QTest Technical Reference - Auburn...

QTest Elite Technical Reference l

100-093-637 C

Copyright information © 2001 - 2004 MTS Systems Corporation. All rights reserved.

Trademark information MTS and TestWorks are registered trademarks of MTS Systems Corporation.

QTest and QTest Elite Series are trademarks of MTS Systems Corporation.

Contact information MTS Systems Corporation14000 Technology DriveEden Prairie, Minnesota 55344-2290 USAToll Free Phone: 800-328-2255 (within the U.S. or Canada)Phone: 952-937-4000 (outside the U.S. or Canada)Fax: 952-937-4515E-mail: [email protected]://www.mts.com

Publication information Manual Part Number Publication Date

7199938 April 2001

100-093-637 A September 2002*

* Document part number change only.

100-093-637 B November 2002

100-093-637 C July 2004

QTest Materials Test Systems Contents 3

Contents

Preface 5

Safety first! 5Contents 5

About This Manual 6Purpose 6Summary 6

Conventions 7Hazard conventions 7Other conventions 8Electronic manual conventions 8

Technical Support 9Start with your manuals 9Technical support numbers 9Before you contact MTS 10If you contact MTS by phone 11Problem Submittal Form in MTS manuals 12

Introduction 13

Scope 13Scope 13

Description 14General description 14System performance 15

Specifications 17

Installation 21

Initial off-loading and moving of QTest System 21Location and ventilation 21Moving the QTest frames 22Moving the palletized machine 22Connection to the supply 23

QTest Materials Test SystemsContents4

External earth connection 24Cable installation 24QTest system connections 25Controller board 27Controller box 27To connect the cables 27Control card removal and installation 28

Operation 29

Main ON/OFF switch 29Handset Operation 29

Manual handset control 29Handset functions 30

Safety Symbols 32Travel limit switches (Physical limits) 34Load cell mounting 35External Connections 36

Applications 36Channel Connector Functions 36External Channel Pin Definitions 37Pins 1-3 and 14-16 for sensor use 37Pins 8, 9, 21, 22 are the digital I/O’s 38Pins 7 and 20 are the quadrature inputs 38Remaining power and ground connections 38

Pin Definitions for User Digital I/O 39On expansion board (J5 Connector) 39User Digital I/O Pin Definitions 39

Maintenance and Repair 41

Monthly machine/frame maintenance 41Semiannual maintenance 42General cleaning 42

Troubleshooting Guide 43

QTest Materials Test Systems Preface 5

Preface

Safety first! Before you attempt to use your MTS equipment in your test system, read and understand the Safety manual. Like an automobile, your test system is very useful—but if misused, it is capable of deadly force. You should not be afraid of your test system, but you should always maintain a healthy respect for it.

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

Contents About This Manual 6

Conventions 7

Technical Support 9

QTest Materials Test Systems

About This Manual

Preface6

About This Manual

Purpose This manual provides detailed information about the QTest Material Testing Systems. The information includes an overview of all the models available, installation, operation, maintenance and repair, and troubleshooting guidelines.

Summary This manual includes the following sections.

Introduction This section reviews the QTest material testing system models, gives you a description of a typical frame, and lists the environmental specifications. This section also provides the technical frame specifications of each QTest frame model and line drawings of the crosshead and tabletop details.

Installation This section gives you specific instructions for properly moving QTest frames, cable installation, and line drawings of the basic controller.

Operation This section provides a graphic of the manual handset control and handset functions. A line drawing of the antirotational load cell mounting is provided as well. Other areas such as travel limit switches and load cell mounting are reviewed.

Maintenance This section gives you a complete guide to the preventive maintenance schedule for all QTest frames. Additionally, a parts list is provided for Qtest frame parts and self-ID load cell parts.

Troubleshooting Guide This section helps you identify common mechanical and electrical problems and provides quick solutions in troubleshooting your QTest test system.

Conventions


Conventions

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

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

Note For general safety information, see the Safety manual included with your system.

Danger notices Danger notices indicate the presence of a hazard which will cause severe personal injury, death, or substantial property damage if the danger is ignored. For example:

High intensity light and dangerous radiation are emitted by class 3B

lasers.

Viewing a class 3b laser directly or viewing it using optical instruments

will cause immediate and severe injury.

Avoid eye or skin exposure to the laser beam. Ensure that all power to the laser is off before attempting any maintenance, service, or adjustment procedure.

Warning notices Warning notices indicate the presence of a hazard which can cause severe personal injury, death, or substantial property damage if the warning is ignored. For example:

Hazardous fumes can accumulate in the test chamber as a result of

testing.

Breathing hazardous fumes can cause nausea, fainting, or death.

Ensure the chamber is properly ventilated before you open the chamber door or put your head or hands into the chamber. To do this, ensure the temperature controller is off and allow sufficient time for the ventilation system to completely exchange the atmosphere within the chamber.

