100303151D Exceed40FSE EN

MTS Exceed® Series 40
Manual Title
FSE Manual
Additional Information
be certain.
100-303-151D
Copyright information © 2021 MTS Systems Corporation. All rights reserved.
Trademark information MTS ,MTS Exceed® and TestSuite are registered trademarks of MTS Systems
Corporation within the United States. These trademarks may be protected in
other countries.
Publication information
Manual Part Number Publication Date
100-303-151 A April 2015
100-303-151 B October 2015
100-303-151 C December 2015
100-303-151 C (reissue) June 2020
100-303-151 D July 2021
2 MTS Exceed ® Series 40 FSE Manual

Contents
Introduction 7
Description 8
Load Frame Components 10
System Specifications 17
Principle of Operation 22
Exceed E40 Series Tools List 24
Installation Instruction 25
Site Preparation 26
Site Preparation Checklist 30
Lift and Move Overview 32
Responsibilities 33
Packaging Dimensions and Weights 35
Load Frame Dimensions and Weights 36
Recommended Hoist Rings 37
Transporting Procedures 38
Moving E42 Single-Column Frames 43
Moving E43.104 Double-Column Frames 45
Moving E43.504/E44/E45 (Standing Position) Frames 47
Moving E45 (Prone Position) Frames 49
Frame Location and Ventilation 51
Leveling the Load Frame 52
Leveling the E42, E43, and E44 Frame 52
Leveling the E45 Frame 53
Installing Optional Enclosures 54
Single-Column Load Frame 54
Dual-Column Load Frames 56
Controller Connections 58
Connecting the main power 58
Installing External Cables (ICE Controllers) 59
Internal Cables (ICE Controllers) 67
Installing External Cables (Insight Controllers) 75
Accessory Mounting Dimensions 82
Model E42.503 Accessory Mounting Dimensions 83
Model E43.304/E43.504 Accessory Mounting Dimensions 85
MTS Exceed ® Series 40 FSE Manual 3

Model E44 Accessory Mounting Dimensions 87
Fixture Mounting 96
Install The Load Cell And Adjust For Coaxiality 97
E42.503 Load Cell Assembly Guide 98
E43.504Load Cell Assembly Guide 100
E44 -10 kN, 30 kN (S-Beam Type) Load Cell Assembly Guide 101
E44-20kN, 30kN (Low Profile Type) Load Cell Assembly Guide 102
System Installation Checklist 109
Verification 115
TEDS Devices Window 116

Display and Edit the Virtual TEDS Information for a Signal 117
Create and Assign a Virtual TEDS File to a Signal 118
Assign a Virtual TEDS File to a Signal 119
TEDS Device Verification Checks 120
View the Device Verification History 122
Device Verification Settings 123
Maintenance 125
Operator maintenance 126

Routine Maintenance Detail 128
Routine Maintenance Overview Checklist 129
PC Maintenance 130
System Inspections 133
System Checks 135
Lubrication 136
Decommissioning 142
Repair 143
Removing Panels 144

Replacing Controller 148

Parameters setting 149
Spare Parts List 151
Spare Parts Lists for Exceed Systems with ICE Controllers 152
Spare Parts List of E42.503 153
Spare Parts Lists of E45.305 165
Spare Parts Lists for Exceed Systems with Insight Controllers 169
Load Cells List 186
Troubleshooting 187
Systems with the ICE Controller 187

Systems with the Insight Controller 192
Appendix 199
Clevis Adapter Dimension 200

Metric Threads Torque Chart 201
Additional Digital I/O Information 202
Concentricity Fixture 203
Electrical Diagrams for Exceed Systems with ICE Controllers 208
E42.503 Electrical Diagram 209
MTS Exceed ® Series 40 FSE Manual 5

Electrical Diagrams for Exceed Systems with Insight Controllers 225
E42 Electrical Diagram 226
E43 10 kN or less Electrical Diagram 228
E43 20 kN 30 kN 50kN Electrical Diagram 230
E44 10 kN Or Less Electrical Diagram 232
E44 20 kN Or 30 kN Electrical Diagram 234
E45 200 kN 300 kN Electrical Diagram 238
Notes 244
Notes 245
Notes 246
Notes 247

About This Manual
Introduction
About This Manual
This manual provides detailed information about the MTS Exceed Series 40
Material Test System. The information includes an overview of all the models
available, system description, installation instructions, calibration information,
maintenance, repair, spare parts list and troubleshooting guide.
MTS Exceed Series 40 Material Test System is the latest generation of

electromechanical material testing equipment from MTS. The purpose of this
manual is to help Field Service Engineers understand MTS Exceed Series 40
Material Test System, its installation and repair instruction. This manual provides
technical information for all MTS Exceed Series 40 Material testing frames;
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.
Contents Description 8
Load Frame Components 10
System Specifications 17
Principle of Operation 22
MTS Exceed® Series 40 FSE Manual Introduction 7

Description
Description
Low-Capacity Mid-Capacity High-Capacity
Every MTS Exceed Series 40 Material Test System is comprised of a load frame,
electronic frame controller, and TestSuite software. The following figure shows
the external features of the various MTS Exceed load frames.
The personal computer is also an integral part of the system. It runs TestSuite
software which provides full machine control, data acquisition and management,
and advanced data analysis and presentation. MTS has minimized the amount of
custom electronics required for your system, thereby making it flexible and
reliable. This is done by connecting the frame and the computer via a standard
USB 2.0 connector for systems with the Insight controller and a standard
Ethernet connections for systems with the ICE controller.
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 non-
preloaded ball screws.
The load frame drive is located in the frame base. The drive motor is connected
to the lower end of the ballscrews by a series of belts and drive pulleys. On the
dual column machines, motor rotation causes synchronous rotation of the
ballscrews, which in turn causes the crosshead to move up or down. On the single
column machines, motor rotation causes the rotation of the single ballscrew,
which in turn causes the crosshead to move up or down.
8 Introduction MTS Exceed® Series 40 FSE Manual

Frame Controller
Frame Controller
The frame controller is responsible for the following:
• Provides main data and signal processing power
• Detects the activation of limit switches
• Provides the interface between the software (computer) and the frame
• Provides digital servocontrol- for speed and position accuracy
• Automatically identifies accessories including load cells and extensometers

with the self-identify feature
• Communicates with handset interface
• Provides programmable data acquisition rate (up to 1000 Hz maximum for

systems with the Insight controller and up to 2500 Hz for systems with the
ICE controller).
• Commands the motor
Software
TestSuite 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
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
TestSuite manual for additional information.

Load Frame Components

The following figures show the various components for the single-column and
dual-column load frames.To familiarize yourself with the various components of
your frame, refer to the figure that shows your model number.
Top Beam
Column Cover
Ball Screw Cover
Limit Rod
Upper Limit Stop

Crosshead
Load Cell Limit Switch Actuator

(inside)
Lower Limit Stop

Adapter
Pin
Handset
Mat
Base Adapter
Power Cord
Base
Controller
Power Switch
Emergency Stop
Leveling Foot
Model E42.503 Rated Force Capacity 5 kN

Column Cover
Top Beam
Ball Screw Cover
Limit Rod
Load Cell
Upper Limit Stop
(inside)
Crosshead
Adapter Limit Switch Actuator
Pin
Handset
Lower Limit Stop
Base Adapter
Controller
Mat (back)
Base
Power Switch
Power Cord
Emergency Stop
Leveling Foot
Model E43 Rated Force Capacity 10 kN

Column Cover Top Beam
Limit Rod
Crosshead
Upper Limit Stop
Load Cell
Limit Switch Actuator

Adapt
Pin
Lower Limit Stop
Handset
Power cord
Base Adapt (Back)
mat
Base Controller
Power Switch
Foot
Emergency Stop
Model E43.304 / E43.504 - Rated Force Capacity 30 kN, 50 kN

Load Cell
(inside)
Top Beam
Adapter
Pin
Limit Rod
Column Cover
Ball Screw Cover

Upper Test Space
Crosshead Upper Limit Stop
Adapter
Limit Switch Actuator
Lower Test Space

Lower Limit Stop
Mat Handset
Controller
(back)
Base
Power Switch Power Cord
Emergency Stop
Model E44.104 / E44.304 - Rated Force Capacity 10 kN, 30 kN

Top Beam
Adapter
Column Cover
Ball Screw Cover
Limit Rod
Upper Test Space

Adapter
Pin
Crosshead Upper Limit Stop
Load Cell
(inside) Limit Switch Actuator
Adapter
Lower Limit Stop
Lower Test Space Handset
Base Adapter
Mat
Base
Power Cord
Controller
Power Switch
Emergency Stop
Model E45.105 - Rated Force Capacity 100 kN

Top Beam
Column Cover
Ball Screw Cover
Limit Rod
Crosshead
Upper Limit Stop
Load Cell
Adapter Limit Switch Actuator
Handset
Pin
Base Adapter Lower Limit Stop
Mat
Base
Controller
Power Switch
Emergency Stop
Model E45.305 - Rated Force Capacity 300 kN

Upper Plate
Top Beam
Column Cover
Ball Screw Cover

Limit Rod
Lower Plate
Upper Limit Stop
Load Cell
Crosshead Limit Switch

Actuator
Connecting screw rod

(Under of crosshead)
Handset
Adapter
Lower Limit
Stop
Base
Emergency Stop Controller
Power Switch
Model E45.605 Rated Force Capacity 600 kN

System Specifications
System Specifications
Environmental Requirements
All MTS Exceed load frames are intended for indoor use only. This indoor
environment must conform to the following environmental specifications.
Parameter Specification
Temperature Operating temperature: 5°C to 40°C (51°F to 104°F)
Storage temperature: -40°C to 55°C (-40°F to 131°F)
Humidity 5-85%, non-condensing
Altitude 2000 m (6562 ft) maximum
Electrical Power Requirements

The following table provides the electrical power requirements of various load
frame types.
Electrical Power Requirements
Model Voltage Frequency Current Maximum Power

E42 Single phase 50/60 Hz 3 Amps 600 W
E43 (10 kN) 200 - 240 VAC
E44 (10 kN)
E43 (30 kN,50 kN) Single phase 50/60 Hz 6 Amps 1200 W

E44 (30 kN) 200 - 240 VAC
E45 (100 kN) Single phase 50/60 Hz 10 Amps 2000 W

200 - 240 VAC
E45 (300 kN) Three phases 50/60 Hz 10 Amps 5000 W

380-415 VAC or
440-480 VAC
optional
E45 (600 kN) Three phases 50/60 Hz 10 Amps 5000 W

380-415 VAC or
440-480 VAC
optional
Facility Power Provide a dedicated circuit for the machine, computer, and monitor.
Requirements:
Overvoltage Category: II
Pollution Degree: 2
Note Electrical connections must be made by qualified personnel and conform

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

Connecting Optional Transformers

Every MTS Exceed Series 40 Material Test System has an optional power
transformer. Customer should select a transformer which supplied by MTS
according to the local voltage range.
The following table provides the transformer requirements for various load frame
types.
Transformer Selection table
Model Transformer Part Number Transformer Parameter 120 V Wall Power

E42 100-277-339 1.5 kVA 16 A
E43 (10 kN) 120 to 220 VAC
E44 (10 kN)
E43 (30 kN,50 kN) 100-248-281 3.0 kVA 32 A

E44 (30 kN) 120 to 220 VAC
E45 (100 kN)
E45 (300 kN) 100-249-050* 14.0 kVA

E45 (600 kN) 208 to 480 VAC
E45 (300 kN) 100-249-048* 14.0 kVA

E45 (600 kN) 600 to 480 VAC
* When you choose this transformer, please make sure that the frame power required voltage is
440-480 VAC (see nameplate). If not, the power input end of inner transformer needs to change to
440-480 VAC. Electrical modifications must be made by qualified personnel and conform to local codes
and regulations.
Transformer The installation procedure for connecting transformers for units is provided
Connections following the figures.

10 kN below
Transformer
1.5 kVA
120 to 220 VAC
* Customer Supplied MTS Supplied

Transformer MTS Supplied
100-277-339 Exceed E42
E43(10kN)
Transformer E44(10kN)
1.5 kVA
* 120 VAC 120 to 220 VAC
Wall Power
Cable
20 kN through 50 kN
MTS Supplied Exceed

E43 (30-50 kN)
E44 (30 kN)
* Customer Supplied
MTS Supplied
Transformer
100-248-281
*Wall Switch
Transformer
MT w d
3.0 kVA
S er C , 15
Po pplie
* 120 VAC
At o ’ft
120 to 220 VAC

Su
tac rd
Wall Power * Conduit

he
d
* Conduit with wire

with wire

100 kN
MTS Supplied Exceed

E45 (100 kN)
* Customer Supplied
MTS Supplied
Transformer
100-248-281
*Wall Switch MT
S
P At
Transformer Su ower tache
pp
* 120 VAC 3.0 kVA lied Cord d
120 to 220 VAC * Conduit ,1
Wall Power * Conduit 5’ft
with wire with wire
300 kN above
step up transformer
* Customer Supplied MTS Supplied Exceed

E45 (300 kN,600 kN)
MTS Supplied
Transformer
100-249-050
* Wall Switch
Transformer
MT w d
14.0 kVA
S er C , 15
Po pplie
At o ’ft
*208, 60Hz
Su
208 to 480VAC
tac rd
3-Phase
he
d
VAC * Conduit * Conduit

Wall Power with wire with wire

300 kN above
step down transformer
* Customer Supplied MTS Supplied Exceed

E45 (300 kN,600 kN)
MTS Supplied
Transformer
100-249-048
* Wall Switch
Transformer
MT w d
14.0 kVA
S er C , 15
Po pplie
At o ’ft
*600, 60Hz
Su
600 to 480 VAC
tac rd
3-Phase
he
d
VAC * Conduit * Conduit
Wall Power with wire with wire

Principle of Operation
Principle of Operation
The following illustrations show MTS Criterion Series 40 Material Test System
block-diagram for the ICE controller and the Insight controller.
Block Diagram for ICE Controllers

Block Diagram for Insight Controllers
Block Diagram for Insight Controllers

Exceed E40 Series Tools List
Exceed E40 Series Tools List
Description MTS Part Number
T-handle hex key wrenches (2 - 10 mm) Standard hand tool
Ball-end hex key wrenches (2 - 10 mm) Standard hand tool
3/8" drive ball-end hex key set (4 - 12 mm) Standard hand tool
1/4" drive metric sockets wrenches Standard hand tool
3/8" drive metric socket wrenches Standard hand tool
1/4" Torque wrench (2 - 25 N*m) Standard hand tool
3/8" Torque wrench (5 - 100 N*m) Standard hand tool
Tape measure (inch & mm) Standard hand tool
Spirit level (magnetic recommended) Standard hand tool
Belt tension gauge (13-68 kg range) 100-247-742
Belt tension gauge (45-135 kg range) 100-247-743
Grease gun w/ extension for zerk fittings 011-351-307
Grease-calc sulf,em frames,red,14 oz 100-483-652
Enclosure door interlock switch key 100-247-744
M10 Hoist rings (E42.503- Qty 1 , E44- Qty 2) 100-228-536
M16 Hoist rings (E43.304, E43.504 & E44 - Qty 2) 100-124-821
M24 Hoist rings (E45.105,E45.305 - Qty 2) 100-214-169
M42 Hoist rings (E45.605 - Qty 2) 100-228-544

Installation Instruction
This section provides instruction for installing your MTS Exceed Series 40
Material Test System.
Unless otherwise specified, it is your responsibility to safely off-load, unpack,

and move the equipment to the final location on your premises. Equipment
insurance is also your responsibility.
Before moving the equipment from the receiving area to its final location, check
the dimensions of all doors and passages through which the machine will travel.
Contents Site Preparation 26

Site Preparation Checklist 30
Lift and Move Overview 32
Frame Location and Ventilation 51
Leveling the Load Frame 52
Installing Optional Enclosures 54
Controller Connections 58
Accessory Mounting Dimensions 82
Install The Load Cell And Adjust For Coaxiality 97
System Installation Checklist 109
WARNING
The MTS Exceed frames are heavy.
Moving the frame using improper procedures can injure personnel (for
example, strained muscles and back injuries) or damage the frame.
When lifting the frame, take the appropriate precautions to prevent injuries to
yourself. Moving and positioning the MTS Exceed frame must be performed by
qualified personnel only.
MTS Exceed 40 frames weigh from 110–3500 kg (242.5–7716 lb). Other

apparatus such as the pallet, packaging, and accessories add to the overall weight.
If you have any questions, call MTS.
MTS Exceed® Series 40 FSE Manual Installation Instruction 25

