INSTRUCTION MANUAL. for LANSMONT VIBRATION TEST SYSTEMS

Transcription

1 VIBRATION TEST SYSTEMS INSTRUCTION MANUAL for LANSMONT VIBRATION TEST SYSTEMS LANSMONT CORPORATION 17 Mandeville Court Monterey, CA (831) FAX (831) Rev 2 (file: 70801a.doc)

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3 Table of Contents SPECIFICATIONS... 1 SPECIFICATIONS... 2 SAFETY... 3 RESIDUAL RISKS... 4 EMERGENCY SITUATIONS... 4 RECEIPT AND INSTALLATION... 5 RECEIPT... 5 SITE PREPARATION... 5 BOLTING DOWN THE MACHINE... 5 Seismic Base Version... 5 Special Foundation Version... 5 HYDRAULIC POWER SUPPLY... 5 INTERCONNECTION... 6 Hydraulics and Controls:... 6 Water:... 6 Plant Air:... 6 Electrical Power: Interface Box... 6 Electrical Power: HPS... 6 Instrumentation... 7 INITIAL START UP... 7 Checking Rotational Direction of HPS Motor... 7 DE-COMMISSIONING... 7 BASIC MACHINE DESCRIPTION... 7 TABLE... 7 ACTUATOR... 8 HYDRAULIC POWER SUPPLY... 8 Electric Motor with Starter... 8 Shaft Coupling... 8 Pump... 8 Inlet (Suction) Filter... 8 Check Valve... 8 Relief Valve... 9 Vent Valve... 9 Accumulator... 9 High Pressure Filter... 9 Pressure Gauge... 9 Heat Exchanger... 9 Water Solenoid Valve... 9 Reservoir... 9 Temperature Switch... 9 Fluid Level Switch... 9 Backflow Control Valve... 9 HPS Hour Meter... 9 CONTROLS OPTIONAL SEISMIC BASE OPTIONAL 1-G SUPPORTS... 10

4 OPTIONAL STROBOSCOPE SETUP LOADING THE TEST SPECIMEN OPTIONAL 1-G SUPPORT SETUP OPTIONAL STROBOSCOPE SETUP CHARGE AMPLIFIERS (OPTIONAL) OPERATION OPTIONAL STROBOSCOPE OPERATION MAINTENANCE GENERAL HYDRAULIC POWER SUPPLY Observation Filter Oil Accumulator Fittings and Fasteners ACTUATOR Piston Rod Servovalve Drainback Flow HYDRAULIC POWER SUPPLY (HPS) OIL CHANGES ADJUSTMENTS HYDRAULIC POWER SUPPLY G SUPPORT CONTROL VALVE TROUBLESHOOTING COMPONENT MANUALS AND DATA SHEETS COMPONENT MANUALS AND DATA SHEETS... 18

5 Specifications LANSMONT MODEL 6000 VIBRATION TEST MACHINE Table Size: Table Weight: 36 inch square High Performance Magnesium Casting, 3/8-16UNC inserts, 6 inch grid 400 lb. (181 kg) Hydraulic Actuator: Pressure Rating: 3,000 psi max. (211 kg/cm 2 ) Stall 2,500 psi Normal Operating Pressure: 6,160 lb. (2,794 kg) Resisting Moment: 14,546 in.-lb. (16,758 cm-kg) Stroke: 6 in. (15.2 cm) peak to peak Piston Weight: Fluid Compatibility: Mechanical Connections: Piston to Table: Actuator to Base: 85 lb. (38.6 kg) MIL STD 5606 or petroleum-based hydraulic fluid Piston rigidly bolted to table through adapter ring (6 ea. 5/8-18 socket head bolts) Actuator assembly held to base by eight high strength bolts (5/8-18) Electrical Connections: DCDT (Position Feedback): Differential Pressure: Servo Valve: Dimensions: 6 Pin Male (MS3106A-14S-6P) 4 Pin Male (PT06AC8-4S) 4 Pin Male(MS3106A-14S-2P) in. high x 10 in. dia. (74.6 cm x 25.4 cm) Hydraulic Power Supply: Pressure Rating: 2,500 psi (176 kg/cm 2 ) max. Normal Operating Pressure: 2,000 psi (141 kg/cm 2 ) Flow Rate: 52 gpm (236 l/min.) nominal Filtration β 2 = 200 Recommended Fluids: Any high-quality petroleum-based hydraulic fluid can be used but it must have a basic viscosity of SUS at 100 F Shell Tellus 46 Mobil DTE 25 Sun Sunvis 921 Chevron EP-9 Fluid Capacity: 275 gallons (208 liters) Accumulator Pre-Charge: 1,500 psi (106 kg/cm 2 ) Motor: Utility Requirements: Power: Cooling Water: Flow Rate: 75 HP (14.9kW), 1800 RPM 460 VAC, 3 Phase, 75 amp 10 psi (0.7 kg/cm 2 ) minimum pressure 17 gpm (18.9 l/min.) at 60 F (15.6 C) or 25 gpm (28.4 l/min) at 75 F (23.9 C) SPECIFICATIONS 6000 VIBRATION TEST SYSTEM - 1 Rev 1a, file (70310a.doc)