��

��


Conventions

Preface8

Caution notices Caution notices indicate the presence of a hazard which will or can cause minor personal injury, cause minor equipment damage, or endanger test integrity if the caution is ignored. For example:

This specimen can develop sharp edges as a result of testing.

Handling the specimen with unprotected hands can result in cuts and

slivers.

Always wear protective gloves when you handle the specimen.

Other conventions Other conventions used in your manuals are described below:

Notes Notes provide additional information about operating your system or highlight easily overlooked items. For example:

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

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

Illustrations Illustrations appear in this manual to clarify text. It is important for you to be aware that these illustrations are examples only and do not necessarily represent your actual system configuration, test application, or software.

Electronic manualconventions

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.

Hypertext links The electronic document has many hypertext links displayed in a blue font. All blue words in the body text, along with all contents entries and index page numbers are hypertext links. When you click a hypertext link, the application jumps to the corresponding topic.

��

Technical Support


Technical Support

Start with yourmanuals

The manuals supplied by MTS provide most of the information you will need to use and maintain your equipment. If your equipment includes MTS software, you should look for README files for additional product information.

If you cannot find answers to your technical questions from these sources, you can use the internet, telephone, or fax to contact MTS for assistance. You can also fill out the Problem Submittal Form that is available on the MTS web site and in the back of many MTS manuals that are distributed in paper form.

Technical supportnumbers

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

MTS web sitewww.mts.com

The MTS web site gives you access to our technical support staff by means of a Problem Submittal Form and a Technical Support link.

• Problem Submittal Form: www.mts.com > Contact MTS > Problem Submittal Form

• Technical Support: www.mts.com > Contact MTS > Technical Support

E-mail: [email protected]

Telephone HELPLine 800-328-2255Weekdays 7:00 A.M. to 6:00 P.M.,Central Time

Fax 952-937-4515Please include an MTS contact name if possible.


Technical Support

Preface10

Before youcontact MTS

MTS can help you more efficiently if you have the following information available when you contact us for support.

Know your site numberand system number

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

Example site number: 571167

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

Example system number: US1.42460

Know information fromprior technical

assistance

If you have contacted MTS about this problem before, we can recall your file. You will need to tell us the:• MTS notification number• Name of the person who helped you

Identify the problem Describe the problem you are experiencing and know the answers to the following questions.• How long has the problem been occurring?• Can you reproduce the problem?• Were any hardware or software changes made to the system before the

problem started?• What are the model and serial numbers of the suspect equipment?

Know relevant computerinformation

If you are experiencing a computer problem, have the following information available.• Manufacturer’s name and model number• Operating software type and service patch information. Examples:

– Windows XP Service Pack 1 (SP1)– Windows 2000 Service Pack 3 (SP3)– Windows NT 4.0 Service Pack 7 (SP7)

• Amount of system memory. Example: 640 MB of RAM.• Amount of free space on the hard drive in which the application resides.

Example: 11.2 GB free space, or 72% free space.• Current status of hard-drive fragmentation. Example: 3% total

fragmentation.

Technical Support


Know relevant softwareinformation

For MTS software application problems, have the following information available.

Station Manager, Version 3.3A, Build 1190, Patch 4

• Names of other non-MTS applications that are running on your computer, such as screen savers, keyboard enhancers, print spoolers, and so forth

If you contact MTSby phone

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

Identify system type To assist your HELPLine agent with connecting you to the most qualified technical support specialist available, identify your system as one of the following types:

• Electromechanical materials test system

• Hydromechanical materials test system

• Vehicles test system

• Vehicles component test system

• Aero test system

Be prepared totroubleshoot

Prepare yourself for troubleshooting while on the phone.

• Call from a telephone close to the system so that you can try implementing suggestions made over the phone.

• Have the original operating and application software media available.

• If you are not familiar with all aspects of the equipment operation, have an experienced user nearby to assist you.


Technical Support

Preface12

Write down relevantinformation

Prepare yourself in case we need to call you back.

• Remember to ask for the notification number.

• Record the name of the person who helped you.

• Write down any specific instructions to be followed, such as data recording or performance monitoring.

After you call MTS logs and tracks all calls to ensure that you receive assistance and that action is taken regarding your problem or request. If you have questions about the status of your problem or have additional information to report, please contact MTS again.

Problem SubmittalForm in MTS manuals

In addition to the Problem Submittal Form on the MTS web site, there is also a paper version of this form (postage paid) in the back of many MTS manuals. Use this form to forward problems you are experiencing with your MTS equipment, whether it be software, hardware, manuals, or service. This form includes check boxes that allow you to select when you expect us to respond to your input. We guarantee a timely response—your feedback is important to us.