Site Preparation
Site Preparation
This section describes the physical, electrical, and mechanical requirements that
must be considered before installing the MTS Exceed Series 40 Material Test
System. Read the following subsections thoroughly to identify installation
considerations that apply to your facility.
Preparing to Receive Prior to receiving the system, ensure suitable rigging equipment is available for
the System lifting and transporting the system components.
Space Requirements Consideration must be given to planning the space requirements around the
equipment for loading specimens and for the proper maintenance of the
equipment. Also, during installation of the equipment, additional space (floor
space and ceiling height) might be required to facilitate moving the various
system components into place. The following illustration is a typical
configuration for a system laboratory plan, allowing for relative placement of the
test machine controls and mechanical components for convenient use. This is
only a suggestion of how an MTS Exceed Series 40 Test System could be
installed. Your requirements should be considered and planned accordingly.
Consideration should also be given to handling specimens, test data, and storage
of fixturing and associated tools necessary for use and service of the system. If
hazardous test specimens (such as those pressurized internally with gas or
fragmentizing materials) are used in the test, protective enclosures and special
laboratory layouts are advised.
Wall
300 mm 1 m (3 ft)
(12 in)
Load
Frame Computer Table
Wall
Work Area
3 m (10 ft)
3 m (10 ft)
26 Installation Instruction MTS Exceed® Series 40 FSE Manual

Site Preparation
Floor Loading Once the final layout for your system laboratory has been developed, the
Considerations dimensional and weight information for the various system components should
be supplied to the building facility personnel to ensure that proper building
loading and vibration considerations have been evaluated.
A review of the final installation plan by building personnel is recommended to

check static and dynamic floor loading.
Mechanical Shock/ Where heavy-load metal tensile testing is performed, vibration produced by
Vibration testing can be introduced into the laboratory floor. Adequate isolation of the load
unit is often possible with the supplied rubber pads on the four feet of load frame.
Electrical Power The input line voltage to the MTS Exceed Series 40 Material Test System must
Distribution be adequately rated for the loads under which the system operates. Size the
power system with adequate reserve for future equipment additions and
installation expansion. Power for load frame console must be considered in the
distribution system, with emphasis on providing “interference free” electrical
power to the controls. Plan routing of power cables away from instrumentation
cables (for example, transducer cables). Avoid long parallel runs of power cables
in close proximity to instrumentation cables. Power cables should be separated
from instrumentation cables by 0.3 to 1 m (1 to 3 ft).
Grounding All equipment related to the load frame should be connected to the same
Requirements electrical circuit if possible. If the computer, monitor or other peripherals are
connected to a different electrical circuit (example; the load frame is connected to
208 VAC power but the computer and monitor are connected to 120 VAC power)
make sure there is no voltage difference between the two different grounds. If
voltage is present, damage could occur to the electronics in the machine, the
computer and monitor or the peripherals being used. This must be resolved
before turning on the equipment.
Where electrical power is of poor quality (noise spikes, poorly regulated, and so
forth) or the ground system in the facility contains electrical noise, attach a 4
AWG wire directly to a good earth ground point such as a 2 m (6 ft) copper
grounding rod driven at least 2 m (6 ft) into the ground. Grounding must conform
to local electrical codes.
Load Frame Power Electrical power to the load frame should be filtered against outside RF
Interference to provide single 200-240 AC, needs to be 50-60 Hz, three phases
380-415 V AC or 440-480 V AC, needs to be 50/60 Hz. An isolated power
source or uninterruptible power supply is recommended if you need to maintain
load frame power when power fails interrupt. Make sure that the service to the
MTS Exceed Series 40 Material Test System is not on a line that can be
accidentally shut off. Power supplied to the MTS Exceed Series 40 Material Test
System should be on an isolated circuit, or on its own transformer from the main
power box.

Site Preparation
Radiated Emissions Operation of the MTS Exceed Series 40 Material Test System can be affected by
sources of electromagnetic interference (EMI) that are near the system controls,
computer, instrumentation cables, and related peripheral equipment. Common
sources of EMI are electric motors, broadcast systems, high-voltage power lines,
power tools, welding equipment, machine tools, mobile communications, radar,
vehicle ignition systems, static electricity, induction heaters, fluorescent lights,
and lightning. The effects of EMI are unpredictable, additional grounding and
shielding might be necessary. Techniques such as using screen cages or other
metal surfaces around the system, along with good grounding practices and
proper storage of magnetic memory medium, are recommended.
Fixture and Specimen Movement of specimens in and out of the test system must be considered early in
Handling the planning of the site layout. With smaller specimens, the use of a rolling work
Considerations cart with storage drawers is often recommended to facilitate the handling of
specimens and to minimize the chance of damage to the specimens prior to and
after the test. As specimen size and fixturing increase beyond the typical lifting
capacity of laboratory personnel, use of an overhead crane, lifting straps, or a
forklift might be necessary to handle specimens or fixtures.
Telephone and Ensure that a telephone line is located within the general testing area. This
Network Access enables the user to contact MTSservice department directly from the testing area
so the user can perform the instructions provided and resolve the situation while
on the telephone with the service representative. This facilitates resolving issues
in a timely manner and reduces the number of repeated phone calls about the
same problem.
It is also suggested that network drops, or digital phone lines, be within the
general testing area. A network connection near the system facilitates distributing
test data via the network. MTSgoal is to provide remote diagnostics in order to
resolve system issues. Having a network drop or digital phone line available will
enable an MTS service representative to dial into the testing system's computer to
diagnose and resolve problems more efficiently. Including the network or digital
lines in your initial site preparation will facilitate adding this function if it
becomes necessary in the future.
Acoustics Some types of testing can produce noise which is undesirable or potentially
damaging to hearing. Acoustical treatment of walls and the ceiling might be
necessary to prevent harm to personnel. If disk drives are included in the system,
acoustical materials should not be of the type that generates or harbors dust.
However, the use of hearing protection is recommended for personnel involved

in long-term testing in a noisy testing environment.
Temperature The operating temperature range of the load frame and the PC cabinet/desk is 5
°C to 40 °C (51 °F to 104 °F). This includes most temperature sensitive
equipment, such as disk drives and memories which are dependent on cooler air
to maintain proper read or write. Although the load cell or force transducer is
temperature compensated, it is recommended that room air heating and cooling
outlets be directed so that they uniformly distribute air throughout the room.
testing must be done at the temperature the sysetem was calibrated at ±10 °C.
This is primarily due to the potential changes in specimen characteristics or test
data associated with changes in temperature.

Site Preparation
Heat Dissipation For comfortable working conditions and proper operation of the equipment, the
heat dissipation of the PC cabinet/desk and other equipment must be considered
in providing adequate heating or air conditioning to the laboratory area.
Heat dissipation for the load frame, the PC cabinet/desk, and other electronic
units can be estimated by summing the losses going to heat in the room
{approximately 6000 Btu/hr (1500 kcal/hr) for a single 15 amp power panel or
8000 Btu/hr (2000 kcal/hr) for a single 20 amp power panel} and the gains from
personnel and other heat inputs such as furnaces. To this figure, you should add
20% additional heat gain for future changes in test requirements.
Altitude Systems operated at high altitudes can have heat dissipation problems because of
the lower density of the air. This type of problem might require the use of an air
conditioned environment or cooling fans to reduce the heat load. Equipment can
be operated at altitudes up to 2000 meters (6500 feet ).
Relative Humidity The recommended relative humidity for the test room is within the range of 5%
to 85% (non-condensing). The risk of static discharge, which easily damages
logic components and causes loss of data in memory devices, is increased by low
humidity. Excessive humidity can result in electrical leakage currents or
component failure.
Leveling System Frames are leveled by adjusting the four feet as necessary. An open-ended
Components wrench and spirit or bubble level must be used.
The FSE should have a spirit level available. Use the spirit level to measure and
adjust the horizontal level of the crosshead in two dimentions from side-to-side
and front-to-back. This is very important for calibration, as a non-level condition
can cause load channel errors. A load frame out of level can also cause noise,
vibration, and premature wear of drive system.
Refer to “Leveling the Load Frame” on page 52 for specific leveling instructions.

Site Preparation Checklist
Site Preparation Checklist

The following checklist provides a quick summary of items that should be
considered when planning and preparing the site location of your test system.
Additional information regarding each item below is provided within this
manual. If you need more specific information, contact your local MTS
authorized office for assistance.
Note This manual provides general guidelines for all types of frames.
Therefore, some of the items listed below may not pertain to your
specific system (such as smaller systems in which size and weight are
not an issue).
Site Location Requirements

• The floor and table are able to support the weight of the frame, and its
computer components.
• The environment complies with the specifications for your specific model:
– Operating temperature
– Storage temperature
– Humidity
– Atmosphere
• The required power supply is available and is compatible with the electrical
requirements for your specific model.
• Electrical outlets are within the minimum distance requirement to the load
frame’s location.
• Phone lines are located within the general testing area so that users can call
the MTS Service department directly from the testing area. It is also
suggested that network drops, or digital phone lines, be within the general
testing area.
• Ceiling clearance is adequate for the load frame, including the additional
space necessary to lift and move the frame by either a forklift or crane.
• The location provides sufficient accessibility for routine maintenance: 1000

mm (3 ft).
• Employees are adequately trained to operate the load frame and its computer
system.

Transporting Requirements
Transporting Requirements
• You have the correct number of packing boxes as stated on the packing list.
• Insurance coverage is secured or verified.
• You have the required equipment for the chosen transporting method.
• You have the appropriate packaging to protect the load frame when moving
or relocating it.
• The pathway from the loading dock to the final site location has sufficient
width and height to fit the frame and forklift (or crane).
• The floor area along the pathway to the final site location is able to support
the weight of the frame and forklift (or crane).
• There are no loose accessories on the shipping skid or frame.
• Your equipment operators have the appropriate licenses and have complied
with your local safety standards (for example: the appropriate training
required by OSHA in the U.S.).

Lift and Move Overview
Lift and Move Overview

This section provides guidelines for lifting and moving your MTS Exceed Series
40 Material Test System.
Unless otherwise specified, it is your responsibility to safely off-load, unpack,

and move the equipment to the final location on your premises. Equipment
insurance is also your responsibility.
Before moving the equipment from the receiving area to its final location, check
the dimensions of all doors and passages through which the machine will travel.
For dimensions, refer to the “Packaging Dimensions and Weights” on page 35

and the “Load Frame Dimensions and Weights” on page 36.
WARNING
MTS Exceed frames weigh from 115–3500 kg (254.5–7716 lb). Other apparatus
such as the pallet, packaging, and accessories add to the overall weight. If you
have any questions, call MTS.

Responsibilities
Responsibilities
This section details the responsibilities of both the customer and MTS to ensure
that the proposed testing area is suitable for the installation and operation of the
testing system.
Customer’s Responsibilities
It is the customer’s responsibility to ensure that all required support services are
available, and that all necessary checks are made prior to installing the testing
system. These services and checks are described below.
Site preparation Proper site preparation is imperative so that the testing system operates in
accordance with its specifications and provides accurate test results. The
customer must ensure that the site requirements are satisfied prior to scheduling
the installation appointment.
Handling and Unless specifically arranged otherwise, it is the customer’s responsibility to

transporting arrange the off-loading, unpacking, and moving of the testing system to the final
site location. For details on handling and transporting your system to its final
location, refer to the moving instructions later in the manual.
Upon special arrangements, an MTS service engineer can supervise the off-
loading and transportation of the load frame to its final site. For additional
information on this service, contact MTS Service department or your local MTS
office.
It is the customers responsibility to provide slings and lifting shackles. Slings and
lifting shackles must conform to local codes and regulations and be sized
correctly to support the weight of the load frame. Weights and thread sizes are
provided in the specifications tables.
Insurance and safety Under MTS standard contract, the shipping terms are Ex-Works (or FOB
Factory), meaning ownership and liability for the testing system transfers to the
customer at MTS loading dock. Unless other shipping terms are specified in a
purchase order, which MTS does not dispute, the Ex-Works shipping terms
apply. Under these terms, the customer is responsible for securing the applicable
transit insurance on the shipment and arranging safe transport to the final
destination. Arrangements can be made through MTS to secure insurance
coverage and shipping, at the customer’s expense.
When transporting a load frame within your own premises, you are responsible
for its safe transport. Upon special arrangements, an MTS service engineer or
Business Partner can supervise the transportation to the load frame’s final site.
For additional information on this service, contact MTS Service department or
your local MTS office .
MTS’ Responsibilities
MTS standard contract requires MTS to provide the necessary services to ensure
that your testing system operates accurately. These services are described below.

MTS’ Responsibilities
Additional services and equipment may be negotiated with MTS, but these
additional services must be mutually agreed upon and specifically described in
your purchase order.
Insurance Under MTS standard contract, the shipping terms are Ex-Works (or FOB
Factory), meaning ownership and liability for the testing system transfers to the
customer at MTS loading dock. Unless other shipping terms are specified in a
purchase order, which MTS does not dispute, the Ex-Works shipping terms
apply. Under these terms, MTS is responsible for insurance coverage while the
testing system is in the factory until it reaches the loading dock for shipping.
Installation When the site location is prepared and all the components are on site, MTS is
responsible for the complete installation of the load frame, its components, and
any additional accessories that may have been purchased. The customer must not
make any attempt to install the load frame without an MTS service representative
present.
Initial operation Once the installation is complete, MTS performs an initial operation of the load
frame and a calibration check to ensure that it is working properly and measuring
accurately. MTS also performs a customer demonstration that briefly describes
how to operate the system.
Documentation MTS provides all the documentation required to operate the system, including
manuals for the load frame and any required software applications.
Manuals for your products and system operation are available on the MTS web
site. Refer to the Manuals tab at http://www.mts.com/en/services/index.htm

Packaging Dimensions and Weights
Packaging Dimensions and Weights
The following table provides the dimensions of various load frame types when
packaged for shipping. If you transfer the load frame from the shipping dock to
its final site location before unpacking the system, then use these dimensions to
ensure that the frame fits through all doorways and hallways.
Packaging Dimensions for Load Frames

Model Width Depth Height Weight
E42.503 920 mm 840 mm 1540 mm 290 kg

(36.22 in) (33.07 in) (60.13 in) (639 lb)
E42.503E 920 mm 840 mm 1840 mm 330 kg
(36.22 in) (33.07 in) (72.441 in) (728 lb)
E43.104 970 mm 945 mm 1875 mm 380 kg
(38.19 in) (37.20 in) (73.818 in) (838 lb)
E43.104E 970 mm 945 mm 2135 mm 420 kg
(38.19 in) (37.20 in) (84.06 in) (926 lb)
E43.304; E43.504 1180 mm 1140 mm 2025 mm 580 kg
(46.46 in) (44.88 in) (79.72 in) (1279 lb)
E43.304E; E43.504E 2360 mm 1230 mm 1135 mm 600 kg
(92.9 in) (48.4 in) (44.7 in) (1323 lb)
E44.104; E44.304 1120 mm 880 mm 2230 mm 650 kg
(44.09 in) (34.65 in) (87.80 in) (1433 lb)
E44.104E; E44.304E 1120 mm 880 mm 2490 mm 695 kg
(44.09 in) (34.65 in) (98.03 in) (1532 lb)
E45.105 Single zone 2440 mm 1500 mm 1348 mm 1880 kg
(96.06 in) (59.06 in) (53.07 in) (4145 lb)
E45.105 Double zone 2440 mm 1500 mm 1348 mm 1910 kg
(96.06 in) (59.06 in) (53.07 in) (4211 lb)
E45.105E Single zone 2740 mm 1500 mm 1348 mm 1980 kg
(107.87 in) (59.06 in) (53.07 in) (4365 lb)
E45.105E Double zone 2740 mm 1500 mm 1348 mm 2010 kg
(107.87 in) (59.06 in) (53.07 in) (4431 lb)
(107.87 in) (61.42 in) (56.30 in) (4916 lb)
(107.87 in) (61.42 in) (56.30 in) (5016 lb)
(119.69 in) (61.42 in) (55.51 in) (5137 lb)
(119.69 in) (61.42 in) (55.51 in) (5235 lb)
E45.605 3160 mm 1960 mm 1760 mm 3602 kg
(124.41 in) (77.17 in) (69.29 in) (7941 lb)

Load Frame Dimensions and Weights
Load Frame Dimensions and Weights

The following table provides the dimensions of various load frame types. If you
transfer the load frame to its final site location after unpacking the system, then
use these dimensions to ensure that the frame fits through all doorways and
hallways.
Load Frame Dimensions
Model Width Depth Height Weight

E42.503 642 mm 582 mm 1300 mm 110 kg
(25.28 in) (22.91 in) (51.18 in) (243 lb)
E42.503E 642 mm 582 mm 1600 mm 120 kg