6 Connections: Mechanical: Electrical: Power: Control: JIC 37º male for hydraulic lines: 2 ea (Parker) 1 ea (Parker) Garden hose fittings for cooling water: 1 ea. 71GH ea. 83 GH phase conduit connector 7 Pin Male (MS3102A-16S-1P) Seismic Base: Weight: 8,000 lb. (3,629 kg) Noise 1 m from the machine an 1.6 m from the ground: <75 dba Permissible Environmental Conditions: Temperature: >55 F (12.8 C) Relative Humidity: <90% Atmospheric Conditions: suitable for human exposure (i.e., non-toxic, non-explosive, etc.) Reference Drawing Numbers: Assembly, Main, 6000 Vib Assembly, Actuator, 6000 Vib Wiring, Actuator Wiring, HPS Assy, Servo Valve Assy, Power Unit, 75 Hp Table Assy, Seismic, 8000 lbs Assy, Controls Assy, Chassis Assy, Cntl, Pwr Amp Assy, Cover, Garolite Cover, Garolite, 36 X 36 SPECIFICATIONS 6000 VIBRATION TEST SYSTEM - 2 Rev 1a, file (70310a.doc)

7 VIBRATION TEST SYSTEMS Introduction The Lansmont Vibration Test System is an electrohydraulic machine intended for the vibration testing of products and packages. The machine can produce sinusoidal and random vibrational motions. Lansmont offers Vibration Test Systems equipped with either Lansmont s exclusive TouchTest Controls or Dactron s Shaker Control System. Options for the Vibration Test System include: A Seismic Base, used to isolate large vibrational forces from the surroundings. A 1-G Support System, used to achieve greater performance and higher permissible test weights. Vibration Stacking Fixtures, used when performing column stack tests to prevent test specimens from walking off the table. Hold Down Fixtures, used to mount test specimens on the table. Specimen Response Instrumentation. The Vibration Test System is supplied with either TouchTest Controls or a Dactron Shaker Control System. The TouchTest controls are Windows based and are presented through Online Help and Instruction. The Dactron controls are presented in a separate instruction manual entitled Dactron Shaker Control System User s Manual. A Stroboscope, used to assist observation of items being tested. Safety CAUTION: This testing machine is capable of producing over several thousands of pounds of force. See the specification sheets for specific force capacity. The hydraulic power supply (HPS) contains rotating components, high dangerous voltages, and components under high pressure [2000 psi (141 kg/cm 2 )]. Dangerous voltage (AC line voltage) appears at several locations inside the control interface and hydraulic power supply, even with the system Power switch OFF. The following are Do s and Do Not s for safe operation of the Lansmont Vibration Test System Vibration System. Taking precedence over any specific rule here, however, is the most important rule of all USE COMMON SENSE. Reading these rules can make the operator aware of dangerous practices to avoid and precautions to take for his own safety and the safety of others. Frequent examinations and periodic inspections of the equipment as well as a conscientious observance of safety rules may save lives as well as time and money. 1. DO read this manual and the following manuals prior to handling, installing and operating the machinery: HPS Hydraulic Systems Information, Instructions and Parts manual, and the control manuals (Dactron Shaker Control System User Manual or TouchTest instruction available through the Help menu). 2. DO be familiar with operating controls and procedures described in these manuals. 3. DO be cautious when observing specimens undergoing testing, as unexpected and dangerous motions can occur. 4. DO unplug the Control System and disconnect 3-phase power to the HPS before removing any covers or working on any of the components. 5. DO be extremely careful to ensure cleanliness during installation, start up, and use as hydraulic servo systems are sensitive to fluid contamination. 6. DO promptly report any malfunction, unusual performance, or damage of the vibration system. VIBRATION TEST SYSTEMS - 3

8 VIBRATION TEST SYSTEMS 7. DO inspect the system regularly, tighten any loose fittings, and keep appropriate records of maintenance. 8. DO NOT place any body part underneath the table or near the piston rod when the system is in operation. 9. DO NOT test objects which may shatter, fragment, implode, explode, or otherwise be hazardous upon failure or during testing unless the objects are suitably enclosed or contained. 10. DO NOT remove the cover of the HPS and attempt to work on it unless you are thoroughly familiar with electrical, mechanical, and hydraulic systems. 11. DO NOT operate the system without the bellows cover in place (optional, required for European models). 12. DO NOT operate the system if it is damaged or not working correctly. 13. DO NOT sit on the table or the seismic base when the system is in operation. 14. DO NOT adjust or repair the machine unless qualified to perform system maintenance. Residual Risks Despite the safety measures incorporated in the vibration system, there still exists the possibility for injury. When the System Protective Interlock in the TouchTest Electronics engages, the system undergoes immediate shutdown. This may cause the table to bounce before coming to a complete stop because the accumulator will still be charged. The test specimen may be jarred off the table and if there is someone in the vicinity of the table, the sudden motion could be injurious. Using the wrong utilities (i.e., incorrect voltage, excessive plant air pressure, etc.) may result not only in poor machine performance but damage to the system as well. Failure to follow operating instructions documented in this manual and the TouchTest Controller manual may lead to potentially hazardous situations. Emergency Situations Except as noted below, standard emergency procedures are acceptable in dealing with emergency situations. In the event of a hydraulic fluid leak, the following procedure should be followed: 1. Turn POWER OFF. 2. The hydraulic fluid is presumed to be practically non-irritating, however the following first-aid procedures should be followed: a. Eye Contact flush eyes with water. b. Skin Contact remove contaminated clothing, wipe excess from skin, flush skin with water, then wash with soap and water. 3. Soak up spill with an absorbent material and dispose of according to local regulations. In the event of a fire caused by the ignition of hydraulic fluid, the following measures should be followed: 1. Use water fog, foam, dry chemical or carbon dioxide to extinguish the fire. 2. Do not use a direct stream of water as the product can be re-ignited on the surface of the water. For more information on safety and emergency procedures, read the Material Safety Data Sheets for hydraulic oil provided with this manual. VIBRATION TEST SYSTEMS - 4 -