QTest Materials Test Systems Introduction 13

Introduction

The QTest™ Elite System product series is the latest generation of system products for material testing equipment from MTS Systems Corporation. Our QTest Elite System works in conjunction with TestWorks 4 software.

Scope This manual provides inportant technical information for the safe operation of the following testing frames:

Use of this equipment in a manner inconsistent with that described in this manual may expose the user to unforeseen hazards.

Scope This manual provides technical information for the following material testing frames:

��

Model Capacity System Type

QTest Elite 1/L 1 KN (225 lbf.) Tabletop

QTest Elite 2/L 2 KN (450 lbf.) Tabletop

QTest Elite 5 5 KN (1,125 lbf.) Tabletop



QTest Elite 10 LP 10 KN (2,250 lbf.) Floor Standing



QTest Elite 100 100 KN (22,500 lbf.) Floor Standing

QTest Elite 150 150 KN (33,700 lbf.) Floor Standing

QTest Elite MultiHead 50 KN (11,250 lbf.) Floor Standing


Description

Introduction14

Description

General description QTest Elite Testing Frames are comprised of a one or two-column load frame and the latest MTS high precision, solid-state electronic frame controller. The followg figure shows the external features of a typical MTS QTest Elite System load frame.

Upper Limit

Crosshead

Lower Limit

Base Adapter

Emergency Stop

Upper Limit Switch

Lower Limit Switch

Controller Connections

Front Rear

Description


System performance The PC that you have chosen is an integral part of the system. It runs the MTS software that provides full machine control, data acquisition and management, and advanced data analysis and presentation. MTS has minimized the amount of custom electronics in your system, making it flexible and reliable as possible. This is done by connecting the frame (through the port on the controller designated for the computer) and the computer ECP port with an IEEE 1284 cable.

The basic load frame has a rectangular shape and includes a base unit, two vertical columns, and a fixed upper transverse member. A base adapter is attached to the top section of the base unit. A moving crosshead, guided by vertical rods, is located between the base and upper transverse member. The moving crosshead is driven by precision ballscrew(s) on the load frame. The crosshead is coupled to the ballscrew(s) with high strength, precision ball nuts and actually rides on the ball bearings that are very efficient in minimizing friction and wear.

The screws are driven by a series of pulleys and belts coupled by a direct drive system, which in turn is driven by a low inertia brushless servo motor. The motor is equipped with resolver feedback for precise velocity and position control.

The QTest Elite is controlled by MTS’s latest high-precision electronics – (see the folowing figure). The controller is separate from the machine which assists in troubleshooting and repair. It is contained in a smaller rectangular box with cables for connection to the load frame.


Description

Introduction16

��

��

��

��

��

�

Handset Connection

Circuit Breaker

Computer Connection

Elite Controller

Crosshead Load Channel Connection

AC Power Inlet

Frame, Motor, Resolver, and E-Stop Connection

Specifications


Specifications

Specifications for individual QTest Elite System Series

Parameter Specification

Maximum load range

QTest Elite 1/L

QTest Elite 2/L

QTest Elite 5

QTest Elite 10

QTest Elite 25

QTest Elite 10 LP

QTest Elite 25 LP

QTest Elite 50 LP

QTest Elite 100

QTest Elite 150

QTest Elite MultiHead

1 KN (225 lbf.)

2 KN (450 lbf.)

5 KN (1,125 lbf.)

10 KN (2,250 lbf.)

25 KN (5,625 lbf.)

10 KN (2,250 lbf.)

25 KN (5,625 lbf.)

50 KN (11,250 lbf.)

100 KN (22,500 lbf.)

150 KN (33,700 lbf.)

50 KN (11,250 lbf.)

Crosshead speed

QTest Elite 1/L and 2/L

QTest 5, 10, and 25

QTest 10 LP, 25 LP, and 50 LP

QTest 100 and 150


Force capacity at max speed

Speed selection

Min. 0.05 mm (0.002 in/min)Max. 1,016 mm/min (40 in/min)Return Speed: 1,016 mm/min (40 in/min)

Min.0.025 mm (0.001 in/min)Max. 1,016 mm/min (40 in/min)Return Speed: 1,016 mm/min (40 in/min)

Min. 0.01 mm (0.0004 in/min)Max. 508 mm/min (20 in/min)Return Speed: 508 mm/min (20 in/min)

Min. 0.005 mm (0.0002 in/min)Max. 508 mm/min (20 in/min)Return Speed: 508 mm/min (20 in/min)

Please consult your local sales representative for information.

100% capacity

Continuously variable via software


Specifications

Introduction18

Crosshead Travel


QTest Elite 5, 10, and 25

QTest Elite 10 LP, 25 LP, and 50 LP

QTest Elite 100 and 150


1,016 mm (40 in.)

1,016 mm (40 in.)

1,219 mm (48 in.)