(25.28 in) (22.91 in) (62.99 in) (265 lb)
E43.104 681 mm 688mm 1617 mm 142 kg

(26.81 in) (23.15 in) (63.66 in) (313 lb)
E43.104E 681 mm 688 mm 1917 mm 155 kg

(26.81 in) (23.15 in) (75.47 in) (342 lb)
E43.304; E43.504 820 mm 775 mm 1770 mm 325 kg

(32.28 in) (30.51 in) (69.69 in) (717 lb)
E43.304E; E43.504E 820 mm 775 mm 2070 mm 345 kg

(32.28 in) (30.51 in) (81.50 in) (761 lb)
E44.104; E44.304 845 mm 716 mm 1862 mm 435 kg

(33.27 in) (28.19 in) (73.31 in) (959 lb)
E44.104E; E44.304E 845 mm 716 mm 2162 mm 450 kg

(33.27 in) (28.19 in) (85.12 in) (992 lb)

(48.43 in) (34.25 in) (80.91 in) (3086 lb)

(48.43 in) (34.25 in) (34.25 in) (3152 lb)

(48.43 in) (34.25 in) (34.25 in) (3197 lb)

(48.43 in) (34.25 in) (34.25 in) (3263 lb)

(47.83 in) (37.80 in) (92.91 in) (3748 lb)

(47.83 in) (37.80 in) (94.29 in) (3847 lb)

(47.83 in) (37.80 in) (104.72 in) (3858 lb)

(47.83 in) (37.80 in) (106.10 in) (3957 lb)
E45.605 1660 mm 1272 mm 2820 mm 3500 kg

(65.35 in) (50.08 in) (111.02 in) (7716 lb)

Recommended Hoist Rings
Recommended Hoist Rings
Size Model
M10 E42.503, E44
M16 E43.304, E43.504
M24 E45.105, E45.305
M42 E45.605

Transporting Procedures
There are three methods for transporting the load frame to the test site:
• Frame Base method—use a forklift to lift the upright load frame from
underneath the base with the shipping skid still attached.
• Crosshead method—use a forklift with padded forks to lift the load frame
from under the crosshead.
• Crane method—use a crane to lift the upright load frame from the
crosshead. If this method is used, MTS recommends using professional
riggers experienced in moving heavy equipment.
Frame base method To transport the load frame using the frame base method:
1. Ensure that the frame is bolted to the shipping skid.
2. Carefully insert the forks under the shipping skid.
3. Move the crosshead to its lowest position so that the frame is not top heavy.
WARNING
The frame may overturn suddenly when lifting the frame.
An overturned frame can cause injury or death to anyone in the immediate

area.
Ensure that all persons in the immediate area are standing away from the frame
during lifting. Do not lift the frame more than 8 cm (3 in) off the floor.
4. Slowly and carefully lift the frame off the floor.
5. Move the frame to its operating location.
6. Slowly lower the frame to the floor.
7. Before placing the frame in its operating location, you must insert the
leveling feet into each corner of the base. The shipping skid must be
removed to insert the feet and before placing the frame in its operating
location. Remove the shipping skid, insert the leveling feet, and position the
frame. Follow the instructions described under “Crosshead method” on page
39.
When the frame is in its operating location, you can proceed with the installation
process.

Load Frame
Shipping Bolt Forklift Arm
Shipping Skid
Lifting the Frame from the Base
Crosshead method This method requires protective padding on either the crosshead or forklift arms
to protect the crosshead from scratching or marring.
This method can be used to:
• Transport the load frame to the site location.
• Lift a tabletop load frame onto a table or workbench.
• Lift the frame to remove the transport skid from the frame’s base and to
mounting the leveling feet.

Forklift Arm
Crosshead
Protective Material
Leveling foot
Lifting the Frame from the Crosshead
To transport the load frame using the crosshead method:
1. Ensure that there are no shipping bolts attached to the skid.
2. Using a forklift with padded forks or protective material around the

crosshead, carefully insert the forks under the crosshead between the
columns.
WARNING

area.
4. Remove the shipping skid, if it has not already been removed.
5. Move the frame to its operating location.
6. Four leveling feet are supplied for the load frame. Thread one leveling foot
into each corner of the base before placing the frame in its testing location.
7. Place the load frame carefully into position.

8. Remove the padded forks from under the frame’s crosshead.
When the frame is in the testing location, you can proceed with the installation
process.
Crane method MTS recommends using professional riggers experienced in moving heavy
equipment.
WARNING

area.
To transport the load frame using the crane method:
Crane Hook
Do not exceed 30°
Lifting Sling
Hoist Ring
Load Frame
Lifting Load Frame with a Crane
1. Attach the two lifting slings to the hoist rings of the top plate and secure
them to the crane hook.

3. Remove the shipping skid, if it has not already been removed.
4. Move the frame to the operating location.
5. Four leveling feet are supplied for the load frame. Thread one leveling foot
into each corner of the base before placing the frame into its testing location.
6. Place the load frame carefully into position.
7. Remove the lifting straps from the top plate, and any protective padding, if
used.
When the frame is in its testing location, you can proceed with the installation
process.

Moving E42 Single-Column Frames

The single-column load frames are shipped with wooden packaging. They are
strapped to the wooden skid. Accompanying components are packed in
cardboard cartons and also strapped to the wooden skid.
Ensure that the test system is placed on a stable or other suitable work platform
that can support the test system weight. Ensure that your users are able to access
the controls and the working space on the system without discomfort when it is
placed on a table or other suitable platform.
WARNING
Before you begin Before moving the load frame, ensure that:
with your local safety standards (for example, the appropriate training
• At the final site location, there is adequate clearance between the ceiling and
the top of the load frame.
• There are no loose accessories on the shipping skid.
• The frame and forklift can fit through all doorways, halls, elevators, or stairs
located from the shipping dock to the final site location.
• Any table upon which the frame is placed is sturdy, level, and capable of
supporting the weight of the machine.
• You have adequate packaging materials to protect the load frame when
moving or relocating it to another site.
Equipment The following items are required by the customer:
A forklift with a load rating that is double the load frame’s gross weight (for
frame weights, see“Load Frame Dimensions and Weights” on page 36).
• Sharp knife
• Screw removal tool
• Safety line or safety belt
• M10 hoist rings if using a crane

Procedure To unpack and position the load frame:
1. Move the load frame, still in the shipping material, to its final location
within your building. Use a forklift to transport the container from the
shipping dock to the final location.
2. Unpack the load frame after it has been moved to its final location.
3. Remove the shrink wrap vapor barrier encasing the load frame.
4. Cut the strapping that secures the load frame to the shipping skid.
5. Remove the fixed wood blocks around the machine.
6. Use the packing list to inventory all the items. Accessories may be in the
container with the load frame or may be packaged separately.
Do not open these boxes until the MTS service representative arrives to
install your testing system. This ensures that no parts are lost prior to
installation.The packing list will indicate the total number of boxes that are
included in the shipment. Count the number of boxes you received to make
sure you have the correct number of boxes.
7. Mount the M10 hoist ring to the top beam of the frame column.
8. Use the crane to slowly and carefully lift the frame clear of the wooden
pallet, and place it in its operating position.
9. Retain all packing materials until the system is satisfactorily installed and all
parts, assemblies, and accessories have been located.
process.

Moving E43.104 Double-Column Frames

E43 double-column MTS Exceed load frames should only be moved using a
forklift (or crane) with a load rating that is double the load frame’s gross weight.
For frame weights, see“Load Frame Dimensions and Weights” on page 36.
Ensure that the test system is placed on a stable or other suitable work platform
that can support the test system weight. Ensure that your users are able to access
the controls and the working space on the system without discomfort when it is
placed on a table or other suitable platform.
WARNING
the top of the load frame, including clearance for lifting the frame via a
forklift.
• The frame and forklift (or crane) can fit through all doorways, halls,
elevators, or stairs located from the shipping dock to the final site location.
• The floors from the shipping dock to the final site location have sufficient
support for the weight of the load frame and forklift combined.
• Any table upon which the frame is placed is sturdy, level, and capable of
supporting the weight of the machine.

• A forklift with a load rating that is double the load frame’s gross weight (for
frame weights, see“Load Frame Dimensions and Weights” on page 36)
• Protective padding for the crosshead
Procedure To unpack and position the E43 load frame:
1. Move the load frame to its final location within your building. Use a forklift
to transport the container from the shipping dock to the final location.
2. Unpack the load frame .
4. Remove the fixed wood blocks around the machine.
6. Position the frame into its operating location (Model E43.104 can’t use
crane method).
• If you use the frame-base method to lift and position the frame into its
operating location, see “Frame base method” on page 38 for details.
• If you use the crosshead method to lift and position the frame into its
operating location, see “Crosshead method” on page 39 for details.
process.

Moving E43.504/E44/E45 (Standing Position) Frames

E44 and E45 (standing position) MTS Exceed load frames should only be moved
using a forklift (or crane) with a load rating that is double the load frame’s gross
weight. For frame weights, see “Load Frame Dimensions and Weights” on page
36.
WARNING
The MTS Exceed frames Exceed 40 series are heavy.
the top of the load frame, including clearance for lifting the frame via a
forklift or crane.
• The frame and forklift (or crane) can fit through all doorways, halls,
elevators, or stairs located from the shipping dock to the final site location.
• The floors from the shipping dock to the final site location have sufficient
support for the weight of the load frame and forklift (or crane) combined.

• A forklift or crane with a load rating that is double the load frame’s gross
weight (for frame weights, see “Load Frame Dimensions and Weights” on
page 36)
• Safety line or safety belt
• Two hoist rings if using a crane
Two M16 hoist rings for the E43.304/E43.504 load frame
Two M10 hoist rings for the E44 series load frame
Two M42 hoist rings for the E45.605 load frame
Procedure To unpack and position the E44 and E45 (standing position ) load frame:
1. Move the load frame to its final location within your building. Use a forklift
to transport the container from the shipping dock to the final location.
2. Unpack the load frame .
4. Use a spanner wrench to dismantle the connection bolt between the load
frame and shipping skid.
6. Position the frame into its operating location.
• If you use the frame-base method to lift and position the frame into its
operating location, see “Frame base method” on page 38 for details.
• If you use the crosshead method to lift and position the frame into its
operating location, see “Crosshead method” on page 39 for details.
• If you use the crane method to lift and position the frame into its operating
location, see “Crane method” on page 41 for details.
process.

Moving E45 (Prone Position) Frames

The E45 (prone position) frame has been shipped in a horizontal position, so it
must be moved into an upright, standing position before placing it in its operating
location. The package cannot be uprighted directly. You need to unpack the
package, and then move the frame into an upright, standing position.
WARNING
Using a crane If you elect to use a crane to move the load frame, MTS recommends using
professional riggers experienced in moving heavy equipment.
• The load frame is not bolted to the shipping skid.
• There is adequate ceiling clearance to allow the load frame to be lifted into a
vertical position, including clearance for the crane.
• A crane with a load rating that is double the load frame’s gross weight (for
frame weights, see “Load Frame Dimensions and Weights” on page 36).
• Two lifting slings, each with a load rating that is double the load frame’s
gross weight
• Two hoistrings:
Two M42 hoist rings for the E45.605 load frame
Procedure To lift the load frame into a vertical position:
1. Remove all packaging material from the frame and ensure that the frame is
not attached to the shipping skid.

2. Attach the two lifting slings to the hoist rings of the top plate and secure
them to the crane hook.
WARNING
The frame can overturn suddenly when lifting the frame.
Overturn of the frame can cause injury, even death in the immediate area.
Righting a Load Frame with a Crane
3. Slowly lift the frame until it is in an upright position and is lifted off the
floor.
4. Slowly move the load frame away from the shipping skid and remaining
packaging materials.
5. When the frame is clear of the packaging material, slowly lower the load
frame to the floor.
6. Remove the slings from the top plate.
The frame can now be positioned into its operating location and then installed by
an MTS service representative. To position the frame into its operating location,
refer to “Moving E43.504/E44/E45 (Standing Position) Frames” on page 47 for
details.

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.

Leveling the Load Frame
Leveling the Load Frame

Leveling the E42, E43, and E44 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.
Equipment The following items are required:
• Spirit or bubble level
• Open-end wrench
18# open-end wrench for E42, E43.104 model
24# open-end wrench for E43.504, E44 model
Procedure To level the frame base:
1. Place a spirit or bubble level on the center of the base beam.
2. Loosen the locknut 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 locknut on each leveling foot.
Frame Base
Locknut.
Adjust nut
Leveling Foot

Leveling the E45 Frame
Leveling the E45 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.
Equipment The following items are required :
• Spirit or bubble level (0.02/1000 mm)
• Open-end wrench
18# open-end wrench for E45.105 model
Procedure To level the frame base:
1. Place a spirit level on the frame upper base plate.
2. Loosen the locknut on each leveling foot using the open-end wrench.
3. Using 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 locknut on each leveling foot using
the open-end wrench.
Adjust nut
Frame Base
Locknut Leveling Foot

Installing Optional Enclosures
Installing Optional Enclosures

Every MTS Exceed Series 40 Material Test System has an optional test area
enclosure. If the MTS test enclosure is not purchased, customers must provide an
enclosure of their own to protect against ejected parts or materials from test
specimens.
Single-Column Load Frame

The optional enclosure for single-column load frames is comprised of a enclosure
body and a front door, which completely encloses the test space.
When shipping, Those components are removed from the frame and packaged
separately. After the frame is placed in its testing location, you need to install
enclosure.
A typical installation procedure for installing an enclosure for single-column

frame is provided following the figure.
4 5
3 6
2
7
1
8
10
13
11
9
12

Single-Column Load Frame
Item Description
1 Front door
2 Horizontal Bar
3 Left Side Panel Assembly
4 Top Bar
5 Rear Higher Bar
6 Spacer
7 M6 Butt Fastener
8 Back Class
9 Right Side Panel Assembly
10 Rear Lower Bar
11 Handset Component
12 Right Connect Bar
13 Left Connect Bar
1. Remove the hand set (Item 11) from the column cover. Insert two M6
C’bore nuts in the each groove of the both side column cover.
2. Install the enclosure body to frame prior to assembling those components

together on the ground, which as shown above.
3. First, use horizontal bar (Item 2) and rear lower bar (Item10) connect left
side panel assembly (Item 3) and right side panel assembly (Item 9) with M6
butt fastener (Item 7). Then insert the back glass (Item 8) into the slots in the
side panel, and install the remaining rear higher bar (Item 5) with the M6
butt fastener (Item 7).
4. Install the top bar (Item 4) with the four M6 butt fastener (Item 7). Do not
over-tighten. You can adjust position for alignment when install to the
frame.
5. When all of the above components are complete, Put the component to the
frame,adjust the top bar to the right position. Thread two M6x30 socket
head screws through the holes on the frame and placer (Item 6).
6. Use right/left connect bar (Item 12 and 13) secure the component to frame.
7. Install front door on hinges and check for proper alignment of safety switch
adjust as needed.
8. When the all of above components are aligned, hand-tighten all fasteners.
9. Install the handset component (Item 11) to the enclosure as the picture
shows, and connect the cable of emergency stop.
10. Remove the protective covering from the panels and door.
When the assembly is completed, it should look like the previous figure.

Dual-Column Load Frames

The optional enclosure for dual-column load frames is comprised of a front
door,a back door, a left panel assembly and a right panel assembly, which
completely encloses the test space.
When shipping, Those components are removed from the frame and packaged
separately. After the frame is placed in its testing location, you need to install
enclosure.
A typical installation procedure for installing enclosure for dual-column units is

provided following the figure.
3
2
2
5
7
4
Item Description
1 Front Door
2 Hinge
3 Left Side Panel Assembly
4 Handset Component
5 Right Side Panel Assembly
6 Back Door
7 Safety Switch

1. Remove the handset component (Item 4) from the column cover, leave the
nuts in the slot of the column cover.
2. Position the right side panel assembly (Item 5) on the frame, and Adjust the
nuts’s position align to the holes on the right side panel assembly.Then
thread the M6x35 screws through the holes on the frame topbeam and the
nuts.
3. Secure the right side panel to the frame using four M6X35 mm socked head
screws. Do not over-tighten. You can position for alignment after the left-
side panel (Item 3) are installed.
4. Repeat Steps 2 and 3 for the left side panel assembly (Item 3).
5. Install front door and back door on hinges and check for proper alignment of
safety switch and adjust as needed. Back door does not use a safety swith,
but is latched with a 6 mm bolt (using a 5 mm hex wrench to tighten).
6. When the all of above components are aligned, hand-tighten all fasteners.
7. Install the handset component to the right of enclosure as the picture shows,
connect the cable of emergency stop.
8. Remove the protective covering from the panels and door.
When the assembly is completed, it should look like the previous figure.