9 VIBRATION TEST SYSTEMS Receipt and Installation Receipt The system is normally shipped in a fully assembled condition. Upon receipt, the equipment should be carefully inspected for damage. If damage has occurred, it should be noted on the shipping papers and a claim should immediately be placed with the transportation company. Lansmont Corporation will furnish an estimate of the cost of repairs if photographs and descriptions of the damaged areas are provided. Site Preparation The machine must be located on the ground level floor. The seismic base version is designed to mount on a concrete floor with a minimum thickness of 4 in. (10.2 cm). The foundation version is designed to mount on a specially designed foundation. The hydraulic power supply (HPS) may be located up to 50 ft. (15 m) away from the actuator and the vibration controls. Be certain that the indicators and gauges are easily accessible for routine monitoring of HPS condition. If the HPS is located in a separate room, insure that sufficient space [at least 3 ft. (0.9 m) on all sides] is provided for maintenance operations. For maximum integrity of the low-level electrical signals the vibration controls should be within 35 ft. (10.7 m) of the actuator/table assembly. Bolting Down the Machine Seismic Base Version The machine can be lifted using a forklift truck. Care should be taken in guiding the forks between the isolation mounts so as not to damage the mounts on the opposite side of the seismic mass. Lift the machine to its final location using a forklift truck or other appropriate handling equipment. Then assemble and attach the seismic base suspension components as shown on the seismic base assembly drawing (be sure to use Loctite brand or equivalent thread-locker on specified bolts). Mark hold-down bolt locations for the isolation mounts and damper assemblies. Move the system aside to drill the floor and install the anchors. When drilling into the concrete, be certain to keep the dust away from the HPS, the actuator, and other critical machine components. The recommended inserts are Hilti HDI concrete anchors manufactured by: HILTI FASTENING SYSTEMS P.O. Box Tulsa, OK Call for the nearest dealer: (800) (918) FAX (800) It will be necessary to remove the isolation mounts from the seismic mass to bolt them to the floor. Then the machine is lowered onto them and bolted down, including the damper assemblies. Special Foundation Version Lift the machine to its final location. Align the actuator base holes over the holes in the foundation plate and secure with the proper bolts. Refer to the foundation drawing. Hydraulic Power Supply The HPS should be placed on a reasonably flat, level surface. Bolting to the floor is not required. Be certain to position the unit for easy viewing of the pressure gauge and thermometer and access to the various adjustments. Leave space [at least 3 ft. (0.9 m) on all sides] for routine maintenance operations. If the HPS is placed in a small room, adequate ventilation must be provided. Normally, the HPS is shipped with its reservoir full of fluid. In this case, a positive seal has been placed in the reservoir s filler/breather assembly for shipment. Before the first operation, it is necessary to remove this seal by VIBRATION TEST SYSTEMS - 5 -

10 VIBRATION TEST SYSTEMS unscrewing the filler/breather attachment screws, discarding the seal, and reinstalling the filler/breather. If the reservoir has been emptied for shipment, the fluid will be contained in one or more drums shipped with the machine. Use a suitable pump, with filtering, to transfer fluid from the drum(s) to the reservoir. Be careful not to introduce any contamination during this transfer operation. Position the HPS as desired. Interconnection Interconnections are shown on drawings supplied with the system. The customer is responsible for the installation and connection of proper utilities. A Lansmont field service engineer will normally do the hydraulic, control, and instrumentation hook-up. Hydraulics and Controls: Three hydraulic connections must be made from the HPS to the system s servo-actuator assembly. 1. Pressure Connection This connection is labeled on the front of the power supply. The fitting must be connected to the pressure port on the right of the actuator s manifold, using the hose provided. Take care not to introduce any contamination. 2. Return Connection This is labeled on the front of the power supply as well. This fitting must be connected to the return port on the left of the actuator s manifold, using the hose provided. Take care not to introduce any contamination. 3. Drainback Connect to the plumbing at the side of the actuator, using the hose provided. Take care not to introduce any contamination. Three control connections must be made from the system s servo-actuator assembly to Lansmont s vibration control interface box: the differential pressure transducer, the servovalve, and the displacement transducer. Another control connection from the HPS to the interface box must also be made. Water: Cooling water must be connected from the facility supply and drain to the two fittings at the front of the power unit. Water temperature should not exceed 75 F (24 C), and pressure should be at least 10 psi (0.7 kg/cm 2 ). The fitting on the manifold of the actuator labeled IN is for the supply line and the fitting labeled OUT is for the drain line. Be certain that the supply and drain lines are not reversed. Plant Air: If the system is equipped with 1-G supports, a plant air source at 80 psi (5.6 kg/cm 2 ) and 0.5 scfm must be installed in the vicinity of the actuator/table/base assembly. A valve, electrically operated from the vibration controls regulates air pressure to the 1-G support reservoirs and airrides. This valve must be mounted on the floor near the machine. Electrical Power: Interface Box Connect the interface box power cord to a 115 VAC, 60 Hz source (220 VAC, 50 Hz optional) which incorporates a fuse or circuit breaker. This source should have a current capacity of at least 20 amps (10 amps for the 220 VAC version) to correspond to the power requirements of the system. To guard against low voltage conditions to the system, avoid light-duty electrical outlets and long or small-gauge extension cords. Electrical Power: HPS The HPS must connect to a power source (see the specification sheet) that incorporates over-current protection and a disconnect power switch. With the power source disconnected, attach the three leads of the facility s 3-phase power to the terminals of the motor starter. Use the 3- phase conduit connector (located on the front of the HPS) or wire directly to the motor starter through its enclosure. VIBRATION TEST SYSTEMS - 6 -