1,219 mm (48 in.)

1,219 mm (48 in.)

Encoder Position Resolution



QTest Elite 10, 25, and 50 LP



0.3 µm (12 µin.)

0.2 µm (8 µin.)

0.1 µm (4 µin.)

0.04 µm (2 µin.)

0.1 µm (4 µin.)

Power Requirements

Voltage*

Frequency

Power

120 or 220 - 230 VAC, single phase

47 - 63 Hz

1.6 kVA

Overall dimensions

Height

Width

Depth

Width between columns

1,753 mm (69 in); 2,253 mm (89 in) - Tall Option

812 mm (32 in)

711 mm (28 in)

425 mm (16.75 in)

Environmental specifications for

frame operation (for indoor use only)

Temperature

Relative Humidity

Altitude

5-40º C (41-104º F)

20 to 80%, non-condensing from 5 to 31º C (41 to 88º F)

Up to 2,000 m (6,500 ft.)

* This specification allows for a variation of up to ± 10% from the values stated


Specifications


Dimensions and weights


Control Box (used with all frames)

Height

Width

Depth

Weight

540 mm (21.3 in.)

280 mm (11.0 in.)

630 mm (24.8 in.)

23 kg (50 lbs.)


Height

Width

Depth

Front to Back Clearance

Weight

1,524 mm (60.0 in.)

356 mm (14.0 in.)

356 mm (14.0 in.)

63.5 mm (2.5 in.)

41 kg (90 lbs.)


Height

Width

Depth

Width between Columns

Weight

1,702 mm (67 in.)

661 mm (26 in.)

508 mm (20 in.)

406 mm (16 in.)

109 kg (240 lbs.)

QTest Elite 10 LP, 25 LP, 50 LP, and

Multi-Head

Height

Width

Depth


Weight

2,387 mm (94 in.)

1,066 mm (42 in.)

584 mm (23 in.)

762 mm (30 in.)

449 kg (990 lbs.)


Height

Width

Depth


Weight

2,336 mm (92 in.)

965 mm (38 in.)

660 mm (26 in.)

558 mm (22 in.)

676 kg (1,490 lbs.)


Specifications

Introduction20

Crosshead detail

Note Crosshead detail varies depending upon frame type.

Tabletop Details

��

��

��

��

��

��

��

��

QTest Materials Test Systems Installation 21

Installation

This section is a guide to help you install your MTS QTest Elite Material Testing Workstation.

Note If the machine is to be shipped from one site to another, it must be transported by AIR RIDE VAN.

Important Unless otherwise specified, it is your responsibility to off-

load and move the equipment to the final location on your

premises. This includes insurance and safety

responsibilities.

Initial off-loading andmoving of QTest

System

Before moving the machine from the receiving area to its final location, be sure to check the dimensions of all doors and passages through which the machine will travel. Please refer to the specifications section of this manual for system dimensions.

If the machine is being relocated for installation at a different site, all load cells, extensometers, and additional accessories should be removed and packed separately.

Location andventilation

The control box can be placed on the floor next to or behind a floor-standing machine, or beneath a tabletop machine. The box should be positioned so that the circuit breaker located on the back panel is accessible.

Ventilation holes are present in the top and bottom of the control enclosure. Do not block either of these openings during use.

For comfortable working conditions and proper equipment operation, heat dis-sipation of the equipment must be considered in providing adequate heating or air conditioning in the laboratory area. Heat dissipation may be approximated by summing the heat losses going into a room (1 kVA is equivalent to 860 kcal/hr [3400 Btu/hr] ) and the gains from other sources such as furnaces and personnel.

QTest Materials Test SystemsInstallation22

Moving the QTestframes

Very heavy equipment! Movement and positioning should be performed by qualified personnel only. Machine weight varies. Please review weight specifications. The pallet, packaging, and accessories add to make the total palletized weight as much as 680 kg (1,500 lbs.). If you have any questions, please contact MTS at 1-800-328-2255.

Moving the palletizedmachine

Pallet jacks rated at 900 kg (2,000 lbs.) or proper fork trucks can be used.

The machine should not be moved by its pallet without the metal stapping firmly in place. Due to the height of the machine and the configuration of the pallet, caution should be used to prevent tip-over type accidents while transporting the palletized machine.

If you choose to move the palletized frame by lifting the machine instead of moving it by pallet, you should use only the correct lifting methods listed below.

• By padded forks under the crosshead.

• By padded strapping around the crosshead (to prevent crosshead and/or label damage).

The load frame may be irreparably damaged if lifted by the incorrect lifting methods listed below.

• DO NOT LIFT by the top plate that joins the ends of the ball screws and extrusions.

• DO NOT LIFT machine by the extrusions (the weight of the machine will damage the extrusions).

• DO NOT LIFT by the ball screws (under the bellows).