Controller Connections
Controller Connections
Connecting the main power
5 kN through 100 kN The input voltage of MTS Exceed frames rated 100 kN or less is single phase
200-240 V, 50/60 Hz.
Note Local electrical codes supersede any information found here.
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 provide 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
buildings main power.
100 kN above The input voltage of MTS Exceed frames rated 100kN above is three phases 380 -
415 V or 440 - 480 V, 50/60 Hz.
The type of power cable is : JZ-602,4G4 mm2,or the same specifications.

compatible with the standards of CCC,CE etc for certification.
Electrical disconnect 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.
Recommended circuit breakers 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.

Installing External Cables (ICE Controllers)

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.
CAUTION
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.
Indicators
Label Indication
Pwr On Power on
Wd Flt Watchdog fault
Ctl Flt Control fault
Ctl Flt Control power
J1 E-Net This is a standard RJ45 connector that 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.
Important If the PC is to be connected to a house network, at least two

Ethernet adapters are required with one adapter dedicated to the
ICE controller. Also, the PC’s network needs to be configured for
IPV6 protocol.

J2 Handset This is intended to connect to the handset. Specifics for this connector are:
• +24 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 RJ45 connector
Pin assignments are as follows:
Pin Signal
1 HMI_TX+
2 HMI_TX-
3 +24 V
4 HMI_INTLK+
5 HMI_INTLK-
6 HMI_GND
7 HMI_RX+
8 HMI_RX-

J4 Enc 1/Enc 2 This connector is intended for encoder-based transducers. Specifics for this
connector are:
• Power: +5 V +/- 0.25 V at 100 mA max

• Signals: Quadrature A and B with index I
• Logic: Differential receivers (can connect single ended)
• Maximum Rate: 100,000 lines/sec = 400,000 counts/sec
Pin Signal
1 ENC1_GND
2 ENC1_TEDS+
3 ENC1_A+_CLK+
4 ENC1_B+_INT+
5 ENC1_I+_DATA+
6 ENC1_DIN+
7 GND
8 ENC2_+5V
9 ENC2_TEDS-
10 ENC2_A-_CLK-
11 ENC2_B-_INT-
12 ENC2_I-DATA-
13 ENC2_DIN-
14 ENC1_+5V
15 ENC1_TEDS-
16 ENC1_A-_CLK-
17 ENC1_B-_INT-
18 ENC1_I-DATA-
19 ENC1_DIN-
20 GND
21 ENC2_TEDS+
22 ENC2_A+_CLK+
23 ENC2_B+_INT+
24 ENC2_I+_DATA+
25 ENC2_DIN+

J6 Monitor 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 and feedback, or command and
error, simultaneously while changing the controller parameters. Therefore, two
monitor outputs are provided. Pin assignments are as follows:
Pin Signal
1 MON1+
2 MON1-
3 no connection
4 MON2+
5 MON2-
6 no connection
7 no connection
8 no connection
9 no connection
The voltage specifics for this connector are:
• Analog +/-10.5 V
• Calibrated to +/-10 V
• 16-bit resolution minimum

J8 Cond 1 and Two external DC conditioner connectors are provided. Up to two external
J9 Cond 2 transducers can be connected such as: axial or transverse extensometers, biaxial
extensometer, auxilary load cells, pressure gages, LVDTs (with external
conditioning), or strain-gaged components. Pin assignments are as follows:
J8 Cond 1
Pin Signal
1 COND1_TEDS+
2 COND1_EX+
3 COND1_EX-
4 COND1_FB-
5 COND1_FBR+
6 COND1_FBR-
7 COND1_FB+
8 COND1_EXS-
9 COND1_EXS+
10 COND1_TEDS-
J9 Cond 2
Pin Signal
1 COND2_TEDS+
2 COND2_EX+
3 COND2_EX-
4 COND2_FB-
5 COND2_FBR+
6 COND2_FBR-
7 COND2_FB+
8 COND2_EXS-
9 COND2_EXS+
10 COND2_TEDS-

J11 Guard The connector should be connected to the safety system (Enclosure switch) or
jumpered for crosshead motion.
The enclosure switch has two NC (normally closed) contacts. One must be
connected between Pin 1 and Pin 6. The other must be connected between Pin 2
and Pin 7.
GUARD_CONFIG1/2-jumpers determine if crosshead motion slows to 540 mm/

min or comes to a complete stop when the enclosure door opens. That is to say,
No Jumpers = complete stop with door open.
Jumpers from Pin3-Pin8 and Pin5-Pin9 = crosshead slows to 540 mm/min

with the enclosure door open.
Pin Signal
1 GUARD_SW1+
2 GUARD_SW2+
3 GUARD_CONFIG1+
4 no connection
5 GUARD_CONFIG2-
6 GUARD_SW1-
7 GUARD_SW2-
8 GUARD_CONFIG1-
9 GUARD_CONFIG2+

J13 User DIO Digital I/O signals include three optically isolated inputs, three optically isolated
outputs, and 12 V power for systems with the Insight controller and 24 V power
for systems with the ICE controller. Functions of each digital input or output are
software selectable. A typical example might be connecting an external switch.
Only DIN1 and DOUT2 & 3 are available for external use. DIN2 & DOUT1 are
used for Fault Status communications with the software. DIN3 is used for
Enclosure door switch status. Pin assignments are as follows:
Note If the optional enclosure is not used, DIN3 is still required by the control
system to bypass the low-speed safety system.
Pin Signal
1 USER_DIN1+
2 USER_DIN2+
3 USER_DIN3+
4 USER_DIN4+
5 USER_DOUT1+
6 USER_DOUT2+
7 USER_DOUT3+
8 USER_DOUT4+
9 no connection
10 USER_DIO_PWR
11 USER_DIO_PWR
12 USER_DIO_GND
13 USER_DIO_GND
14 USER_DIN1-
15 USER_DIN2-
16 USER_DIN3-
17 USER_DIN4-
18 USER_DOUT1-
19 USER_DOUT2-
20 USER_DOUT3-
21 USER_DOUT4-
22 USER_DIO_PWR
23 USER_DIO_PWR
24 USER_DIO_GND
25 USER_DIO_GND

J14 E- Stop This connector is intended to connect to a remote Emergency-Stop switch. If not
used, a jumper plug must be installed. If you are building a cable, the maximum
length is 30.48 m (100 ft) with 18 AWG. The switch should be wired normally
closed, such that when the switch is pressed, an interlock is generated. Pin
assignments are as follows:
Pin Signal
1 ACC_ESTOP_OUT2-
2 no connection
3 ACC_ESTOP_MON+
4 ACC_ESTOP_MON-
5 ESTOP2B-
6 ACC_ESTOP_OUT1-
7 ESTOP3B
8 ESTOP2A-
9 ACC_ESTOP_OUT2+
10 no connection
11 no connection
12 no connection
13 ESTOP3A
14 ACC_ESTOP_OUT1+
15 no connection
Connector Schematic for Reference:
J15 Acc J15 is an accessory connection that is reserved for future applications.

Internal Cables (ICE Controllers)
Internal Cables (ICE Controllers)

Following are the cable pin/signal tables for the internal cabling.
J11/J27 Guard Switch Jumpers

J20 E-Stop
J20 E-Stop

J22 Drive I/O
J22 Drive I/O

J22 Drive I/O

J23 Drive Safety
J23 Drive Safety

J24 System IO Controller
J24 System IO Controller

J25 Power Controller
J25 Power Controller

J26 Conditioner 3
J26 Conditioner 3

Installing External Cables (Insight Controllers)

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.
CAUTION
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 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.
J2 Handset 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 Signal
1 Transmit+
2 Transmit-
3 +12 V
4 INTLK+
5 INTLK-
6 Analog GND
7 Receive+
8 Receive-
J3 Interlock J3 is intended for remote interlock connection. If not used,a pin jumper should be
connected to clear the system interlock.
J4 Encoder 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..
J5 Digital I/O 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 202. 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:.
Pin Signal
1 DIN1+
2 DIN2+
3 DIN3+
4 DOUT1+
5 DOUT2+
6 DOUT3+
7 No Contact
8 +12 V
9 DIN1-
10 DIN2-
11 DIN3-
12 DOUT1-

13 DOUT2-
14 DOUT3-
15 Analog GND
J6 and J7 Monitor 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
J8 and J9 DC The J8 connector should be connected to J16 DC Cond Insight connector, the J9
Conditioner connector should be connected to J17 DC Cond Insight connector. The cable
from J8 to J16 must be connected when using the J14 DC Cond User connector
for system operation, and the cable from J9 to J17 must be connected when using
the J15 DC Cond User connector for system operation.
J10 Encoder User 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
• Logic: Differential receivers (can connect single ended)
• Maximum Rate: 100,000 lines/sec = 400,000 counts/sec.
Pin Signal
1 TEDS+_1
2 A+_1
3 A-_1
4 +5_1
5 I+_1
6 I_1
7 Analog GND_1
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
21 I_2
22 Analog GND_2
23 B+_2
24 B-_2
25 TEDS-_2
J11 Encoder Insight 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.
J12 E-Stop Input The connector should be connected to the safety system (Enclosure and E-Stop
switch) or jumpered for crosshead motion.
Enclosure switch has two NC contacts. One must be connected between Pin 5
and Pin 6. The other must be connected between Pin 12 and Pin 13. E-Stop
switch has two NC contacts. One must be connected between Pin 2and Pin 3. The
other must be connected between Pin 10 and Pin 11.
Pin Signal
1 No Contact
2 ESTOP1A+
3 ESTOP1A-
4 No Contact
5 GUARD1A+
6 GUARD1A-

7 No Contact
8 No Contact
9 No Contact
10 ESTOP2A+
11 ESTOP2A-
12 GUARD2A+
13 GUARD2A-
14 No Contact
15 No Contact
J13 E-Stop Output This connector is intended to connect a remote Emergency-Stop switch. If not
used, a jumper plug must be installed. If you are building a cable, the maximum
length is 30.48 m (100 ft) with 18AWG.The switch should be wired normally
closed, such that when the switch is pressed, an interlock is generated.
• ESTOP3 = emergency stop switch with two sets of contacts (optional

remotely mounted).
• ESTOP_OUT = optional ESTOP output for accessory, includes two contact

outputs and one feedback, For use with pneumatic/hydraulic grip controls,
furnaces, environmental chambers, and so on.
Pin Signal
1 ESTOPB_OUT-
2 No Contact
3 ESTOP_OUT_MONITOR-
4 ESTOP_OUT_MONITOR+
5 ESTOP3B+
6 ESTOPA_OUT-
7 ESTOP3B-
8 ESTOP3A+
9 ESTOPB_OUT+
10 No Contact
11 No Contact
12 No Contact
13 ESTOP3A-
14 ESTOPA_OUT+
15 No Contact

J14 and J15 DC Two external DC conditioner connectors are provided. Up to two
Conditioner User external,transducers can be connected such as: axial or transverse extensometers,
biaxial extensometer, auxiliary load cells, pressure gages, LVDTs or strain-gaged
components.
Pin Signal
1 EX+
2 EX-
3 No Contact
4 FB+
5 FB-
6 No Contact
7 No Contact
8 TEDS+
9 No Contact
10 EXS+
11 No Contact
12 RECALL(FBR+)
13 RECALL(FBR-)
14 TEDS-
15 EXS-
J16 and J17 DC Cond The J16 connector should be connected to J8 DC Cond connector, the J17
Insight connector should be connected to J9 DC Cond connector. The cable from J16 to
J8 must be connected when using the J14 DC Cond User connector for system
operation, and the cable from J17 to J9 must be connected when using the J15
DC Cond User connector for system operation.

Crosshead load cell

connector
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.
Pin Signal
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-

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.

Model E42.503 Accessory Mounting Dimensions
Base beam
Φ50
Model E42.503 Base Beam Mounting Dimensions
Crosshead
+0.06
60 +0.03
+0.06
30 +0.03
vΦ25x16
Φ12.5 Thru
Model E42.503 Crosshead Mounting Dimensions
Top Beam
M10
Model E42.503 Top Beam Mounting Dimension

Base beam
Φ50
64±0.1
38

Crosshead
4-M6x12
50±0.1
42±0.1
Model E43.104 Upside Of Crosshead Mounting Dimensions
Top beam
64±0.1
180±0.1
4-M8x16
Model E43.104 Underside Of Top Beam Mounting Dimension

Model E43.304/E43.504 Accessory Mounting
Model E43.304/E43.504 Accessory Mounting Dimensions
Base beam
38
Model E43.304/E43.504 Base Beam Mounting Dimension

Crosshead
vΦ20x20
8-M6x15 Φ89
Model E43.304/E43.504 Underside of Crosshead Mounting Dimensions

Model E43.304/E43.504 Accessory Mounting
Top beam
64±0.1
4-M8x16 180±0.1
Model E43.304/E43.504Underside of Top beam Mounting Dimension
2-M16x32
340±0.1
Model E43.304/E43.504 Topside Of Top beam Mounting Dimension

Model E44 Accessory Mounting Dimensions
Base beam
Model E44.104/E44.304 Base Beam Mounting Dimensions

Crosshead
400 Horizontal Clearance
45° 45°
Φ60
4-M8x25
Model E44.104A/E44.304A Topside Of Crosshead Mounting Dimensions
400 Horizontal Clearance 4-M10x35

64
70
Model E44.104B/E44.304B Topside Of Crosshead Mounting Dimensions
Φ32 Φ89
8-M6x18
Model E44.304ACBT Topside of Crosshead Mounting Dimensions

Model E44.304ATBC Underside of Crosshead Mounting Dimensions

Top beam
2-M10x25 4-M10x30
98
64
70
430
Model E44.104/E44.304 Topside of Top Beam Mounting Dimensions

Base beam
M24x2x25 6-M12x25
vΦ132x20.5 Φ100
4-M10x20
125
75
4-M12x25 280
Crosshead
8-M10x20
40
Φ126
Model E45.105 Underside of Crosshead Mounting Dimensions

2-M4x12
Φ42
68
Model E45.105 Upside of Crosshead Mounting Dimensions
Top beam
540
2-M24x45
Model E45.105 Topside of Top Beam Mounting Dimensions
180
6-M12x20
64
Φ100
4-M8x15
Model E45.105 Underside of Top Beam Mounting Dimensions

Base beam
Crosshead
Model E45.305 Underside of Crosshead Mounting Dimensions
2-M3x8
87
Φ165.1 Φ116.8
16-M12x35 8-M10x25
Model E45.305 Upside of Crosshead Mounting Dimensions

Top beam
550
2-M24x40
Model E45.305 Topside of Top Beam Mounting Dimensions

Base beam
350
vΦ75x60
40x5=200
12-M20x40
40
10-M16x35 Φ160
Φ178 10-M16x35
Crosshead
Φ228
Φ106
16-M16x40
Model E45.605 Upsside of Crosshead Mounting Dimensions

Top beam
Model E45.605 Upside of Top Beam Mounting Dimensions
2-M8x20
211 88
140
42
C3 Φ42
12
Φ78
Model E45.605 backside of Top Beam Mounting Dimenions

Fixture Mounting
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 illustration.
For mechanical dimensions of grip adapters, mounting Pin and mounting dowel,
please refer to “Clevis Adapter Dimension” on page 200 for details.
Locking
Collar
Mounting Pin
Mounting Dowel
(Clevis Pin Adapter)
(Pin)
Load Frame
Adapter

Install The Load Cell And Adjust For Coaxiality
Install The Load Cell And Adjust For Coaxiality

Mounting load cells typically involves securing the load cell to the frame via a
threaded bolt along with associated hardware (in most cases a flat washer,
adapter sleeve, and plate assembly). The following figures show the standard
mounting configurations. Load cell mounting/adapter bolts should be lubricated
with light oil or grease before being assembled and torqued to specifications.
For other revolved bolts torque specified, please refer to “Metric Threads Torque
Chart” on page 201 for details.
For mechanical dimensions of concentricity fixture, please refer to

“Concentricity Fixture” on page 203 for details.
Note When installing a mounting bolt or an adapter bolt into load cell, check
the length of bolt to avoid “bottoming” the bolt in the load cell hole. Doing
so will permanently damage the load cell.
Load Cell Bolt Torque Specifications
Load Cell Type Bolt Thread Lube and Torque to Wrench Size
5 N-250 N S-Beam* M6 x 1 mm 11 N•m M5 hex
500 N-2 kN S-Beam M6 x 1 mm 11 N•m M5 hex
5 kN S-Beam M12 x 1.25 mm 93 N•m M10 hex
100 N- 500 N Low Profile Shear Beam† M6 x 1 mm 14 N•m M5 hex
10 kN Low Profile Shear Beam M6 x 1 mm 11 N•m M5 hex
50 kN (E43 model) Low Profile Shear Beam M6 x 1.25 mm 11 N•m M5 hex
50 kN(E45 model) Low Profile Shear Beam M10 x 1.5 mm 53 N•m M8 hex
100 kN Low Profile Shear Beam M10 x 1.5mm 53 N•m M8 hex
200 kN and 300 kN Low Profile Shear Beam M12 x 1.75mm 93 N•m M10 hex
500 kN and 600 kN Low Profile Shear Beam M16 x 2mm 230 N•m M14 hex
* When installing S-beam style cells, support the grip adapter while torquing the adapter bolt to prevent
damaging the load cell from torque twist.
† When installing profile style cells, Torque the bolts to the torque specified in the table in a crisscross
pattern. Bring bolts to 33% of full torque, then bring to 66% of full torque,and then to 100% full torque.