11 VIBRATION TEST SYSTEMS The facility s 3-phase source must incorporate a disconnect power switch and over-current protection. Be certain that the facility voltage matches one of the motor nameplate voltages and that the motor is jumpered correctly. The motor can be severely damaged by attempted operation from the wrong supply voltage (for example, a 460 volt motor may not operate properly from 415 volts). Do not attempt to run the HPS until proper rotational direction has been checked as outlined below. Instrumentation The control accelerometer(s) may be attached to the bottom of the vibration table at prepared locations. Be certain to tape or otherwise fasten the cables out of harm s way. The specimen response accelerometer(s) may be attached as desired to the test item. Again, take care to see that the cables are not damaged as the table and specimen move during vibration. Initial Start Up (This is normally performed by a Lansmont field service engineer.) Checking Rotational Direction of HPS Motor It is important that the HPS motor rotates in the proper direction; the pump will not work properly and can be damaged by prolonged backwards operation. To make this check, first turn power ON. With the cover removed from the HPS, have a helper observe the rotational direction of the motor (look into the top of the motor to see rotation of the cooling fan). Proper direction is clockwise. Momentarily turn the pump on, wait half a second, then turn the pump off. With TouchTest controls, select SYSTEM UTILITIES MANUAL OPERATION HPS MOTOR to start the pump, HPS OFF to stop the pump. With Dactron controls, from the HPS CONTROL PANEL, select HPS START to start the pump, STOP to stop the pump. CAUTION: Do not operate for more than several seconds (3 seconds maximum) to confirm pump/motor rotation. Prolonged counterclockwise rotation will damage the system. If the rotation is wrong, remove power from the 3-phase circuit and reverse the connections of two of the three incoming power leads (wires) in the HPS motor starter box. De-Commissioning To dismantle the machine for purposes of relocation or disposal, reverse the steps outlined for installation and assembly. Dispose of the hydraulic fluid in an appropriate disposal facility in compliance with local regulations. Basic Machine Description The basic components of the system are the table, the hydraulic actuator, the hydraulic power supply, and the instrumentation. Typical optional subsystems and accessories include a seismic base, 1-G supports, and a stroboscope. Table The table provides a flat horizontal surface upon which the test specimen is mounted. The standard table is a deeply ribbed aluminum casting for stiffness and light weight. The top surface is drilled and fitted with Keenserts for the mounting of test specimens/fixtures. A variety of tables may be furnished with the system, in accordance with customer requirements. VIBRATION TEST SYSTEMS - 7 -

12 VIBRATION TEST SYSTEMS The table is rigidly attached to the actuator through an aluminum adapter ring so that vibrational motion produced by the actuator is accurately transmitted to the table s surface. Actuator The actuator converts fluid power (from the hydraulic power supply) into vibratory motion. It is a heavy-duty double-ended hydraulic cylinder. The actuator bearings are low-friction hydrofilm composites designed for long life and high side load capacity. The actuator is fitted with high strength elastomer bumpers which protect the system and specimen if an unlikely overstroke condition should occur. The servovalve, which directs hydraulic fluid to and from the actuator, is mounted directly on the actuator. This is done to extend high frequency performance by minimizing fluid volume downstream of the servovalve. The valve controls fluid flow in proportion to a command signal. A differential pressure transducer is also closecoupled to the actuator. This device provides a feedback signal proportional to piston differential pressure, which improves acceleration waveforms and enhances stability of the control loop. A displacement transducer, mounted inside the actuator, senses piston position, which is used as feedback in the control loop. Hydraulic Power Supply The hydraulic power supply (HPS) is a selfcontained unit that furnishes high-pressure fluid required to drive the system. In addition to a large electric motor and hydraulic pump, it incorporates filters, gauges, control valves, an oil cooler, and various interlock and protection devices to comprise a safe, reliable, and quiet power unit. The power supply is remotely controlled from the either TouchTest or Dactron controls. The unit has several interlocks that prevent operation under out of limit conditions. These interlocks include high and low oil temperature, low fluid level in the reservoir, and motor overtemperature. The unit is designed to operate continuously at 2000 psi (141 kg/cm 2 ). The unit s maximum supply pressure is 2500 psi (176 kg/cm 2 ). The HPS features a constant displacement pump. Typical sound level measurements at a 3 foot distance (0.9 m) are less than 75 dba. The HPS includes the following components: Electric Motor with Starter This is an electric motor with starter which incorporates overload relays. Should one or more of these relays open for any reason (motor overload, motor problems, facility power problems, etc.) it is necessary to remove the starter s cover and push the RESET button. Shaft Coupling This unit is located between the motor and the pump. It compensates for any misalignment in the two shafts. Additional information is contained in a separate HPS manual. Pump The pump is especially designed for quiet operation and reliable performance. To service the pump, the power unit top plate must be removed. Additional information is contained in a separate HPS manual. Inlet (Suction) Filter This filter is used to prevent contamination from entering the suction side of the pump. It is located on the suction line, near the bottom of the reservoir. If it is suspected that this filter is clogged, it must be removed from the tank and cleaned with a good solvent. To service the suction filter, the power unit top plate must be removed. Additional information is contained in a separate HPS manual. Check Valve The check valve merely prevents reverse flow back through the pump. Additional information is contained in a separate HPS manual. VIBRATION TEST SYSTEMS - 8 -