• DO NOT LIFT by the base unless the frame is resting on a pallet.

��

��

��


Connection to thesupply

Possible shock hazard. If an outlet of the appropriate type is not available, contact a qualified electrician to make the connection.

All the QTest products require a ground connection for safe operation. The unit is supplied with a detachable 3-conductor power cord, and must be connected to a 3-conductor grounded outlet. The equipment voltage and rating is marked on the outside of the enclosure.

The operating voltage of the QTest is not user-selectable. Contact technical support for assistance if a voltage change is necessary.

In North America for 120V operation, the cord will be equipped with 3-prong plug (NEMA 5-15P). To ensure proper grounding, only connect to a properly grounded receptacle (NEMA 5-15R).

In North America for 220V operation, the cord will be equipped with a 3-prong twist-lock plug (NEMA L6-20P). This plug must be used with a matching locking receptacle (NEMA L6-20R) to ensure proper grounding. If you do not have a receptacle of this type available, contact a qualified electrician to make the connection.

In Europe for 230V operation, the cord will be equipped with a plug of type CEE 7/7 (Schuko). If you do not have a mating receptacle available, contact a qualified electrician to make the connection.

Power cords for other countries are available upon request.

The QTest has an IEC 60320 C20 appliance inlet. The inlet connector configuration is shown below.

��

� �


External earthconnection

The QTest systems have an additional ground connection on the rear of the enclosure. This must be connected to a low-impedance ground for proper EMC performance.

Cable installation

System power must be off while attaching cables, otherwise damage to equipment may result.

Your system will be installed by an MTS representative. The intent of this section is to describe to the user how the QTest system is integrated with their existing material testing equipment. Be sure all cable connections are tight and double-check your work before powering-up the system.

The Emergency Stop switch must be connected and functional. Never disable the Emergency Stop switch. Serious injury or death may result.

Exercise care when connecting cables. Be sure that you are using the correct cables and that all connections are secure. When you are finished, double check to be sure that all components are connected properly. See Figure 3-1 on the next page.

��

��


QTest systemconnections

��

��

��

��

�

��

1

2

Cable Description MTS Part #

1 IEEE 1284 Cable 100-079-273

2 E-Stop Cable 100-086-514


��

� � �

�� !��"#$��%&'� ��%(��)%**�' ��%+*��)%**�'

�*%'�,��-

�%*(-��

��

��

� � �

� .

�� !��"#$��%&'�

��%(��)%**�' ��%+*�� $�*%'�,��-�%*(-��

��%+*�.� ��$��%+*�� $+,+�%'�!*��/��

Basic Controller

Basic Controller with Expansion Board


Controller board Note The rear panel of your Elite controller has 6 cable ports.

1. One 25-pin D-sub connector for a strain channel (DC analog input, self-ID, digital input/output).

2. One 25-pin D-sub connector for interfacing computer and controller (cable 1 above).

3. Two BNC analog outputs.

4. One 25-pin connector for a load channel.

5. One J-connector for manual handset controller (RS-232).

Controller box 1. One 20-pin Circular Amphenol connector for motor feedback.

2. One 5-pin Circular Amphenol connector for motor power.

3. One 9-pin D-sub connector for Emergency Stop (cable 2 above).

To connect the cables You must use the correct cables for each connection.

1. Use the 25-pin connector on both ends of the cable (IEEE 1284 cable), to connect the parallel port on the computer to the frame (port designated by a picture of a computer).

2. Connect the 5-pin Circular Amphenol connector for motor power from the control box to the frame.

3. Connect the 20-pin Circular Amphenol connector for motor feedback from the control box to the frame.

4. Use the 9-pin connector on both ends to connect from the Control Box to the frame.

5. If you are using an extensometer, use an extensometer cable (a long cable with a 25-pin connector on one end and a 5-pin circular connector on the other) to connect it to Strain 1 channel on the frame. If you are using a second extensometer, then connect it to the Strain 2 channel.

6. Attach buffered inputs/outputs to the BNC connectors on the frame.


Control card removaland installation

The control card is located in the control box. The controller is responsible for A/D conversion of load and strain signals, servo control, and detecting limit switch activation. Should you be instructed to replace it, follow the steps below.

Disconnect the control box from the AC power before proceeding. Electric shock or equipment damage may result.

1. Remove the 6 screws attaching the controller plate to the side of the frame.

2. Slide the casing out of the side - disconnect the 50-conductor ribbon cable - the 8-pin power supply cable.

3. Reattach the cables in the proper ports on the new controller and reinsert the casing.

��

QTest Materials Test Systems Operation 29

Operation

Main ON/OFF switch The main power switch for the machine is on the manual handset (see “Manual handset control”). Wait approximately 5 seconds the first time the frame is powered up before pressing the ON button. This allows the electronics to warm up. The frame is also equipped with an Emergency Stop button and a circuit breaker switch (in the rear of the machine). The Emergency Stop will cut the power to the whole system and is used for emergency purposes only.