E42.503 Load Cell Assembly Guide

Allen Screw M12x30
Washer
Pin
Mounting Plate
Fixture Base
Load Cell
Allen Screw M6x16
Adapter
Allen Screw M12x30
Model E42 -5 kN
Procedure 1. Install the load cell and clevis adapter:
a. Place washer into keyway located on crosshead.
B. Install load cell alignment mounting plate and the load cell to proper
positions on underside of crosshead. hold in place.
C. Insert Allen screw M12x30 through crosshead and fasten load cell to the
middle cross beam.
D. Lube and tighten Allen screw M12x30 using torque wrench to 93 N·m
(69 lb-ft).
E. Fasten grip clevis adapter to load cell with Allen screw M12x30.
2. Install the fixture base: Fasten fixture base to the loadframe,using Allen
screw M6x16. Do not fully tighten screws at this time.
3. Adjust for coaxiality and torque load cell:
a. Move crosshead so that there is approximately 50mm between the

Adapter and Fixture base. Check relative alignment of adapters with
machinist’s straight edge. Adjust as needed.
B. Raise crosshead and Insert concentricity fixture into upper and lower
adapters. Pre-load to 90% of frame full load and tighten Allen screws
for load cell.
C. Repeat steps above to adjust the coaxiality of the base adapter. Tap base
adapter with mallet if necessary.
D. Alignment is complete when pin easily slides in and out of grip clevis
adapter.
E. Use the concentricity fixture and pre-load to 90% of full load and then
torque base adapter Allen screw M6 x16 to 11 N·m (8.2 lb-ft).


Allen Screw M12x30
Washer
Mounting Screw M6
Fix torque is 10N•m
Support Plate Pin
Load Cell
Fixture Base
Adapter
Allen Screw M6x16
Allen Screws M12x30
Model E43 -10 kN

Procedure 1. Install the Load Cell：
a. Connect adapter to the load cell. Fasten with using Allen screws
M12x30.
B. Assemble load cell and load cell support plate. Use washer and Allen
screws M12x30 to connect load cell to support plate.
C. Use M6x25 screws and washers to fasten load cell assembly to

crosshead. Do not fully torque at this time. For the installation position,
see the above figure.
D. Fasten grip clevis adapter to load cell with Allen screw M12x30.
2. Install Fixture base: Place Fixture base on the load frame, using Allen screw
M6x16. Do not fully tighten screws at this time.
3. Adjust the coaxiality and torque load cell:
a. Move crosshead so there is approximately 50mm between the adapter

and fixture base. Check relative alignment of adapters with machinist’s
straight edge. Tap load cell support plate with mallet if necessary to
adjust.
B. Raise crosshead and insert concentricity fixture into upper and lower
adapters. Pre-load to 90% of frame full load. Torque Allen screw
M12x30 for load cell to 93 N·m (69 lb-ft).
C. Relax load to zero and repeat steps above to adjust the coaxiality of the
load cell support plate and base adapter. Tap load cell support plate or
base adapter with mallet to adjust.
D. Alignment is complete when pin easily slides in and out of grip clevis
adapter.
E. Pre-load to 90% of full load. Torque load cell support plate Allen screw
M6x25 to 11 N·m (8.2 lb-ft). Torque base adapter Allen screw M6x20
to 11 N·m (8.2 lb-ft).

E43.504Load Cell Assembly Guide
E43.504Load Cell Assembly Guide
Fixture Base
Assembly Plate
Load Cell Pin
Allen Screw M6x45

Allen Screws M12x30
Locking Nut
Cruciform Adapt-
Model E43 -30 kN,50kN

Procedure 1. Install the Load Cell:
a. Fit load cell and assembly plate into recess on underside of crosshead.
Insert lubed Allen screw M6×45 and spring washers to secure load cell
in eight places to crosshead. Do not fully tighten screws at this time.
B. Thread the locking nut onto cruciform adapt. Thread into load cell, and
tighten the locking nut close to the end surface of the load cell.
2. Install Fixture base: Place Fixture base on the load frame. Secure with lubed
Allen screw M12×30. Do not fully tighten screws at this time.
3. Adjust the coaxial alignment and tighten load cell screws:

straight edge. Tap fixture base with mallet if necessary to adjust.
adapters. Make sure fixture rotates freely in upper and lower adapter.
Insert upper and lower pins. Alignment is complete when upper pin
rotates freely in upper adapter.
C. Pre-load to 90% of frame full load. Torque Allen screw M6 for load
cell to 11 N·m (8.2lb-ft).Tighten lock nut on threaded connecting rod
using mallet and chisel or claw wrench.
D. Relax load to zero and re-check pin in upper adapter. Make sure it
moves freely.
E. Pre-load to 90% of frame full load. Torque Allen screws for base
adapters needed.

E44 -10 kN, 30 kN (S-Beam Type) Load Cell Assembly
E44 -10 kN, 30 kN (S-Beam Type) Load Cell Assembly Guide

Allen Screw M12x40
Washer
Mounting Screw M10

Fix Torque is 20N•m
Mounting Plate
Pin
Fixture base
Load Cell
Allen Screws M8x16
Adapter
Allen Screw
M12x40
Model E44 -10 kN, 30 kN (S-Beam Type)

a. Connect adapter to the load cell, using Allen screw M12×40.
B. Assemble the load cell and Mounting plate. Use washer and Allen
screw M12x40 to connect load cell to mounting plate.
C. Use Allen screw M10x30 and washers to fasten load cell assembly to
crosshead. Do not fully torque at this time. For the installation position,
see the above figure.
D. Fasten adapter to load cell with Allen screw M12x40 and washer.
2. Install Fixture base: Place Fixture base on the load frame, Secure with lubed
Allen screws M8×16 and washer. Do not fully tighten screws at this time.
3. Adjust the coaxiality and torque load cell:

straight edge. Tap load cell support plate with mallet if necessary to
adjust.
adapters. Make sure fixture rotates freely. Insert pins in upper and
lower clevis. Machine is aligned when upper pin moves freely in and
out of upper adapter.
C. Pre-load to 90% of frame full load. Torque Allen screw M12×40 for
load cell to 93 N·m (69 lb-ft).

E44-20kN, 30kN (Low Profile Type) Load Cell
D. Relax load to zero and repeat steps above to adjust the coaxiality of the
load cell support plate and base adapter. Tap load cell support plate or
base adapter with mallet to adjust.
E. Pre-load to 90% of full load. Torque load cell support plate Allen screw
M10x30 to 53 N·m (39 lb-ft). Torque base adapter Allen screw M8x16
to 27 N·m (20 lb-ft).
E44-20kN, 30kN (Low Profile Type) Load Cell Assembly Guide

Allen Screw M18x45
Mounting Plate
Connect Threaded
Top Beam
Crosshead
Top Adapter
Load Cell pad
Load Cell
Allen Screws Pin
M6x40
Round Nut Fixture Base
Locking Collar
Adapter Allen Screws M8x16
Model E44 -30 kN (Low Profile Type)

a. Fit the load cell and the load cell pad into recess on underside of
crosshead, using the screws M6x40 and the spring washers to secure
load cell.Do not fully tighten screws at this time.
B. Place the connect threaded rod through the middle cross beam and the
inner hole of the load cell pad to connect to the screwed hole of the load
cell, and tighten the connect threaded rod by using the round nut, and
make sure the round nut is close to the end surface of the load cell.
C. Thread the locking Collar onto adapter. Thread onto connect threaded
rod . Then tighten the locking collar close to the end surface of the
round nut.

E44-20kN, 30kN (Low Profile Type) Load Cell
2. Install Fixture base and top adapter: Place fixture base to loadframe.Secure
with lubed Allen screw M8x20 and spring washer. Place Mounting Plate to
top beam. Secure with lubed Allen screws M10×16 and spring washer.
Connect upper adapter to the mounting plate with Allen screw M18×45. Do
not fully tighten screws at this time too.
3. Adjust the coaxiality and tighten load cell screws:

straight edge. Tap fixture base with mallet if necessary to adjust.
B. Raise crosshead and insert concentricity fixture into adapter and fixture
base. Make sure fixture rotates freely, Insert pins in clevis. Alignment
is complete when pin rotates freely in upper adapter.
C. Pre-load to 90% of frame full load. Torque Allen screws M6×50 for
load cell to 11 N·m (8.2 lb-ft). Tighten round nut and locking collar on
threaded connecting rod using mallet and chisel or lock nut
wrench.Torque fixture base Allen screw M8×16 to 27 N·m (20 lb-ft).
D. Relax load to zero and re-check pin in adapter. Make sure it moves
freely.
E. Pre-load to 90% of frame full load. Torque all Allen screws to the rated
torque.
F. Raise crosshead so there is approximately 50mm between the top

adapter and connect threaded rod. Check relative alignment of adapters
with machinist’s straight edge. Tap mounting Plate with mallet if
necessary to adjust.
G. Move crosshead and insert concentricity fixture into top adapter and
connect threaded rod. Make sure fixture rotates freely. Insert pins in
clevis. Machine is aligned when upper pin moves freely in and out of
top adapter.
H. Torque Allen screw M10x25 to 53 N·m (39 lb-ft). Torque Allen screw
M18x45 to 230 N·m (170 lb-ft).


Allen Screws M12x30
Dust Cover
Connect Threaded Rod

Upper Adapter
Crosshead
Load Cell pad
Load Cell
Lower Adapter
Allen Screws
M10x65
Allen Screws
Round Nut M12x30
Locking Nut
Adapter
Model E45 -100 kN

Procedure 1. Install the Load cell:
a. Fasten the dust cover to the upper crosshead by using the philips screw
M4x8.
B. Fit the load cell and the load cell pad into recess on underside of
crosshead, using the Allen screw M10x65 and the spring washers to
secure load cell.Do not fully tighten screws at this time.
C. Place the connect threaded rod through the middle crosshead and the
inner hole of the load cell pad to connect to the screwed hole of the
load cell, and tighten the connect threaded rod by using one round nut,
and make sure the round nut is close to the end surface of the load cell.
D. Thread the another Locking nut and adapter onto connect threaded rod.
Then tighten the 2nd locking nut close to the top surface of the adapter,
using mallet and chisel or lock nut wrench.
2. Install Fixture base and top adapter: Place Lower adapter to load frame.
Secure with lubed Allen screw M12x30 and spring washer. Place Upper
adapter to topbeam. Secure with lubed Allen screw M12x30 and spring
washer. Do not fully tighten screws at this time too.

and lower adapter. Check relative alignment with machinist’s straight
edge. Tap lower adapter with mallet if necessary to adjust.

B. Raise crosshead and insert concentricity fixture into adapter and lower
adapter. Make sure fixture rotates freely, Insert pins. Alignment is
complete when pin rotates freely in upper adapter.
C. Pre-load to 90% of frame full load. Torque Allen screws M10×65 for
load cell to 53 N·m (39 lb-ft). Tighten 1st lock nut on threaded
connecting rod using mallet and chisel or lock nut wrench.Torque
lower adapter Allen screw M12×30 to 93 N·m (69 lb-ft).
D. Relax load to zero and re-check pin in adapter. Make sure it moves
freely.
E. Pre-load to 90% of frame full load. Torque all Allen screws as the rated
torque for lower adapter.
F. Raise crosshead so there is approximately 50mm between the upper

adapter and connect threaded rod. Check relative alignment of adapters
with machinist’s straight edge. Tap upper adapter with mallet if
G. Move crosshead and insert concentricity fixture into upper adapter and
connect threaded rod. Make sure fixture rotates freely. Insert pins in
clevis. Machine is aligned when upper pin moves freely in and out of
upper adapter.
H. Torque upper adapter Allen screw M12x30 to 93 N·m (69 lb-ft).

Dust cover
Mounting Plate
Load Cell
Allen Screws
M10x65
Locking Nut
Lower Adapter
Adapter Allen Screws

M12x35
Model E45 -300 kN

Procedure 1. Install the Load cell:
a. Fasten the dust cover to the upper crosshead by using the philips screw
M4x8.
B. Fit the load cell and the load cell pad to the underside of crosshead,
using the Allen screw M10x65 and the spring washers to secure load
cell.Do not fully tighten screws at this time.
C. Thread the locking nut onto adapter. Thread them into load cell, then
tighten the locking nut close to the end surface of the load cell.
2. Install lower adapter: Place Lower adapter to loadframe. Secure with lubed
Allen screw M12x35 and spring washer. Do not fully tighten screws at this
time too.

and lower adapter. Check relative alignment with machinist’s straight
edge. Tap base plate with mallet if necessary to adjust.
B. Raise crosshead and insert concentricity fixture into adapter and lower
adapter. Make sure fixture rotates freely. Insert pins. Alignment is
complete when upper pin rotates freely in upper adapter.
C. Pre-load to 90% of frame full load. Torque Allen screw M10x65 for
load cell to 53 N·m (39 lb-ft).Tighten lock nut on adapter using mallet
and chisel or claw wrench.
moves freely.
E. Pre-load to 90% of frame full load. Torque Allen screw M12x35 for
lower adapter as needed to rated torque.


Allen Screws M36x70
Top Beam
Lower Pressure Plate
Base Cover
Allen Screw M16x90 Bending Middle base
Load Cell Allen Screws M5x20
Load Cell Pad Connector
Crosshead
handle Upper pressure plate
Connect Threaded Rod Fixture Bases
Allen Screws M16x70
Model E45 -600 kN

Procedure 1. Install connector, the Allen screw M5x20, upper compression platen, the
bending middle base, and the handle on the top beam.
2. Fasten the load cell and the load cell plate to the middle crosshead by using
the Allen screw M16x90.
3. Route the connect threaded rod through the crosshead from below to
connect to the base cover.
4. Fasten the lower pressure plate to the base cover through the Allen Screws
M36x70.
5. Fasten the fixture base to the lower beam by using the washer and the Allen
Screws M16x70.
6. Adjust the coaxial alignment and tighten load cell screws:
a. Move crosshead so there is approximately 50 mm between the connect

threaded rod and fixture bases. Check relative alignment of adapters
with machinist’s straight edge. Tap base clevis adapter with mallet if
B. Raise crosshead and insert concentricity fixture into connect threaded

rod and fixture bases. Make sure fixture rotates freely. Insert pins.
Alignment is complete when upper pin rotates freely in upper adapter.
C. Pre-load to 90% of frame full load. Torque Allen Screw M16x90 for load
cell to 230 N·m (170 lb-ft). Tighten base cover on threaded connecting
rod using mallet and chisel or claw wrench.

moves freely.
E. Pre-load to 90% of frame full load. Torque Allen Screw M16x90 for
load cell to 230 N·m (170 lb-ft) for Fixture bases as needed. Torque
Allen Screw M36x70 for load cell to 2700 N·m (2000 lb-ft).

System Installation Checklist
System Installation Checklist

The system will be installed by an MTS installation Engineer. The system will
also be checked to ensure that all components are operating as intended.
Depending on the system configuration, the following activities will be
performed:
Installation Check
• Verify that all components purchased are present according to contract and
packing list.
• Confirm the field power specifications meet the electrical power

requirements by the use of multimeter.
• Attach all required cables between controller and load unit.
– Transducers
– Deformation sensor (extensometer, deflectometer, etc)
– Power line
– USB2 data connection for systems with the Insight controller and the
Ethernet connection for system with the ICE controller
• Install purchased grips and fixtures as required (including water, power,

pneumatic supply or oil needed for the grips).
• Install purchased environmental simulation products such as any furnaces,

chambers, etc.
ICE Controller Troubleshooting - Customer Supplied PCs

Workstation MTS recommends workstations that meet or exceed the following specifications:
Recommendations
• Intel Core i5 or AMD Ryzen 5, 3.2 GHz Processor, or faster (overclocked or
turbo boost specsacceptable)
• 8.0 Gb RAM minimum, 16 Gb RAM recommended
• Hard Drive with at least 20 Gb of free disk space
• DVD-ROM Drive
• (2) Ethernet Network Cards
• Recommended minimum screen resolution is 1280 x 1024 (for optimal view

of interface)

ICE Controller Troubleshooting - Customer Supplied
Setup In the Network and Sharing Center of the customer’s PC, it will be necessary to
make sure the IPV6 option is selected for the network connection that is assigned
to the ICE controller. » This is found in the properties section of the network
connection for the ICE controller. » Make sure Internet Protocol Version 6 (TCP/
IPv6) is checked as shown.