13 VIBRATION TEST SYSTEMS Relief Valve This valve controls the system hydraulic pressure. Additional information is contained in a separate HPS manual. Vent Valve This cartridge type solenoid valve directs fluid either through the relief valve or to the heat exchanger and then to the reservoir. This valve is controlled by the vibration control panel. Additional information is contained in a separate HPS manual. Accumulator This is a bladder-type accumulator used for surge control and to supply peak flows to the actuator. It must be kept charged with nitrogen for proper system operation. Additional information is contained in a separate HPS manual. High Pressure Filter This unit is an extremely fine filter used primarily to protect the servovalve from contamination. Its element should be changed periodically. Pressure Gauge This is a glycerine-filled gauge used to measure output pressure. Additional information is contained in a separate HPS manual. Heat Exchanger This is a fluid-to-water heat exchanger used to keep fluid temperatures at safe operating levels. Water Solenoid Valve This device controls the flow of water through the heat exchanger to cool the hydraulic oil. The valve is automatically turned on and off by the control system. One stage of the oil temperature switch turns the water valve on when the oil temperature exceeds 85 F (29.4 C). The water valve will close if oil temperature falls below 85 F or if the vibration controls are turned off. Additional information is contained in a separate HPS manual. Reservoir This is a welded steel structure, treated on the inside to inhibit corrosion. It is equipped with a filler/breather, a filter status indicator, and a fluid level gauge with a thermometer. The filler/breather cap contains a filter to prevent foreign material in the air from entering the reservoir. The cap should be left in place at all times. The reservoir has an internal baffle to aid in air removal and fluid cooling. Temperature Switch This is a three stage temperature switch which will not allow the HPS to operate if the oil temperature is too hot, >135 F (54.4 C) or too cold, <55 F (12.8 C). The third stage of this switch activates the cooling system as described under Water Solenoid Valve above. Additional information is contained in a separate HPS manual. Fluid Level Switch A float switch is suspended in the reservoir to sense if the fluid level is too low. The signal from this switch is connected to the control system to shut down the HPS if the fluid falls below a certain level. Additional information is contained in a separate HPS manual. Backflow Control Valve This component is a restrictor valve which controls flow out of the accumulator, through the dump valve and heat exchanger when system high pressure is shut down. Additional information is contained in a separate HPS manual. HPS Hour Meter This meter is located on the door of the enclosure on the HPS. It records the total running time of the hydraulic power supply. This is useful for indicating when periodic VIBRATION TEST SYSTEMS - 9 -

14 VIBRATION TEST SYSTEMS maintenance is required, and as a measure of approximate test hours The HPS wiring schematic and a complete, separate manual is included at the rear of this binder. Controls Lansmont s TouchTest Controls or Dactron s Shaker Controls for Vibration represents a complete electrohydraulic vibration control and instrumentation system. The TouchTest control and instrumentation system is normally housed in a custom console called the SystemStation. All control functions, both sine and random, are incorporated, as well as acquisition and analysis of vibration data. Dactron s Controls are normally housed in a Desk Top Computer System. High-quality printouts are obtained via a laser printer. Compatible computer files may be exchanged through an externally-accessible 3½inch floppy disk drive. The system may be furnished with up to eight control/measurement accelerometers. The system is completely menu-driven, with control inputs made by touching indicated areas of the screen. Other than a three-position keyswitch, there are no conventional knobs, buttons, or operator controls. Output data may be displayed on the screen in both digital and graphical formats. The three-position keyswitch is located either above the keyboard shelf on the SystemStation (TouchTest) or on Lansmont s electronic Interface Box (Dactron Control System). To start the machine under normal conditions, turn the key clockwise from OFF to ON to START and release the key. The key will return to the ON position upon release. To power down the machine during normal circumstances, turn the key counterclockwise from ON to OFF. The Emergency Power Off (EPO) button is located on the System Station (TouchTest) or Lansmont s Interface Box (Dactron). It cuts power to the system in the event that a hazardous situation, not controlled by the existing interlocks, arises. If such an instance occurs, depress the EPO and the system will instantly turn itself off. Once the hazard is removed, twist and pull the EPO button out and restart the system normally. CAUTION: Do not reset the system until all personnel and equipment are clear and safe machine operation can be ensured. Optional Seismic Base This is a massive steel block riding on a lowfrequency, damped suspension system. It isolates the actuator s high vibrational forces from the floor and surrounding area so that the system may be mounted on a normal concrete laboratory floor. The damped suspension system consists of neoprene isolation mounts, and dampers (shock absorbers). The use of the steel seismic base eliminates the requirement for a large reinforced concrete foundation. If a seismic base is not furnished with the system, a sizable reinforced foundation must be provided by the customer. The actuator mounts directly to the top surface of the seismic base. The 1-G supports option also mounts directly to the top of the base. An optional set of seismic spacers is available for the Vibration Test System (required for European models). Placed between the seismic base and isolation mounts, these spacers provide increased clearance between the floor and the base. An optional bellows assembly kit is also available for the Vibration Test System (required for European models). The bellows assembly covers the actuator in order to deny access to moving parts while the machine is in operation. If the bellows becomes damaged, call Lansmont Corporation for replacement information. Optional 1-G Supports The 1-G support subsystem was designed to increase the ultimate specimen weight capacity of the vibration system. Its basic function is to support the static weight of a heavy specimen and table. With this accomplished, the actuator is free to provide the dynamic input only. The 1- G supports also act as anti-rotation restraints for the table. VIBRATION TEST SYSTEMS