Handset Operation

Manual handsetcontrol

��

��+-�'%0

�)��&�1)��'

��-�

��%��-�

�%�-��-�

��%��*��%��22

��--)�%(��*

��--)�%(��1*

��--)�%(��

��,�%��%&'��*3�+�*��*-

��-�'��+(�'%0��3��''��*��-��4-�#��,�%��%&'��#��-�'�-��"�3)%�%3��-�'�*,

QTest Materials Test SystemsOperation30

Handset functions The Manual Control Handset is the main ON/OFF switch for the frame and provides a quick and easy way to control the machine for setting up fixturing, repositioning the crosshead, adjusting for different specimen sizes, or executing a test function.

Note Refer to the individual applications section to determine when each button is active.

Handset Controls (part 1 of 2)

Item Description

Crosshead Up - moves the crosshead in the upward direction while pressed.

Crosshead Down - moves the crosshead in the downward direction while pressed. The speed and mode are controlled by TestWorks 4 software if TestWorks 4 software is active.

Crosshead Return - returns the crosshead to the original position (zero point). Applies only if TestWorks 4 software is active.

Power Off - turns the power off to the frame. (Press the button for approximately 1 second. This eliminates the possibility of turning the power off when a test is running).

Power On - turns the power on to the frame. (Wait approximately 5 seconds for the initial power up of the frame. Afterwards, just press the button to power-up the frame).

Pause - pauses the test action. This must be pressed again for the test to resume. Applies only if TestWorks 4 software is active


Start - starts the test action. Applies only if TestWorks 4 software is active.

Stop - stops the test action.

Thumb-wheel - makes a fine crosshead adjustment (clockwise – up; counterclockwise – down).

See the TestWorks 4 software manual for more information on these functions:

Result Display - an option that is setup in the software which allows you to view up to four results on the LCD Display (two rows, eight characters long) at the end of a test.

F1 and F2 - programmable functions that are setup in the software as digital inputs. This allows you to define the test function (that is, start test, pause, hold position, and so forth).

Handset Controls (part 2 of 2)

Item Description

��

��


Safety Symbols

These symbols are present on the “exterior” of the testing system.

Item Description

Caution or Warning - refer to manual for description of hazard.

High Force Moving Parts - can cause severe injury or equipment damage. Stay clear of moving parts while using machine.

Wear Eye Protection - stay clear and use eye protection while test is in progress.


These symbols are present “inside” the testing system enclosure.

Item Description

Caution or Warning - refer to manual for description of hazard.

Hazardous Voltage - contact with live components may cause shock or burn. Disconnect system from main power before servicing.

Moving parts can crush or cut. Do not operate the system with covers removed. Disconnect system from main power before servicing.

Safety ground connection.

Caution. Hot surface.


Travel limit switches (Physical limits)

The limit switches are located on the crosshead. They are normally closed (designated by a green light – fail safe mode) and are activated when the adjustable limit comes in contact with the limit switch. The limit can be positioned anywhere along the extrusion to prevent the crosshead from traveling beyond that point.

Always adjust the limits whenever you change grips or fixtures.

Damage to equipment or personal injury may result.

When a physical limit is reached there are three ways to get the crosshead moving again:

• Utilize 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 TestWorks 4 software manual for further details.

• Manually move the adjustable limit along the guide column away from the crosshead until the limit switch is no longer active.

• Use the manual handset control to move the crosshead until the limit switch is no longer active.

��


Load cell mounting

MTS offers a wide range of precision, self-ID tension/compression load cells for the QTest Elite frames. Load cells range in size and force capacity from .5 N to 100 KN. Self-ID load cells are automatically recognized by the software, enabling the user to switch without manual software input. The following figure shows the anti-rotational load cell mounting with grip adapter. Please contact your Sales Engineer for assistance in selecting the proper load cell.

�+*

5�+��(%��'�

5�+��(%��

��%(��''

��--)�%(

�*�+��%�+�*��*�+*,��'%��

��--)�%(��'�


External Connections

Applications Following are some typical ways the external connections can be used.

• applicationsDrivehead/Carriage motion limits

• Auxiliary limits

• Grip closure detect

• Calibration relay control

• Preamp gain select

• Grip control

• Auxiliary sensors (LVDT’s, etc.)

• Auxiliary instrumentation (extensometers, etc.)

Channel ConnectorFunctions

The follwing table lists the connectors and their functions.