On the properties tab of the IPv6 section, make sure both selections are
automatic:
The ICE controller communicates over Ethernet IP v6. To get communication

going to the ICE controller, the FSE only has to enable IPv6 and enable
automatic connection. Start TW diag, search for the controller.

If a customer supplies their own PC with a strict IT security policy in place,

discuss with the customer the need for IPv6 to be enabled to communicate with
the machine. Often IPv6 is disabled as a part of the policy. This will prevent
communication with the ICE controller.
If needed, an FSE can demonstrate connectivity by using their FSE laptop and
common Windows tools, like TCPView or Wireshark.
1. Shut down any VPN (which will disable ethernet communications) session.
2. Connect straight through cable to FSE laptop ethernet port
3. Open TCPView session
4. Start TWDiag and select search above
5. Note that ICE broadcasts on port 1900 on group address FF02::C
6. Note that once located, Twdiag will show a connection using port 32771
7. Follow notes on enabling IPv6 in registry settings on the Microsoft web site:
https://docs.microsoft.com/en-us/troubleshoot/windows-server/networking/
configure-ipv6-in-windows

Functional Check
Functional Check
• Verify communication and power up operation via handset. Verify handset
commands generate proper crosshead response/motion.
• Verify E-stop and limits are functional.
• Verify position control and speed accuracy.
• Verify signal response and display readings for position, load, and strain (if
applicable).
• Configure and set up the control system parameters.
• Insure that the system is properly adjusted and “tuned”.
• Use the shunt calibration method of verify Self-ID callibrations.
• Verify system operation in closed loop control.
• Verify operation of emergency and safety features
• Verify the operation of any additional control or monitor products purchased

from MTS.
Additional Purchased Options

• Calibrations: if purchased.
• System performance demonstrations: if purchased.
• Custom test method creation: if purchased.

On-site computer integration: if purchased. On-site computer integration
does not include peripheral or network integration. If time permits, at the
end of the installation, the MTS Service Engineer will assist your
Information Services Technician with the integration of peripherals and
network capabilities. The MTS Service Engineer is not trained in
information systems troubleshooting techniques and is not responsible for
compatibility issues regarding the integration of devices other than those
required for communication with the MTS supplied controller.

Additional Purchased Options

Verification
Verification procedure is to verify that a device is working properly.
There are two levels of Verification, daily and official. Customer should perform
a daily Verification to verify that devices are functioning properly. The daily
Verification is really a shunt verification. TestSuite compares the daily shunt
values to the shunt values recorded in the TEDS file. TEDS cells use 4 shunt
values to compare the full bridge. Each time performing a daily Verification,
TestSuite calculates a Verification factor for the device, and compares it to the
original Verification factor. If there is a significant deviation between the values,
there will be a warning, or the device will be locked so that it cannot be used.
Official Verification compares your device to a known standard for accuracy.

This type of Verification should be performed once a year by a certified
Verification service, such as MTS Service.
MTS Exceed® Series 40 FSE Manual Verification 115

TEDS Devices Window
TEDS Devices Window

Access
Note This feature only applies to MTS Criterion,Exceed and MTS Insight
systems.
Follow these steps to calibrate your device:
1. Controller menu > TEDS Devices window.
2. The TEDS Devices window shows the calibration source (virtual TEDS file
or TEDS device) and provides access to the calibration settings for the
signals that use a virtual TEDS file.
Overview
The TEDS Devices window shows all the signal resources and TEDS
assignments associated with the controller and allows you to:
• Create a virtual TEDS file for a controller resource.*
• Update a virtual TEDS file.*
• Assign a virtual TEDS file to a controller resource.
• Configure a device verification for the selected device.
• Perform a device verification for the selected device.
• View the Device Verification History for the selected device.

* Requires the Edit Calibration Values privilege.
Note Editing the information for a device that has a TEDS chip can only be
performed by an MTS Field Service Engineer.
116 Verification MTS Exceed® Series 40 FSE Manual

Display and Edit the Virtual TEDS Information for a
Display and Edit the Virtual TEDS Information for a

Signal
Note Editing the information for a device that has a TEDS chip can only be
performed by an MTS Field Service Engineer.
Note This feature only applies to MTS Exceed and MTS Insight systems.
1. On the Controller menu, click TEDS Devices.
2. Select a signal (with a TEDS file assigned as a source) from the signal list.
3. Click Details.
4. Edit the TEDS settings as required.
5. Click OK to save your changes.
Any changes will overwrite the settings in the TEDS file that is assigned to the
signal.

Create and Assign a Virtual TEDS File to a Signal
Create and Assign a Virtual TEDS File to a Signal

2. Select a signal.
3. Click New.
If the selected signal is an encoder:

A. The TEDS Details window appears with default encoder settings.
B. If necessary, edit the settings and click OK.
C. In the Save As TEDS window, type a name for the TEDS file and click
Save.
D. The new TEDS file is now listed as the source for the signal.
If the selected signal is _Load, _Strain1, or Strain2:

E. In the TEDS Selector window, select the type of device.
Analog Input Device:

Bridge-type sensor such as a load cell or strain gage.
High-Level Voltage-Output Sensor: Non-bridge sensor (such as a string pot) that

provides a high-level voltage output.
F. Click OK.
G. Click Yes to save the settings as a new file.
H. Perform a device verification.

Analog Input Device:
Assign a Virtual TEDS File to a Signal

2. Select a signal.
– If a signal already has a file assigned to it, click Remove to remove the
source assignment.
– If a signal does not have a file assigned to it, click New.
3. Click Assign.
4. In the Open TEDS window, select a compatible TEDS file.
The default directory for virtual TEDS files is: MTS TestSuite\Devices.
5. Click Open.
6. Perform a device verification.

Perform a Device Verification Check
TEDS Device Verification Checks

TEDS Device Verification Check procedures only apply to MTS Exceed and
MTS Insight Systems.
1. Perform a Device Verification Check
2. View the Device Verification History
3. Device Verification Settings

A device verification check compares device readings recorded during
actual,calibration to the readings recorded during the check to help identify
problems associated with a device.
2. Select a signal from the signal list.
3. Click Verify.
4. Follow the on-screen prompts to verify the device.


View the Device Verification History

The Device Verification Check History window shows the history of all the
device verification checks run against the selected signal (device).
2. Select a signal.
3. Click History.

Device verification prompt
Device Verification Settings
Device verification prompt

The device verification prompt is used to remind an operator to run a device
verification before being running a test. To configure a device verification
prompt:
3. In the TEDS Details panel, select the Device Verification Prompt for the
device. For example, if set to Daily, each day, the operator will be prompted
to run a device verification before being allowed to run tests.

Warning/Lock-Out Ranges
Warning/Lock-Out Ranges
During a device verification, the application compares the new signal value
obtained during the check to the value obtained when the device was calibrated.
To configure a warning/lock-out range for a device:
3. Set the Warning and Lock-Out ranges.
– If the difference between the new value(s) and the original value(s) is
beyond the Warning Range, a warning message appears. The user must
determine whether to proceed with testing or to resolve the problem
with the device.
– If the difference between the new signal value and the original signal
value is beyond the Lock-Out Range, an error message appears. The
application will not allow you to run a test until the problem has been
resolved.

Maintenance
To ensure that the frames continues working at its optimal performance, it is
recommended that the machine receive an annual service check. MTS Service
department can perform this annual service, and replace any damaged or worn
parts to ensure that your machine operates to its stated specifications.
MTS offers many service agreements that provide a variety of services, including
annual service visits. Contact your local MTS office for details on a service
agreement or contract that best matches your needs.
Contents Operator maintenance 126

Routine Maintenance Detail 128
Lubrication 136
MTS Exceed® Series 40 FSE Manual Maintenance 125

Operator maintenance
Operator maintenance
Operator only performs preventive maintenance. Preventive maintenance is the
periodic inspection, cleaning of the testing system. The following sections
provide guidelines for operator maintenance.
Daily Maintenance Checks

Before operating the system each day, ensure:
• All cable connections are tight and secure.
• All grips, fixtures and accessories are free of dirt, damage and deformation.
• The load frame is level. If an adjustment is necessary, refer to the leveling

instructions in the Installation chapter.
• Signal and power cables have adequate slack to prevent excessive strain on
connectors.
• All cables are free of wear and chafing. Re-route the cables if necessary, and
replace any damaged cables.
• After turning on the system, make sure that power is adequately supplied to
the electronics.
Correct any problems before you operate the testing system. If you require
assistance, contact your local MTS Service department.
Periodic Inspections
Every month, perform the following inspections:
• Visually inspect the machine for any loose fittings. Check the limit stops,
cable connections, and connections for any accessories that are attached to
the machine. Tighten any loose connections that you may find.
• 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 any additional interlocks are functioning properly. For example, the
interlock switches on the door of a test area enclosure.
126 Maintenance MTS Exceed® Series 40 FSE ManualMTS

General cleaning
General cleaning
WARNING
Be careful not to spill any 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.
CAUTION
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.
Clean your machine 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.

Routine Maintenance Detail
Routine Maintenance Detail

This section describes the routine maintenance procedures. Proper maintenance
is important because it can improve system quality and extends the life of the
system.
Some routine maintenances are 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.

Routine Maintenance Overview Checklist
Routine Maintenance Overview Checklist
Recommended service to be performed at each running time interval noted
Calendar Time Using 8 Hours Running Time Rate per Day Daily Weekly Annually
Running Time-Hours 8 40 2000

Check Shunt Calibration X*
Clean Work Area/Machine Surface X
Activate and reset Limits and E-Stop X
Inspect Cable/Connections X
PC Maintenance
Back up TestSuite files (*.reg/.cal files) MTS†

HD Defragmentation 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 E-Stop MTS
Check Upper Limit MTS
Check Lower Limit MTS
Check Load Cal/Shunt Cal MTS

Lubrication
Crosshead/Ball Screw (calcium sulfonate grease) MTS
Drivetrain Bearings (if applicable) MTS

Frame and Work Area
Clean Off Frame and Work Area MTS
* Symbol 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.
† Symbol 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.

PC Maintenance
PC Maintenance
The PC maintenance includes the following operations:
Back-up TestSuite files (*.reg/.cal files)

To back-up is to make spare copies of files and store them separately to the
originals. Computers have a tendency to go wrong from time to time, these days
total hard drive failure is rare, but it does happen. One of the more common
problems nowadays is the threat from viruses, with some of the more serious
infecting the master boot record of a hard drive’s file system. If the master boot
record of a hard drive is infected with a virus, then the Fdisk utility, or similar,
would most likely have to be run, the chances are the data on the drive would be
lost, or at least costly to recover. Operating system failure and bad software
installation are other things that can cause problems when it comes to recovering
files.
The test data is very important, you need to back up these TestSuite files (*.reg/
.cal files) periodically. Customer-specific back up files are found in the C:\MTS
TestSuite directory. Pay particular attention to the number of tests within a given
project file, as a large amount of data within a project can lead to sluggish
application behavior or even crashes.
How frequently you back up will depend on how often you use your PC and what
you use it for. MTS recommends that you do a full back-up once a week/month
(depending on PC use).
You can back up your files to the following back-up devices:
• USB Flash Drives
• CD Writers/DVD Writers
• ZIP Drives
• External Hard Drives
HD Defragmentation
Defragmentation is the term given to the process of scanning the file system and
rejoining the split files back into consecutive pieces.
The process of defragmenting can be time consuming, but it is one of the easiest
ways to increase the performance of your PC, the frequency of which a PC
should be defragmented will directly depend on the amount of usage.
HD Defragmentation
Defragmentation is the term given to the process of scanning the file system and
rejoining the split files back into consecutive pieces.
The process of defragmenting can be time consuming, but it is one of the easiest
ways to increase the performance of your PC, the frequency of which a PC
should be defragmented will directly depend on the amount of usage.

HD Defragmentation
Defragmenting in To defragment in Windows 10 perform the following procedure:

Windows 10
1. Click on the Start button and go to Windows Administrative Tools. Select
Defragment and Optimize Drives.
2. Under Status, select the disk you want to defragment.
3. To determine if the disk needs to be defragmented or not, click Analyze.

Once Windows is finished analyzing the disk, you can check the percentage
of fragmentation on the disk in the Last Run column. If the number is above
10%, you should defragment the disk.
4. Click Optimize.
Note If the hard drive is optimized, all applications will work better including
TestSuite (not just TW). It is a good idea to setup the computer to
optimize on a weekly basis.

HD Defragmentation
Defragmenting in To defragement in Windows 7 performs the following procedures:

Windows 7:
1. Click on the Start button and go to All Programs.
2. Select the Accessories folder.
3. Select the Systems Tools folder.
4. Click on Disk Defragmenter. The Disk Defragmenter window will open.
5. Under Current status, select the disk you want to defragment.
6. To determine if the disk needs to be defragmented or not, click Analyze

disk.
Once Windows is finished analyzing the disk, you can check the percentage
of fragmentation on the disk in the Last Run column. If the number is above
10%, you should defragment the disk.
7. Click Defragment disk.

System Inspections
System Inspections
System inspections includes the following inspections:
Inspect drive belts for excessive wear

Inspect drive belts for excessive wear, please perform the following items:
1. Visually check the belt excessive wear, frayed cords, cracked edges, tears,
etc.
If any defect has been found, replace the drive belt. Cracks on the rib side of a
belt are considered acceptable. If the belt has chunks missing from the ribs, it
should be replaced.
2. Using a belt tension gauge, measure the belt tension. If the belt tension is not
as specified, adjust belt tension using belt idler adjustment bolt. Turn motor/
drive system and recheck belt tension for tight spots.
Recommend FSE has belt tension gages from 7 kg to 150 kg ranges. MTS
recommend measuring gages for FSE use are:
• Part number 100-247-742; belt tension gage 13.6-68.0 kg (30-150 lbs)
• Part number 100-247-743; belt tension gage 45.4-136.1 kg(100-300 lbs)
Using belt tension gauge refers to the following figure..
Belt tension Gauge

Inspect cable connections
Refer to the following table for drive belt tension.
Model E42.503 E43.104 E44.104 E44.304 E45.105 E45.305 E45.605 Tension force (N)
Belt
HTD-590-5M-20 X 150-180
HTD-1455-5M-20 X 150-180
HTD-1520-8M-35 X X 250-300
STPD-900-S5M-25 X 190-220
950H200 X 550-600
HTD-872-8M-40 X 450-500
980XH500 X 900-1000
800-8MGT-20 X 150-200
3500-14MGT-90 X 900-1000
Inspect cable connections

Cables and connectors should be checked for loose screws, cable abrasion,
broken wire ties, dirt or contaminates, etc.

System Checks
System Checks
System checks include the following checks:
Check E-stop
Trigger E-stop button and verify the system interlocks. Reset E-stop and verify
interlock can be cleared.
Check limit stops

It is recommended that you periodically test limit stops on the load frame.
To test the limit stops:
1. Ensure that the system is on and the crosshead is stationary.
2. Secure the upper limit stop (or lower limit stop) to the limit switch rod.
3. Push the upper limit stop in up direction and verify TestSuite interlocks and
reports “Upper Limit Active”.
4. Clear interlock and repeat for lower limit.
5. Lubricate the limit stops and rod with light oil.