15 VIBRATION TEST SYSTEMS The 1-G support system consists of pedestal/reservoir assemblies, air bladder support springs, a control valve, and required hoses and plumbing. The upward force exerted by the air bladders is directly proportional to the air pressure within them. The control system automatically operates the control valve to maintain proper pressure in the airrides, so that the table and specimen weight is just counteracted. Optional Stroboscope A number of different stroboscopes are available for use with Lansmont Vibration Systems. The stroboscopes repetitively emit a very short pulse of bright light which can appear to stop component motions. They are essentially standalone units, separate from the vibration machine, except for the sync connection. This connection, from the Interface Box Sync output to the strobe s input, synchronizes the light flashes with the system operating frequency (in the sine mode). Setup Loading the Test Specimen Any convenient method may be used to lift the test item onto the table (forklift, overhead crane, manpower, etc.). Try to position the test item so that the center of gravity is near the center of the table. It is usually necessary to secure the test item to the vibration table surface. Threaded inserts are provided on the table surface for this purpose. All-Thread rods with wood or aluminum cross bars have been used successfully to secure items to the table. Some tests (i.e., Column Stack Testing) do not require the test item to be secured to the table surface. For these situations a channel iron or wood dam should be used, or alternately, the Lansmont column stack vibration fixtures (optional) can be used to prevent the item(s) from walking off the table surface. Optional 1-G Support Setup If the system is equipped with 1-G supports, the pressure will be automatically set by the Controller. Maximum bladder pressure is 80 psi (5.6 kg/cm 2 ). Optional Stroboscope Setup Before attempting to set up or use the stroboscope, please read its instruction manual, included separately, for general information, control locations, control functions, etc. With reference to the interconnections drawing, insure that the strobe is properly connected to the Sync jack on the electronic Interface. No other setup of the strobe is required. It may be used in the free-running mode or synchronized with the operating frequency of the system (by virtue of the Sync connection) as outlined in its manual. Charge Amplifiers (Optional) Charge amplifiers (if used) should be set up in accordance with their own instruction manuals. It is necessary to determine the output sensitivity from the charge amps in mv/g and enter those numbers into the Controller Channel Definitions. The maximum input permitted is mv (10 volts) peak. Operation Before attempting to operate the Vibration Test System, read either the TouchTest Online Instruction (Help) or the Dactron Shaker Control System User s Manual in its entirety. Since the machine is not equipped with conventional controls, it is critical that the user understands how to operate the equipment. VIBRATION TEST SYSTEMS

16 VIBRATION TEST SYSTEMS The vibration system can be stopped manually. Several screens have a STOP button, however, in the event of an emergency the Emergency Power Off (EPO) button can always be engage to stop a test and shut down the Hydraulic Power Supply (HPS). In the event of out-of-limit conditions, the system shuts itself down via a system of interlocks. Once the fault is corrected, the interlocks will reset, and the vibration test can be re-started. To turn Power ON, rotate the key in the threeposition keyswitch clockwise from OFF to ON to START and release the key. To turn Power off, rotate the key counter-clockwise from ON to OFF. In the event of a hazardous situation beyond the control of the interlocks, the system can be stopped by pushing the EPO button. System power is cut off immediately and the system shuts down. Once the hazard has been eliminated, the system can be reset by twisting and pulling the EPO button out. Restart the system normally. Optional Stroboscope Operation Operation of the strobe is covered in its manual. It may be necessary to darken the room to maximize the effects of the stroboscopic light. Maintenance Careful maintenance will prolong the life of the system. Failure to follow the maintenance procedures can result in premature wear and will void the warranty. Prior to performing any maintenance procedures, unplug the vibration controls and disconnect 3-phase power to the HPS. General Unplug the vibration controls and disconnect 3- phase power to the HPS before performing any system maintenance. Periodically check the tightness of all machine fittings and fasteners. Maintenance procedures for other machine components are contained in individual manuals included in this binder. Hydraulic Power Supply Disconnect 3-phase power to the HPS before removing any covers, working on any of the components, or performing any maintenance. Refer to the separate HPS manual for further information. Observation Routinely observe the output pressure and examine the HPS for leaks, etc. Qualitatively measure component temperatures by putting a hand on them (motor, pump, relief valve, heat exchanger, etc.). Listen for any unusual noises. Shut down immediately if anything abnormal is observed and investigate the source of the problem. Filter The high-pressure full-flow filter should be changed after the first hours of operation and after every 1000 hours thereafter. Find the replacement element part number on the cover of the filter housing (refer to the HPS Oil Change Instructions at the end of this section). Oil The hydraulic fluid should be drained after the first hours of operation and after every 1000 hours thereafter. When filling the HPS, be extremely careful not to introduce any dirt into the system (refer to the HPS Oil Change Instructions at the end of this section). The fluid capacity of the HPS is listed on the specifications sheets (pages 1 and 2). Any high-quality petroleum-based hydraulic fluid can be used but it must have a basic VIBRATION TEST SYSTEMS

17 VIBRATION TEST SYSTEMS viscosity of SUS at 100 F (37.8 C). The viscosity must stay within the range of 102 SUS and 1500 SUS over the anticipated operating temperatures. Recommended fluids are: Shell Tellus 46 Mobil DTE 25 Sun Sunvis 921 Standard Rykon 21 Chevron EP-9 Accumulator The accumulator on the HPS was precharged with nitrogen to 2000 psi (141 kg/cm 2 ) prior to shipment and should hold this pressure indefinitely without adjustment. However, it is recommended that this pressure be checked every few months, particularly when the system is new. Use a dry nitrogen source, high pressure hose, gauge, and Parker (or equivalent) accumulator pressure fitting. 1. Using a suitable accumulator charging hose/fitting assembly, connect the accumulator to a 1500 psi dry nitrogen source (nitrogen bottle with regulator). 2. Using the fitting, depress the pin on the accumulator s valve to admit nitrogen. 3. Allow the pressure to remain connected for at least 5 minutes to let pressure and temperatures stabilize. 4. Release the accumulator s valve pin. 5. Disconnect the charging assembly. This procedure should be followed one a year or whenever the accumulator charge pressure is suspected of being low. Fittings and Fasteners Periodically check the tightness of all HPS fittings and fasteners. Actuator Routinely check the actuator for leaks, loose fasteners, etc. Piston Rod Periodically wipe off the piston rod and inspect it for signs of undue wear. Servovalve See the servovalve manual. Drainback Flow The actuator incorporates both high and low pressure seals. Any fluid which goes through the high pressure seals is trapped by the low pressure seals and returned to the reservoir through a small diameter hose. Periodically remove this hose at the actuator and check for fluid flow with the system running. Hydraulic Power Supply (HPS) Oil Changes IMPORTANT: This procedure for oil changes is NOT to be used if the hydraulic hoses have been disconnected from the machine or the HPS. If the hoses have been disconnected, a flushing valve will have to be used to remove any possible contamination before running the system with the servovalve in place. The fluid capacity of the HPS is shown on the Specifications Sheet that accompanies this manual. 1. Remove the oil filler cap and the screws that hold down the oil filler assembly. 2. Pump the old oil out of the HPS reservoir and into 55 gallon drums. Dispose of the old oil in an appropriate disposal facility in compliance with local regulations. 3. Pump the fresh hydraulic oil (see recommended fluids below) into the HPS reservoir, reinstall the oil filler assembly and replace filler cap. Do not install new filter yet. 4. Turn the HPS on (see section Checking Rotational Direction of HPS Motor for power on/off instruction). This will circulate the new oil and trap any possible contaminants in the old oil filter. Leave the HPS running for 20 minutes. VIBRATION TEST SYSTEMS