Connector J1 J2 J3 J4

Function Auxiliary Load Strain 1 Strain 2 Strain 3

Analog Input Yes Yes Yes Yes

Shunt Cal Yes Yes Yes Yes

Sensor Excitation DC DC DC AC

±15V, +5V DC Supplies Yes Yes Yes Yes

Self-ID Yes Yes Yes Yes

Quadrature Input N/A If no ballscrew encoder Yes Yes

2 Digital Inputs N/A Yes Yes Yes

2 Digital Inputs N/A Yes Yes Yes

Debugging RS-232 N/A Yes N/A N/A


External Channel PinDefinitions

The following illustration shows the pin definitions for load and strain channels.

Pins 1-3 and 14-16 forsensor use

ANA IN- (1) and ANAIN+ (14)

These pins are the analog ±V in from the sensor. The signal is tied directly to the pre-gain amp, then routed to the channel gain amp. The signal is converted into a differential signal, which is then fed directly to the A/D. Maximum input voltage is ±10V.

ANA EXC- (2) and ANAEXC+ (15)

These are the excitation voltage ± for the sensor. Excitation is 2.5V, 5V or 10V selectable and the maximum output current is 250mA. The strain 3 connector (J4) provides AC excitation for LVDT’s. Excitation frequency is 1, 2.5, and 5 kHz selectable.

ANA CAL SHUNT (3) andANA EXC SENSE (16)

ANA EXC SENSE is tied to EXC+ on the sensor end. When the cal shunt is activated, excitation is routed in through ANA EXC SENSE, through the cal relay, and out ANA CAL SHUNT to the cal resistor in the sensor.

�

�

.

#

6

7

8

"

9

��

��

��

�.

�#

�6

�7

�8

�"

�9

��

��

��

�.

�#

�6

�6��!��

�

�

.

#

6

7

8

"

9

��

��

��

�.

�#

�6

�7

�8

�"

�9

��

��

��

�.

�#

�6

�6��!��

ANA IN -ANA IN +ANA EXC -ANA EXC +ANA CAL SHUNTANA EXC SENSE

-15 V ANA GROUND

+15 V

+5 V DIG GROUND

DIG IN1DIG IN2DIG OUT1DIG OUT2

ANA IN -ANA IN +ANA EXC -ANA EXC +ANA CAL SHUNTANA EXC SENSE

-15 V ANA GROUND

+15 V

+5 V DIG GROUND

DIG IN1DIG IN2DIG OUT1DIG OUT2

QAQB

Aux Load Strain 1, 2, 3


Pins 8, 9, 21, 22 are thedigital I/O’s

DIG IN1 (8) and DIG IN2(21)

DIG IN1 and 2 are optically isolated active low inputs. Active low means that a “logical 0” or 0V must be applied to the input to make it “active.” The DIG IN’s have a maximum input voltage of 5V dc.

DIG OUT1 (9) and DIGOUT (22)

DIG OUT1 and 2 are active low outputs. When activated, the DIG OUT’s go low (0v). The DIG OUT’s can sink/source around 3 amps depending on temperature.

Pins 7 and 20 are thequadrature inputs

CH2X QA (7) CH2X QB(20)

CH2X QA and CH2X QB are quadrature inputs. This can be any encoder that outputs quadrature. The most common example is the use of the DX2000. The maximum quadrature frequency is 2 MHz.

Remaining power andground connections

Pin 4: -15vPin 5: +15vPin 6: +5vPin 7: NC (J1 and J11)Pin 10: NC (J1 and J11)Pin 13: NCPin 17: Analog groundPin 19: Digital groundPin 20: NC (J1 and J11)Pin 23: NC (J1 and J11)


Pin Definitions for User Digital I/O

On expansion board(J5 Connector)

Digital inputspecifications

• Fully opto-isolated differential input• Differential voltage for “On” state is minimum 2.5V, maximum 28V• Input current maximum 15mA at 28V

Digital outputspecifications

• Fully opto-isloated output• Maximum current 20 mA• Maximum voltage 28 VDC

User Digital I/O PinDefinitions

.8��!��

�

�

.

#

6

7

8

"

9

��

��

��

�.

�#

�6

�7

�8

�"

�9

��

��

��

�.

�#

�6

�7

�8

�"

�9

.�

.�

.�

..

.#

.6

.7

.8 DIG IN 1H+5 V

DIG IN 1L

DIG OUT 1HDIG OUT 1L

DIG IN 2H+5 V

DIG IN 2L


DIG IN 3H+5 V

DIG IN 3L


DIG IN 4H+5 V

DIG IN 4L



Digital Input Examples Note Pinout shown is for Dig In bit #1.

Digital Output Example Note Pinout shown is for Dig Out bit #1.

�9

�8

�"

.8

5�

:6��

Switch Input

�"

.8:6��

��

Logic Level Input

�7

.6:6��:�#��

Relay Output Logic Level Output

�7

.6

:6��

��

� �

QTest Materials Test Systems Maintenance and Repair 41

Maintenance and Repair

Disconnect the power cord from the wall outlet before cleaning or

lubricating any part of the test frame. Regular maintenance is needed to

prolong the life of your frame and keep it performing optimally.

