install the issue still exists, contact the local service center
of the computer manufacturer directly or via MTS China, to repair the
computer.
Displacement cannot be cleared or displayed. Normally, it is caused by an
incorrect sequence in turning on testing system; shut off the software and
restart it.
If restarting does not solve the problem, delete the testing software, and
install the software again.
Check all cable connections.
If communication between the PC and the Exceed system are not working
try the following:
• Remove the USB connector from the Exceed system and plug it back
in and see if communications starts between the two.
• Shut off power to the Exceed system and turn it on again, see if
communication starts between the two.
Check that:
• The power cable is plugged in.
• The line voltage is within specified machine limits.
Cannot clear interlocks
MTS Exceed™ Series 40 Product Manual Troubleshooting
Check:
• If Emergency-Stop is active.
• For system interlocks (servo error, limits).
• For system faults.
77
Decommissioning
CAUTION
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.
To decommissioning the system:
1. Remove specimen and fixtures. Large grips should be removed if the load
frame could be tipped over.
2. Isolate the system from electrical power.
3. 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.
4. Disconnect all cables from the controller.
5. Cover the material testing machine with a dust cover, such as plastic foil.
Allow for sufficient ventilation or place a dehumidifier near to the
equipment.
6. Place the accessories and the instruction manual in a clean, dust protected
place, such as a tool cabinet.
Electrical components and parts can contain hazardous chemicals and
compounds.
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.
Customer should follow internal safety policies for safe disposal of parts of the
machine. Refer to MSDS for oils and greases that are used on the machine.
MTS Exceed™ Series 40 Product Manual Decommissioning
79
Appendix
Additional Digital I/O Information
The digital inputs have an MOCD223 optical isolator with 2.7 Kohm, ½ Watt
series resistor. To reliably turn on, they need 1 mA of current. This means the
minimum input high voltage is 4.0 V DC. The maximum input voltage is 28.0 V
DC. The device should be off for input voltages less than 1.0 V.
The digital outputs are implemented by an AQV252G PhotoMOS relay with a
0.75 Amp poly fuse in series. Although the device is rated at 60 V peak, it is
recommended that a maximum of 48 V be applied. If the load is highly inductive,
such as a relay coil, an appropriate snubber network should be used near the coil
terminals to prevent large flyback voltages from exceeding the device ratings.
Additional Digital I/O Information
A typical example might be connecting an external switch.
MTS Exceed™ Series 40 Product Manual Appendix
81
Maintenance and Service Logs
Contents
8 Hours/Daily 84
40 Hours/Weekly 85
2000 Hours/Annual 86
PC Maintenance and System Inspection 86
System Checks 87
Lubrication 88
Frame and Work Area 89
MTS Exceed™ Series 40 Product Manual Maintenance and Service Logs
83
8 Hours/Daily
8 Hours/Daily
S
HUNT CALIBRATION
CHECK
D
ATE
P
ERFORMED BY
8 Hours/Daily Service Interval Recommendation
C
LEAN WORK AREA
MACHINE SURFACE
P
ERFORMED BY
N
OTES
Maintenance and Service Logs
84
MTS Exceed™ Series 40 Product Manual
40 Hours/Weekly
40 Hours/Weekly Service Interval Recommendation
V
D
ATE
ERIFY LIMITS AND
E
MERGENCY-STOP
P
ERFORMED BY
I
NSPECT CABLE
CONNECTIONS
P
ERFORMED BY
40 Hours/Weekly
/
N
OTES
MTS Exceed™ Series 40 Product Manual Maintenance and Service Logs
85
2000 Hours/Annual
2000 Hours/Annual
PC Maintenance and System Inspection
2000 Hours/Annual Service Interval Recommendation
PC M
AINTENANCE
B
ACK UP
TESTING
SOFTWARE FILES
H
ARD DRIVE
DEFRAGMENT
(*.REG/.CAL
F
ILES
)
D
ATEPERFORMED BYPERFORMED BY
S
YSTEM INSPECTION
I
NSPECT/CLEAN
CONTROLLER
P
ERFORMED BYPERFORMED BYPERFORMED BYNOTES
I
NSPECT DRIVE
BELTS FOR
EXCESSIVE
WEAR
I
NSPECT CABLE
CONNECTIONS
Maintenance and Service Logs
86
MTS Exceed™ Series 40 Product Manual
2000 Hours
System Checks
S
YSTEM CHECKS
C
HECK
E
MERGENCY
STOP
D
ATE
P
ERFORMED BYPERFORMED BYPERFORMED BYPERFORMED BYNOTES
2000 Hours/Annual Service Interval Recommendation
C
HECK UPPER
-
LIMIT
C
HECK LOWER
LIMIT
C
HECK LOAD
CAL/SHUNT CAL
2000 Hours
MTS Exceed™ Series 40 Product Manual Maintenance and Service Logs
87
2000 Hours
2000 Hours
Lubrication
L
UBRICATION
C
ROSSHEAD/BALL
SCREW
LITHUM GREASE
D
ATE
P
ERFORMED BY
2000 Hours/Annual Service Interval Recommendation
B
(#
WHITE
EARING IN BASE PLATE
)
(#
WHITE LITHUM
GREASE
P
)
ERFORMED BY
D
RIVE TRAIN
BEARINGS (IF
APPLICABLE
P
ERFORMED BY
)
N
OTES
Maintenance and Service Logs
88
MTS Exceed™ Series 40 Product Manual
2000 Hours
Frame and Work Area
2000 Hours/Annual Service Interval Recommendation
F
RAME AND WORK AREA
C
LEAN/REPLACE AIR
FILTER
D
ATE
P
ERFORMED BY
C
LEAN GUIDE COLUMNS
WITH
WD40 (D/G/S
SERIES FRAMES
P
ERFORMED BY
2000 Hours
C
LEAN OFF FRAME
AND WORK AREA
)
P
ERFORMED BY
N
OTES
MTS Exceed™ Series 40 Product Manual Maintenance and Service Logs
89
m
MTS Systems Corporation
http://www.mts.com/en/Global/index.asp
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