18 VIBRATION TEST SYSTEMS 5. Stop the HPS and install the new filter (see HPS component manual for proper filter element, or look on the cover of the filter housing for the part number). Turn the pump on again and run the HPS for another 20 minutes. 6. Stop the HPS and return to the MAIN MENU. Now the system is ready for use. Adjustments No internal adjustments of the electronic controls should be attempted by the user. Special techniques, test circuits, and instruments are required to test these units. Please contact Lansmont for information regarding Maintenance and Calibration services and Service contracts. Hydraulic Power Supply There are three adjustments that can be made at the HPS and the procedures for making these adjustments are as follows: 1. Relief Valve Pressure Setting Locate the relief valve on the HPS drawing (see Figure 9). System pressure is set using the screw and locking nut at the relief valve. Clockwise rotation increases pressure, counter-clockwise rotation decreases it. This adjustment cannot be made if the solenoid valve is de-energized or if there is free flow between the pressure and return lines. With the hoses properly connected to the actuator, use the controller to turn HPS and High Pressure ON. Adjust the relief valve s screw while watching the gauge until the desired pressure is reached. The normal setting should be 2000 psi (175 kg/cm 2 ). 2. Backflow Valve Adjustment Locate the backflow valve on the HPS drawing (see Figure 9). This valve controls the rate of pressure decay when the system high pressure is turned off. Adjustment is by a screw with a jam-nut. While alternately turning high pressure on and off from the controller the valve should be adjusted for a pressure decay of 1 to 2 seconds when system High Pressure is OFF. The HPS s pressure gauge actually reads pressure at the relief valve so it cannot be used to observe pressure decay. However, the sound of fluid passing through the backflow restrictor valve can easily be heard when pressure is shut off and can be used to adjust for a 1 to 2 second decay time. 3. Temperature Switch Setting Locate the temperature switch on the HPS drawing (see Figure 9). Remove the cover to gain access to the control adjustments. The temperature switch marked HI should be set to 125 F (51.7 C). The temperature switch marking LO should be set to 55 F (12.8 C). The third switch marked H2O should be set to 85 F (26.7 C). 1-G Support Control Valve If adjustment of the 1-G Support control valve is required, proceed as follows: 1. Disconnect supply pressure to the 1-G Support control valve. Turn on the vibration controller (TouchTest or Dactron) and start any type of normal test. Allow to run for one minute. This will cause the maximum drive signal output to the control valve. Shut down the test. 2. Reconnect supply pressure to the 1-G Support control valve. Set this pressure to at least 80 psi (5.6 kg/cm 2 ). The pressure delivered to the air bladders should immediately begin to rise. Turn the span adjustment on the 1-G Support control valve VIBRATION TEST SYSTEMS

19 VIBRATION TEST SYSTEMS so that the maximum pressure to the air bladders is 70 psi (4.9 kg/cm 2 ). 3. Disconnect the 1-G Support control valve s cable at the Interface Box. The delivered pressure should begin to fall. Turn the zero adjustment on the 1-G Support control valve so that the pressure bleeds to zero. Do not turn past the point where all the air just bleeds off. 4. Repeat sets 2 and 3 until both the zero and full-scale pressures are accurate and repeatable. VIBRATION TEST SYSTEMS

20 VIBRATION TEST SYSTEMS Troubleshooting The following is a brief list of common problems encountered and their remedies. If a particular problem cannot be found here, please consult Lansmont directly at LANSMONT ( ) for help. PROBLEM CURE Hydraulic Power Supply cannot be started. --Temperature Interlock System oil temperature is either above 125ºF (51.7ºC) or below 55ºF (12.8ºC). Check thermometer. If temperature is above 125ºF (51.7 C), check for proper cooling water supply. Allow oil to cool (1 hour) and push interlock button. If temperature is below 55ºF (12.8ºC), check room heating temperature, oil viscosity is too high for pump below 55ºF. When oil has warmed (65ºF or so), push interlock button. If oil temperature is OK, temperature switches need adjustment. High range should be set to 125ºF, low range to 55ºF, water temperature switch set to 85ºF (26.7 C). See ADJUSTMENTS section. If the interlock continues to flash after pushing the interlock button, the fault condition has not yet been remedied. --Level Interlock Fluid level in reservoir is too low. Top off tank to top of sight level gauge with recommended hydraulic fluid. Push interlock reset button. --Interlocks Normal 3-phase power motor could be shut off. Check disconnect box for incoming power. Motor has overheated. Allow motor to cool. Check heaters for proper current rating. Push RESET button on motor starter. Power does not come on at all. Check facility power input to the SystemStation Interface (TouchTest controls) or Interface Box (Dacton controls). Check fuses at the Interface. HPS will not start. No power to the HPS. Check 3-phase power input to HPS. Fault condition exists. Check overload relays in HPS motor starter box. Check faults temperature, level, etc. VIBRATION TEST SYSTEMS