Monthly machine/frame maintenance

1. Check the inside of the frame for the following:

A. The fan is free of all material and spins easily with no noise.

B. The filters on the vent and fan are free from dust.

C. There is no grease on the ballscrew pulleys and/or belts.

D. There are no liquid spills or testing debris in the machine.

E. The belts do not show excessive wear.

2. Clean the debris from under and around the testing frame.

3. Wipe down the rubber protective mat with a mild detergent.

4. Check for loose cable connections and tighten any that are found to be loose.

5. Make sure all system covers are back in place after the above checks. Reconnect the power cord in the outlet and power up the test frame. Next - verify the Emergency Stop button is functioning properly.

6. Test the limit switches by manually moving the adjustable limits.A limit switch fault should be indicated on the computer screen.

��

QTest Materials Test SystemsMaintenance and Repair42

Semiannualmaintenance

1. Remove system covers and vacuum or blow out any dust or debris from inside the test frame.

2. Grease ballscrews at the crosshead fittings—use # 2 hardness white lithium grease available from MTS (Lubriplate No. 1200-2 multipurpose grease).

3. Verify speed and position accuracy of the frame. Refer to the TestWorks 4 software manual for further details.

Note MTS offers annual maintenance and calibration plans. It is strongly recommended that you enroll in one of these plans. Contact your sales engineer for more information.

General cleaning Clean your machine as often as needed. Use a mild detergent or cleaning fluid to wash the extrusions, base, crosshead, and rubber mat. Keep the rubber mats free of sharp debris, oil, or chemicals which might damage the rubber.

QTest Materials Test Systems Troubleshooting Guide 43

Troubleshooting Guide

Use this chapter to identify mechanical and electronic problems with your QTest testing system. If you need additional assistance, see “Technical Support” on page 9.

Symptom Possible Cause

Crosshead will not move • Load frame is not powered up (Limit switches on the crosshead are not lit up red and/or the handset LCD is not on).

• One or both of the physical limits are tripped.

• Line voltage is too low or too high.

• If the crosshead moves with the handset:

– Computer/frame interface cable is loose or improperly connected.

– Improper machine parameters. Contact the MTS HELPLine for further assistance.

• If the crosshead does not move with the handset:

– Unplug the handset and then reconnect it.

– Frame is in fault condition. Cycle the power to the frame.

– Other problem(s) with the test frame. Contact the MTS HELPLine for further assistance.

Crosshead moves in only

one direction

• One of the physical limits is activated.

Crosshead always moves

at maximum speed

• Controller not receiving position feedback. Contact the MTS HELPLine for further assistance.

• Check the cables between the motor and the servo amp.

Crosshead stops beyond

where it should have

• Incorrect machine parameters. Contact the MTS HELPLine.

QTest Materials Test SystemsTroubleshooting Guide44

Crosshead will not stop • Servo is improperly connected.

• Improper machine parameters. Contact the MTS HELPLine for further assistance.

• Controller error. Contact the MTS HELPLine for further assistance.

Limit is always active —

cannot clear

• Proximity limit switch on the crosshead is obstructed.

• Limit switch is defective. Contact the MTS HELPLine for further assistance.

• Mongoose controller limit switch circuitry is malfunctioning. Contact the MTS HELPLine for further assistance.

Limit switches not

functioning

• Defective limit switch. Same as above. DANGER — DO NOT RUN MACHINE! Contact the MTS HELPLine for further assistance.

Will not pull rated

maximum load

• Defective servocontroller. Contact the MTS HELPLine for further assistance.

• Load cell is not calibrated.

Improper machine

parameters

• Contact the MTS HELPLine for further assistance.

Load cell will not calibrate • Load cell is not connected.

• Defective load cell.

• You are attempting to automatically calibrate a non-MTS load cell. These must be manually calibrated.

• Improper calibration information being used. Check the load cell information in the testing software.

Load cell amplifier

defective

• Contact the MTS HELPLine for further assistance.

Load plateaus • Defective load cell.

Unusual noise • Grinding sound indicating that a moving part is rubbing. Lubrication is needed. Inspect belt and screw bearings. Contact the MTS HELPLine for further assistance.

• Debris caught in the cooling fan.

Symptom Possible Cause

mMTS Systems Corporation14000 Technology DriveEden Prairie, Minnesota 55344-2290 USAToll Free Phone: 800-328-2255

(within the U.S. or Canada)Phone: 952-937-4000

(outside the U.S. or Canada)Fax: 952-937-4515E-mail: [email protected]://www.mts.com

ISO 9001 Certified QMS

QTest Technical Reference - Auburn...

Documents

Transcript of QTest Technical Reference - Auburn...