Lubrication
Lubrication
The following areas of the machine will require periodic lubrication:
• Ballscrews - The ballscrews are lubricated via a ballnut that is located on the
crosshead where the ballscrew intersects the crosshead. As the crosshead
moves up and down, the ballnut disperses a thin layer of lubricant over each
ballscrew as the ballscrew passes through the ballnut. Periodically, the
ballnut must be filled with lubricant to ensure that the ballscrews remain
well lubricated. The following sections describe the ballscrew lubrication
procedures for various machines.
• The E42 models have a unique design that uses linear guide carriages. These
carriages also require periodic lubrication. Refer to section “Linear Guide
Carriages” in this chapter for instructions.
Lubricate equipment
To perform lubricating mantenence you need the following equipments:
• Calcium sulfate complex grease
• Grease gun
• Soft lint-free cloth

Lubricating ballscrew ballnut on the E42 model

To lubricate the ballscrew ballnut on the E42 single column models:
1. Turn the power switch to the Off (O) position and disconnect the power
cable from the main power source. Ensure that the POWER indicator light
on the handset does not illuminate.
2. Detach the top ballscrew cover from the crosshead, locate the grease nipple
inside the column cover.
3. Use a grease gun to apply the grease into the grease nipple as shown in the
below figure. It is not necessary to remove the guide column cover.
4. Fill the ballnut until grease oozes from the upper of the ballnut. Wipe away
the excess grease.
5. Re-attach the top ballscrew cover to the crosshead.
6. Re-connect the power cable to the main power source and turn on the
system. Verify that the POWER indicator light on the handset illuminates.
7. Use handset to move the crosshead over the full stroke of the frame to
distribute the grease in the ballnut and coat the entire length of the ballscrew
shaft.
Ballscrew Cover
Grease nipple Column Cover
Crosshead


To lubricate the ballscrew ballnut on the E43 double column table models:
2. Detach the bottom ballscrew cover from the crosshead, locate the grease
nipple inside the column cover.
4. Fill the ballnut until grease oozes from the bottom of the ballnut. Wipe away
the excess grease.
5. Re-attach the bottom ballscrew cover to the crosshead.
6. Repeat the 2-5 steps to lubricating the other side ballscrew.
shaft.
Ballscrew Cover
Crosshead
Grease Nipple
Column Cover


To lubricate the ballscrew ballnut on the E44 double column floor models:
2. Detach the top ballscrew cover from the crosshead, locate the grease nipple
inside the column cover.
4. Fill the ballnut until grease oozes from the top of the ballnut. Wipe away the
excess grease.
5. Re-attach the top ballscrew cover to the crosshead.
shaft.
Ballscrew Cover
Grease Nipple
Crosshead
Column Cover


To lubricate the ballscrew ballnut on the E45 double column floor model:
2. Detach the bottom ballscrew cover from the crosshead, locate the grease
nipple inside the column cover.
4. Fill the ballnut until grease oozes from the bottom of the ballnut. Wipe away
the excess grease.
5. Re-attach the ballscrew cover to the crosshead.
shaft.
Ballscrew Cover
Crosshead
Grease Nipple
Column Cover

Lubricating linear guide carriages on the E42 model

On the E42 models, the linear guide column must also be lubricated periodically,
based on the same schedule as the ballscrew ballnut. There are two carriages that
carry the crosshead along the linear guide column. These two carriages contain
grease that lubricates the guide column as they travel along the guide column.
Each carriage has its own grease nipple. One is located above the crosshead
(behind the ballscrew cover) and the other is located below the crosshead.
Grease Nipple Crosshead
Carriages
Ballscrew Cover
To lubricate the linear guide column:
2. Detach the column covers and slide it away from the column, locate the
grease nipple on each carriage.
3. Use a grease gun to apply the grease into the grease nipple.
4. Fill each carriage until grease oozes from them. Wipe away the excess
grease.
5. Re-attach the column covers.

7. Use the handset to move the crosshead over the full stroke of the frame to
distribute the grease and coat the entire length of the linear guide column.

Decommissioning
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:
• Remove specimen and fixtures. Large grips should be removed if the load
frame could be tipped over.
• Isolate the system from electrical power.
• 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.
• Disconnect all cables from the controller.
• Cover the materials testing machine with a dust cover, such as plastic foil.
Allow for sufficient ventilation or place a dehumidifier near to the
equipment.
• Place the accessories and the instruction manual in a clean, dust protected
place, such as a tool cabinet.
CAUTION
Electrical components and parts can contain hazardous chemicals and

compounds.
Improper disposal of hazardous chemicals and compounds can cause

injury and death . In addition, it can cause contamination of the soil, air, and
water.
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.
Repair
Contents Removing Panels 144
Replacing Controller 148
Parameters setting 149
MTS Exceed® Series 40 FSE Manual Repair 143

Removing Panels
Removing Panels
Some installation and repairmen situations may require you to remove the load
frame covers in order to access components.
WARNING
Do not operate the system with the protective covers removed.
Rotating machinery within the base and columns can cause personal injury.
Disconnect the main power to the load frame before removing the protective
panels. Dangerous voltages within the base structure can cause personal injury.
Removing E42 Panels

Equipment You need a screwdriver.
Before you start Check for the following:
• The load frame power is off.
• The load frame power cable is disconnected from the main power source.
Procedures To remove right panel on the E42 model performs the following procedures:
1. Remove the protective mats and any tools or testing items from load frame.
2. Use the screwdriver to loosen the twelve M4 Philips screws on the top of the
base panel.
3. Carefully lift the panel away from the base.
Philips Screw
Rubber Mat
Removing the Panel on E42 Model
144 Repair MTS Exceed® Series 40 FSE Manual

Removing E43 Panels
Removing E43 Panels

Procedures To remove back panel on the E43 model performs the following procedures:
2. Use the screwdriver to loosen the ten M4 Philips screws on the cover of
motor.
3. Carefully lift the cover of motor panel away from the base.
4. Use the screwdriver to loosen the ten M4 Philips screws on the back panel.
5. Carefully pull back the back panel away from the base.
Front Panel
Rubber Mat
Philips Screw
Back Panel
Cover of Motor
Removing the Panel on E43 Model

Removing E44(10 kN, 30 kN) Panels
Removing E44(10 kN, 30 kN) Panels

Procedures To remove back panel on the E44(10 kN, 30 kN) model performs the following
procedures:
2. Use the screwdriver to loosen the sixteen M4 Philips screws on the front
panel and back panel.
3. Carefully pull out the back panel and front pannel away from the base.
Rubber Mat
Back Panel
Philips Screw
Front panel
Removing the Panel on E44 (10 kN, 30 kN) Model

Removing E45 Panels
Removing E45 Panels

Procedures To remove front panel and back panel on E45 model performs the following
procedures:
2. Use the screwdriver to loosen the sixteen M4 Philips screws on the front
panel and back panel.
3. Carefully pull out the back panel and front pannel away from the base.
Back Panel
Front Panel
Removing the Panels on E45 Model

Replacing Controller
Replacing Controller
Use the following procedures if a frame controller unit fails.
Equipment You need a Phillips screwdriver.
Before you start Check for the following conditions:
• The power switch is in the off position (O).
• The load frame cable is disconnected from the main power source.
Procedure To replace controller performs the following procedures:
1. Disconnected the all external cables to the frame controller.
2. Use the Phillips screwdriver to remove the six screws on the panel of
controller.
3. Carefully pull out the controller from the base.
4. Disconnected the all internal cables to the frame controller.
5. Replace the controller with a new controller.
6. Connected the all internal cables to the new frame controller.
7. Secure the new controller to the machine base with the six screws.
8. Connected the all external cables to the new frame controller.

Parameters setting
Parameters setting
Parameters setting of MTS Exceed controller
1. Go to C:\Program Files (x86)\MTS Systems\MTS
TestSuite\SelectControllerTypeUtility.exe. Make sure the correct controller
type is selected.
2. Start TW Diag.exe. The first time you connect to a new ICE controller, you
will need to change the controller type to ICE (Search).
3. Confirm controller type and log in as FSE if needed. Select the proper frame
category and type.
4. Select “Controller” tab.
5. Check the display defaults box to see the default tuning parameters. Press
the Apply Defaults button to apply the default directory to the controller.
Parameters setting of servo

1. Install the YASKAWA software (SigmaWin+ ) on PC.
2. Remove the front panel or back panel away from the base, and connect the
servo to the PC that has installed with SigmaWin+ software by using USB
debugging servo cables.
3. Power on the equipment and load the software, then import the proper
parameters of YASKAWA servo according to the machine model.

Parameters setting of servo

Spare Parts List
This section provides listing of the parts and assemblies that make up the load
frame. You can use the information in this section as a reference for obtaining
replacement parts.
Contents Spare Parts Lists for Exceed Systems with ICE Controllers 152
Spare Parts Lists for Exceed Systems with Insight Controllers 169
Load Cells List 186
MTS Exceed® Series 40 FSE Manual Spare Parts List 151

Spare Parts Lists for Exceed Systems with ICE
Spare Parts Lists for Exceed Systems with ICE

Controllers
The following pages provide spare parts lists for Exceed systems with the ICE
controller.
152 Spare Parts List MTS Exceed® Series 40 FSE Manual

Spare Parts List of E42.503

Item Description EP Part No. Qty
1 SWITCH-SAFETY, DOOR, ASSY E42, E43, E44, E45
SWITCH-SAFETY 440K-E33041 AB 100-302-571 1
CABLE GLAND AG-16 KSS 100-417-767 1
2 DUSTPROOF CURTAIN 100-392-289 2
3 RUBBER PAD 100-392-179 1
4 SWITCH-EMERG STOP 800FP-MT44PX02 AB 100-302-573 2
5 KNOB-THUMB, LIMIT, E42, E43, E44, E45 100-302-582 2
6 BLOCK-LIMIT SWITCH 100-279-088 2
7 SWITCH-POWER, E42, E43, E44, E45 100-302-576 1
8 SERVO DRIVE-SGD7S-2R8A00A002 YASKAWA 100-302-586 1
9 MOTOR-SGM7J-04AFC6S YASKAWA 100-302-592 1
10 RESISTOR-REGENERATION, E42, E43, E44 100-325-430 1
11 FILTER-POWER A/C, 1KN-100KN, C4X 100-252-443 1
12 SWITCH POWER SUPPLY-LS200-24,TDK-LAMBDA 100-422-419 1
13 CONTROL RELAY, CAD32BL, SCHNEIDER 100-424-477 1
14 BELT-DRIVE, BALLSCREW, E42.503 100-302-580 1
15 CONTROLLER ASSY-ENCL, PWA, ICE CHASSIS 100-461-587 1


3 MAT-RUBBER_ E43.104 100-530-592 1
6 SWITCH POWER SUPPLY-LS200-24, TDK-LAMBDA 100-422-419 1
14 BELT-DRIVE, E43.104 100-302-578 1
15 ROLLER BEARINGS 100-303-299 4


3 RUBBER PAD 100-392-173 1
6 BELT-DRIVE, BALLSCREW, C43.304, C43.504 100-252-466 1
9 BEARING_6204-2Z/TIMKEN 100-394-973 4
10 BELT-DRIVE, GEARBOX, C43.304, C43.504 100-252-457 1
14 CONTACTOR-E43.504, E44.304, E45 100-325-437 1
15 SERVO DRIVE-SGD7S-7R6A00B202 100-486-719 1
17 MOTOR-SGM7G-09AFC61 YASKAWA 100-302-589 1


3 RUBBER PAD 100-392-184 1
6 CABLE-D15P TO D15S CONNECTION 100-392-723 1
14 BELT-DRIVE, E44.304, E44.104 100-302-579 1


3 RUBBER PAD 100-392-184 1
7 SERVO DRIVE-SGD7S-7R6A00B202 100-486-719 1
10 CONTACTOR-E43.504, E44.304, E45 100-325-437 1
14 CABLE-D15P TO D15S CONNECTION 100-392-723 1
15 BELT-DRIVE, E44.304, E44.104 100-302-579 1


3 RUBBER PAD 100-392-172 1
9 CONTACTOR-E43.504, E44.304, E45 100-325-437 1
10 SERVO DRIVE-SGD7S-120A00B202 100-486-720 1
12 RESISTOR-REGEN, C43, C44, C45.504/504W/105 100-252-437 1
14 DEEP GROOVE BALL BEARING 100-392-301 6
15 BEARING-BALL, BELT CAM, C43.304, C43.504 100-252-471 3
16 BELT-DRIVE, GEARBOX, E45.105 100-302-581 1
17 BELT-DRIVE, BALLSCREW, E45.105 100-302-574 1
18 BELT-DRIVE, E45.105 100-302-593 1

Spare Parts Lists of E45.305

3 RUBBER PAD 100-392-182 1
6 TRANSFORMER-INTERNAL, E45.305, E45.605 100-325-444 1
7 FILTER-POWER A/C, C45.305/605 100-267-317 1
9 CONTACTOR-E43.504, E44.304, E45 100-325-437 1
11 DISCHARGE RESISTOR 100-376-595 1
15 SYNCHRONOUS TOOTH BELT 100-375-725 1
17 BEARING-BALL, BELT CAM, C45.504/W, C45.105 100-252-474 4
18 DISCONNECTOR-E45.305, E45.605 100-325-446 1

19

2 DUST CURTAIN 100-392-297 4
5 TRANSFORMER-INTERNAL, E45.305, E45.605 100-325-444 1
6 CIRCUIT BREAKER 100-392-256 1
7 FILTER-POWER A/C, C45.305/605 100-267-317 1
10 CONTACTOR-E43.504, E44.304, E45 100-325-437 1
11 DISCHARGE RESISTOR 100-376-595 1
15 BEARING-ROLLER, BELT CAM, C45.605 100-287-785 8
16 SYNCHRONOUS BELT 100-392-640 2
17 BELT-DRIVE, BALLSCREW, C45.605 100-287-784 1

Spare Parts Lists for Exceed Systems with Insight
Spare Parts Lists for Exceed Systems with Insight

Controllers
The following pages provide spare parts lists for Exceed systems with the Insight
controller.


The following table lists the spare parts of E42.503.
6
7
15
4
8
14
9
13
10
16
11 12

1 SWITCH-SAFETY,DOOR,ASSY,E42,E43,E44,E45
SWITCH-SAFETY,DOOR,E42,E43,E44,E45 100302571 1
CABLE GLAND ,E42,E43,E44,E45 100325427 1
2 BALLSCREW-COVER 100302554 2
3 MAT-BASE,RUBBER 100325428 1
4 SWITCH-EMERG STOP,E42,E43,E44,E45 100302573 2
5 KNOB-THUMB,LIMIT,E42,E43,E44,E45 100325429 2
6 SPRING-LIMIT SWITCH, E42,E43,E44,E45 100302594 2
7 SWITCH-POWER,E42,E43,E44,E45 100302576 1
8 AMPLIFIER-YASKAWA E42.503,E43.104,E44.104 100302586 1
9 RESISTOR-LOAD,E42.503, E43.104, E44.104 100252480 1
10 RESISTOR-REGENERATION,E42, E43, E44 100325430 1
11 FILTER-POWER A/C,E42,E43,E44,E45.105 100252443 1
12 POWER SUPPLY-E42.503, E43.104, E44.104 100302584 1
13 SWITCH-SAFETY RELAY,E42,E43,E44,E45 100325431 1
14 BELT-DRIVE,BALLSCREW,E42.503 100302580 1
15 MOTOR-A/C BRUSHLESS,E42.503,E43.104,E44.104 100302592 1
PCA-E4X INTERFACE BOARD 100390246 1

16
PWA - INSIGHT CONTROLLER ,ROHS 100326155 1


3
4
6 7 8 9 10 11 12 4 13 14 17 15 16

CABLE GLAND ,E42,E43,E44,E45 100325427 1
2 BALLSCREW-COVER,E43.104 100302567 4
3 MAT-BASE,RUBBER,E43.104 100325432 1
6 POWER SUPPLY,E42.503, E43.104, E44.104 100302584 1
8 AMPLIFIER-YASKAWA,E42.503, E43.104, E44.104 100302586 1
14 BELT-DRIVE,E43.104 100302578 1
15 BEARING-ROLLER,BELT CAM,E43.104,E44 100303299 4
16 MOTOR-A/C BRUSHLESS,E42.503, E43.104, E44.104 100302592 1

17


The following table lists the spare parts of E43.504:
3
4
17
16
18 15
14
13
6 7 8 4 9 10 11 12

CABLE GLAND ,E42,E43,E44,E45 100325427 1
3 MAT-BASE,RUBBER,E43.504 100325433 1
6 BELT-BALLSCREW,E43.504 100325434 1
9 BEARING-ROLLER,BELT CAM,E43.504 100325435 4
10 BELT-DRIVE,E43.504 100325436 1
12 POWER SUPPLY,E43.504,E44.304,E45 100302583 1
14 CONTACTOR,E43.504,E44.304,E45 100325437 1
15 AMPLIFIER-YASKAWA,E43.504,E44.304 100302588 1
17 MOTOR-A/C BRUSHLESS,E43.504,E44.304 100302589 1