21 VIBRATION TEST SYSTEMS No acceleration signal or acceleration control. Check condition of accelerometer(s) and accelerometer cable(s). If multiple channels are available, trade components to locate the fault. Check connections to Interface. Uneven motion of the vibration table. Check hydraulic pressure. If the gauge on HPS reads low but returns to normal 2000 psi (141 kg/cm 2 ) when the table motion is stopped, condition is caused by flow limiting. Change frequency or reduce acceleration amplitude. Degraded performance, system instability. Check hydraulic power supply pressure, filter condition, etc. Check vibration controller setup parameters. VIBRATION TEST SYSTEMS

22 VIBRATION TEST SYSTEMS Component Manuals and Data Sheets The following component information is included with this manual: Dactron Certificate of Calibration ** Hydra-Power Systems hydraulic power supply MOOG servovalve** Paine Instruments differential pressure transducer Lucas-Schaevitz DCDT Flowjet Model 2100 pump Fairchild T6000 Electro-pneumatic transducer ** Accelerometer(s) ** Charge Amplifier(s) ** Stroboscope ** ** denotes optional documention VIBRATION TEST SYSTEMS

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24 B Rev C LANSMONT CORP SINGLE LEVEL CURRENT BILL OF MATERIAL August 24,2007 ASSY,MAIN, 6000 TTV, TEAM Seq# Item Rev Description Qty Units Comment B D ACTUATOR ASSY,6000, 1.00 EA 3 S SHCS,5/8-18x3-1/ EA - 4 S SHCS,5/8-11x2-1/ EA - 12 S WSHR,FLT,HRD,5/8,MCS1#98029A EA 24 S LABEL,LANSMONT LOG0,LARGE 3.625"x7.688" 1.00 EA 25 S PLT,SERIAL NUMBER,ALUM. 2.00"x 3.00" 1.00 EA B ASSY, MAIN, 6000 TTV 0.00 EA REF DWG

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29 B Rev D LANSMONT CORP SINGLE LEVEL CURRENT BILL OF MATERIAL March 20,2007 ASSY,SERVOVALVE,TEAM #V140-V20 Seq# Item Rev Description Qty Units Comment 1 S SERVOVALVE,1000 Hz,18in3/SEC.,TEC4 #V EA 3 S SHCS,3/8-16X3-1/2 MCS A EA 4 S ACCUMULATOR,BLADDR,1-GAL,3000PSI, 1.25" 2.00 EA 5 S FTG,O-RG-MJIC,1"x 1" PARKER # EA 7 S SERVOVALVE,SLAVE,TEC4 #V EA 8 S HOSE,PUSHLOK-1/4,PARKER # FT 9 S SHCS,3/8-16X3/ EA 11 S CLAMP,ACCUMULATOR,1-GAL BRACKET, 4.00 EA 12 S SHCS,5/16-18x3/ EA 13 S HOSE,VIB,1"x3FT FEM 37JIC SW, 2.00 EA 14 S FTG,MJICxO-RG 90,1"x 1"PARKER# EA 15 S FTG,RDCR,0-RING,1.25"x 1", 2.00 EA 16 S FTG,O-RG-MJIC,1/2"x1/4" PARKER# EA 17 S FTG,O-RG-MJIC,1/4"x 1/4" PARKER# EA 18 S FTG,HOSE END,FJIC,HP,1/4" 2.00 EA 19 S HOSE,HI PRESSURE-1/4,PARKER # FT 20 S FTG,MPIPE-MJIC,1/8"x1/4" PARKER# EA 21 S FTG,HOSE END,FJIC,1/4x1/4 BRASS, 2.00 EA ECO2 ASSY,SERVOVALVE W/SLAVE,TEAM #V EA REF DWG

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33 B Rev J LANSMONT CORP SINGLE LEVEL CURRENT BILL OF MATERIAL March 20,2007 ASSY,SEISMIC BASE,8000lb ACTUATO Seq# Item Rev Description Qty Units Comment B NON SEISMIC BASE,8000lb,6000 ACTUATOR,CAST 1.00 EA - 2 S DAMPER,GABRIEL #82001 SHOCK, EA B A BLOCK,MTG,DAMPER,SEISMIC EA B B PL,DAMPER,MTG,SEISMIC (A OPTION 4.50") EA - 5 S ISOLATION MT,NEOPRENE, EA B A SPCR,DAMPER,1.25" EA 7 S LOCTITE TL EA AS REQ. 8 S HX HD,7/16-14 x 3-1/2,ZINC PLATED EA 9 S HX HD,1/2-13x1,ZINC PLATED EA 10 S HX HD,7/16-14x2-1/4 GR 4,ZINC PLATED EA 11 S HX HD,5/8-11 x 11 GRD-5 ZINC PLATED EA 13 S WSHR,FLT,STL,SAE 1/2" ZC MCS1#90126A EA 14 S WSHR,FLT,STL,SAE 7/16"ZC MCS1#90126A EA 15 S WSHR,FLT,STL,SAE 5/8" ZC MCS1#90126A EA 16 S NUT,NYLOK,7/16-14, (ZINC PLATED STEEL) EA 17 S WSHR,LK,SPLT RNG,5/8" ZC MCS1#91102A EA J ASSY,SEISMIC BASE,8000lb EA REF DWG

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43 DRAIN CL CL CL

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