18


17
6
7
8
9
10 11 12 4 13 14 15 18 16

CABLE GLAND ,E42,E43,E44,E45 100325427 1
2 BALLSCREW-COVER,E44.104,E44.304 100302505 4
3 MAT-BASE,RUBBER,E44.104,E44.304 100325438 1
7 POWER SUPPLY,E42.503, E43.104, E44.104 100302584 1
8 AMPLIFIER-YASKAWA,E42.503, E43.104, E44.104 100302586 1
14 BELT-DRIVE,E44.104 100302579 1
16 MOTOR-A/C BRUSHLESS,E42.503, E43.104, 100302592 1
17 CABLE ASSY-LOADCELL JUMPER 100325439 1

18


18
6 7 8 9 10 11 12 13 4 14 15 16 17

CABLE GLAND ,E42,E43,E44,E45 100325427 1
2 BALLSCREW-COVER,E44.104,E44.304 100302505 4
3 MAT-BASE,RUBBER,E44.104,E44.304 100325438 1
6 POWER SUPPLY,E43.504,E44.304,E45 100302583 1
8 RESISTOR-REGENERATION,E42,E43,E44 100325430 1
10 CONTACTOR,E43.504,E44.304,E45 100325437 1
14 CABLE ASSY-LOADCELL JUMPER 100325439 1
15 BELT-DRIVE,E44.304 100302579 1

18


6 7 8 9 10 11 12 13 4 20 14 15 16 17 18 19

CABLE GLAND ,E42,E43,E44,E45 100325427 1
3 MAT-BASE,RUBBER,E45.105 100325440 1
6 POWER SUPPLY,E43.504,E44.304,E45 100302583 1
8 FILTER-POWER A/C,E42,E43,E44,E44,E45.105 100252443 1
9 CONTACTOR,E43.504,E44.304,E45 100325437 1
10 AMPLIFIER-YASKAWA,E45.105 100302585 1
12 RESISTOR-REGENERATION,E45.105 100267315 2
15 BEARING-ROLLER,GEARBOX,E45.105 100325435 3
16 BELT-DRIVE,GEARBOX,E45.105 100302581 1
18 BELT-DRIVE,E45.105 100302593 1
19 MOTOR-A/C BRUSHLESS,E45.105 100302590 1

20


5
3
19
18 6 7 8 9 10 11 12 13 14 4 15 16 17

CABLE GLAND ,E42,E43,E44,E45 100325427 1
3 MAT-BASE,RUBBER,E45.305 100325443 1
6 INTERNAL TRANSFORMER,E45.305,E45.605 100325444 1
7 FILTER-POWER A/C,E45.305,E45.605 100267317 1
8 POWER SUPPLY,E43.504,E44.304,E45 100302583 1
9 CONTACTOR,E43.504,E44.304,E45 100325437 1
11 RESISTOR-REGENERATION,E45.305,E45.605 100325445 1
15 BELT-DRIVE,E45.305 100302575 1
17 BEARING-ROLLER,BELT CAM,E45 100303301 6
18 DISCONNECTOR,E45.305,E45.605 100325446 1

19

18
19 17
16
15
5 6 7 8 9 10 13 3 14 11 12

CABLE GLAND ,E42,E43,E44,E45 100325427 1
5 INTERNAL TRANSFORMER,E45.305,E45.605 100325444 1
6 DISCONNECTOR,E45.305,E45.605 100325446 1
7 FILTER-POWER A/C,E45.305,E45.605 100267317 1
8 POWER SUPPLY,E43.504,E44.304,E45 100302583 1
10 CONTACTOR,E43.504,E44.304,E45 100325437 1
11 RESISTOR-REGENERATION,E45.305,E45.605 100325445 1
16 BELT-DRIVE,GEARBOX,E45.605 100325449 1

19

Load Cells List
Load Cells List
Load Cell Type Mounting Model No. Part No. with Capacity (N)
Thread TEDS
LPS-0.6KG 100-475-294 5N
Shear Beam M6X1.0 LPS-1KG 100-475-293 10N
LPS-2KG 100-475-292 20N
BAB-XS-5M 100-475-291 50N

M8X1.25
BAB-XS-10M 100-475-290 100N
BSA-XS-25KG 100-475-289 200N

M6X1.0
BSA-XS-50KG 100-475-227 500N
M10X1.5 BSS-XS-100KG 100-475-288 1000N

S-Beam
BSS-200KG 100-475-287 2000N
M12X1.75 BSS-XS-500KG 100-475-286 5000N
BSS-XS-1T 100-474-950 10000N
BSS-XS-2.5T 100-474-951 20000N

M18X1.5
BSS-XS-5T 100-474-952 30000N
DBSL-2T 100-474-953 20000N
M16X1.5 DBSL-3T 100-474-954 30000N
DBSL-5T 100-474-955 50000N
DBSL-XS-5T 100-474-956 50000N

Low Profile M24X1.5
DBSL-XS-10T 100-474-957 100000N
LPS.205 100-467-455 200000N

M36X3
LPS.305 100-466-085 300000N
M72X3 LPS.605 58-503-302 600000N

Systems with the ICE Controller
Troubleshooting
Systems with the ICE Controller
General failure
Troubleshooting List (part 1 of 4)
Symptom Possible problem Solution

Test Frame will Power switch is off Check power switch
not Power On
Problem with AC mains Check facility AC mains power
Power cord is loose in Push power cord into IEC connector firmly
IEC connector
Faulty power switch Check power switch with meter
Faulty power supply Check power supply for AC input and DC output
TestSuite Ethernet disconnected Check Ethernet connection

communications
problem Ethernet port not Ethernet not properly configured for IPv6. See Installation
properly configured section
TestSuite configured for Check the frame configuration in TWDiag_I.exe or TestSuite

wrong frame type System Configuration
Multiple copies of Check for multiple TestSuite application in the Windows

TestSuite application Taskbar.
open
Using Windows Task Manager, check for multiple copies of
“Testwrks.exe” and end all of the open copies.
Reboot the PC and cycle the frame power to clear an

software or communication issues.
TestSuite did not close Using Windows Task Manager, check for multiple copies of
application properly on “mtstwe.exe” and end all of the open copies.
last instance
software or communication issues
OS (Windows) problem Verify the Windows OS is working correctly.
Reboot PC and check for communications with frame.
Check Ethernet for proper operation.
Test Frame is off Shut down TestSuite application and power on the frame.
Frame controller needs Shut down TestSuite application and cycle power on the
to be reset frame.
MTS Exceed® Series 40 FSE Manual Troubleshooting 187

General failure
Can not clear E-stop switch is pressed Release E-stop button (turn clock-wise).
interlocks
External E-stop is active 1. Check for activated external E-Stop buttons.
2. Disconnect external E-stop devices and insert J14

jumper plug.
3. Diagnose any E-stop conditions on external devices.
Machine enclosure door 1. Close enclosure (Guard) door.

is open (if equipped)
2. Check enclosure switch is aligned with door plunger.
3. Check enclosure switch cable.
Machine enclosure door Check cable or jumper plugged into J11.

Watchdog LED is on Verify Ethernet connection and TestSuite is running.
Safety system has Check for red LED on controller panel (next to green “Power
faulted (red LED on On” LED). Refer to “safety system fault” below.
controller)
Load cell is 1. Check load cell cable connection.

disconnected / missing
2. If using upper work zone (E43.304, E45.105, and
E45.305 both standard and extended length
frames) check the upper zone load jumper is in place
and secure.
Upper and lower limit Check for upper or lower limit switch tripped.
switches are active
Yaskawa drive fault 1. Cycle the frame power and reboot PC.
2. Check the Yaskawa drive using SigmaWin+ software for

faults.
Strain channel device • Check for loose or disconnected extensometer /

disconnected or loose deflectometer.
• Check in TWDiag_1.exe to disable the overload interlock

(Panel tab, middle right side).
Load cell feedback > Check the load cell is plugged in and check the output
110% full scale or voltage using “Channel Diagnostics” in TestSuite. The output
damaged should be less than the max. electrical value in the TEDS file
(and very close to 0.000 volts).
Strain channel device > Check the extensometer or deflectometer is plugged in and
110% full scale or check the output voltage using “Channel Diagnostics” in
damaged TestSuite. The output should be less than the max. electrical
value in the TEDS file (and very close to 0.000 volts).
188 Troubleshooting MTS Exceed® Series 40 FSE Manual

General failure
Safety system Controller needs to be Exit TestSuite application and cycle frame power
faulted (red LED reset.
on controller)
Safety system will Safety system has Check fault codes in TestSuite or TWDiag_I.exe (Fault Codes
not reset after detected a fault. and descriptions listed below).
cycling power
Fault 0 - Velocity The two redundant The controller Interface board has a hard failure. Replace
Limit mismatch Velocity Limit checks do controller.
not match.
Fault 1 - ESTOP The two ESTOP circuits Check the ESTOP wiring, switch contacts, and jumper plugs.
Switch are not in same state /
condition.
Fault 2 - Guard The two Guard switch Check the Guard switch, cable and J11 connector. This fault
Switch contacts are not in same can also be caused by opening or closing the guard door very
state / condition. slowly.
Fault 3 - ESTOP A The ESTOP A chain The ESTOP A chain circuit has a fault. The driver and the
Driver sense and driver are in sense (feedback) are in different states.
different states.
1. Check the ESTOP connectors and cables (J14 & J20)
for loose connections, breaks or shorts.
2. If the cables and connectors check OK, then replace the
controller.
Fault 4 - ESTOP B The ESTOP B chain The ESTOP B chain circuit has a fault. The driver and the
different states.

controller.
Fault 5 - CRM1 The CRM1 chain sense The CRM1 chain circuit has a fault. The driver and the sense
Driver and driver are in different (feedback) are in different states.
states.

controller.
Fault 6 - CRM2 CRM2 is not currently Not currently used - if this fault is active individually, replace
Driver used. the controller.
Fault 7 - Drive The Drive Enable sense The Drive Enable signal is an output from the Interface board
Enable Driver and driver are in different to an input on the Yaskawa drive. If this fault is active, the
states. driver output and the sense feedback are in a different state.
1. Check the Yaskawa drive using SigmaWin for faults.
2. Check the Drive I/O cable (J22).
3. If the drive and cable check OK, then replace the

controller.

General failure
Fault 8 - The Controller Ready The Controller Ready signal is an output from the Interface
Controller Ready sense and driver are in board to an input on the Yaskawa drive. If this fault is active,
Driver different states. the driver output and the sense feedback are in a different
state.

controller.
Fault 9 - CRM The CRM Sense 1. Check the CRM relay and CRM sense contact for proper
Sense (feedback contact) on operation.
the CRM relay is not in
the correct state. 2. Check the J24 connector and CRM cables for loose
connections, breaks or shorts.
Fault A - Power The Interface board has Check the power supply DC output voltages for correct output
Fail detected power failure (+/- 0.05 volts)
on +5 v, +12 v, -12 v, or
+24 v* (* 30kN and
above frames)
Fault B - Velocity The velocity measured Check that TestSuite is configured for the correct frame type
Check by Interface board and default tuning is selected.
exceeded the 600
mm\min velocity limit
with guard door open.
Fault C - Velocity The analog velocity limit The Interface board outputs 0v (Interlocked), 2.5 v (speed
Limit sense and driver are at limited mode) or 10 v (normal operation, guard closed) to
different voltages. Yaskawa drive on J22, Pin 2. This is a velocity limit input for
the Yaskawa drive.
1. Check the Yaskawa drive using SigmaWin+ for faults.

controller.
Fault D - Guard The Guard configuration The Guard cable has 2 jumpers to configure “Interlock when
configuration jumpers are not set for open” or “Speed limit when open” option. The two jumpers
same option. are not configured the same. Check cable or jumper on J11,
Pins 3-8 and 5-9.
Fault E - ESTOP The ESTOP OUT Sense Check the cable connected to J14 and any accessories
OUT sense (feedback contact) on an connected to the auxiliary ESTOP circuit (grip controllers,
auxiliary accessory is furnace, temperature chambers, etc.)
not in the correct state.
Fault F - Drive Yaskawa drive safety Yaskawa drive interlock. This should clear when Interlocks
EMD1 block active (does not are cleared. If it will not clear:
generate a fault)
1. Verify there are no ESTOPS active.
2. Check the Yaskawa drive using the SigmaWin+ software

for faults.

TestSuite is Unable to Connect to the Controller
TestSuite is Unable to Connect to the Controller

Note This is for Exceed machines with the Insight controller.
The Cause: Communication issues can develop if:
• There is another instance of mtstwe.exe, mtstwx.exe, or TW Diag.exe

currently running on the PC.
• The frame is not powered on or the controller is not functioning correctly.
• The Ethernet cable is not plugged in or the Ethernet connection is faulty.
• The Windows network setup is not correct for the ICE controller. Network
must be configured to use IPv6.
• The FrameSettings.xml file has become corrupted.
The Solution: 1. With the PC and the test frame turned on, disconnect the Ethernet cable
from the PC and the test frame.
2. Shut down the PC and the test frame. This will close all instances of
mtstwe.exe, mtstwx.exe, and TW Diag.exe.
3. Turn on the test frame and attempt to operate the test frame with the handset.
A. If the test frame can be operated with the handset, the controller is
functioning correctly.
B. If the test frame can NOT be operated with the handset, note what is
displayed on the handset and disconnect the handset.
4. Turn on the PC and reconnect Ethernet cable.
5. In Windows go to Control Panel>Networks.
A. Verify that IPv6 is Enabled.
B. Verify that IPv4 is Disabled.
6. Verify that the Ethernet port shows it is connected and then try running
TW Diag.exe.
7. If communication is still not established, email technical support with
details of the problem.

Systems with the Insight Controller
Systems with the Insight Controller
General failure
Symptom Possible problem Solution

Test Frame will Power switch is off Check power switch.
not Power On
Problem with AC mains Check facility AC mains power.
Power cord is loose in Push power cord into IEC connector firmly.
IEC connector
Faulty power switch Check power switch with meter.
Faulty power supply Check power supply for AC input and DC output.
TestSuite USB cable disconnected Check USB connection.

communications
problem USB driver not loaded Check “Device Manager” in Windows for “MTS EM
for specific USB port on Controllers” - if not there, find the USB device w/ yellow
PC “problem” graphic and reinstall the drivers manually, using the
drivers in “:\Program Files\MTS Systems\TestSuite”. The
system may find and load two drivers.
TestSuite configured for Check the frame configuration in TW Diag.exe or TestSuite

wrong frame type System Configuration.
Multiple copies of Check for multiple TestSuite application in the Windows

TestSuite application Taskbar.
open
Using Windows Task Manager, check for multiple copies of
“mtstwe.exe” and end all of the open copies.

software or communication issues.
TestSuite did not close Using Windows Task Manager, check for multiple copies of
application properly on “mtstwe.exe” and end all of the open copies.
last instance
software or communication issues
OS (Windows) problem Verify the Windows OS is working correctly.
Reboot PC and check for communications with frame.
Check any other USB devices for proper operation.
Test Frame is off Shut down TestSuite application and power on the frame.
Frame controller needs Shut down TestSuite application and cycle power on the
to be reset frame.

General failure
Can not clear E-stop switch is pressed Release E-stop button (turn clock-wise).
interlocks
Machine enclosure door Close enclosure (Guard) door.
Check enclosure switch is aligned with door plunger.
Check enclosure switch cable.
Machine enclosure door Check cable or jumper plugged into J12 and J13.
J3 jumper is loose / Check J3 jumper is plugged in securely.

missing
Load cell is Check load cell cable connection.

disconnected / missing
Upper and lower limit Check for upper or lower limit switch tripped.
switches are active
Yaskawa drive fault Cycle the frame power and reboot PC.
Check the Yaskawa drive using SigmaWin+ software for

faults.
Strain channel device Check for loose or disconnected extensometer /

disconnected or loose deflectometer.
Check in TW Diag.exe to disable the overload interlock

(Panel tab, middle right side).
Load cell feedback > Check the load cell is plugged in and check the output
110% full scale or voltage using “Channel Diagnostics” in TestSuite. The output
damaged should be less than the max. electrical value in the TEDS file
(and very close to 0.000 volts).
Strain channel device > Check the extensometer or deflectometer is plugged in and
110% full scale or check the output voltage using “Channel Diagnostics” in
damaged TestSuite. The output should be less than the max. electrical
value in the TEDS file (and very close to 0.000 volts).

General failure
Safety system Controller needs to be Exit TestSuite application and cycle frame power.
faulted reset.
Safety system will Safety system has Check fault codes in TestSuite or TW Diag.exe (Fault Codes
not reset after detected a fault and descriptions listed below).
cycling power
Fault 0 - Velocity The two Velocity Limit Not currently used - if this fault is active individually, replace
Switch switches (SW1 & SW2) the controller.
do not have the same
setting.
Fault 1 - ESTOP The two ESTOP circuits Check the ESTOP wiring, switch contacts, and jumper plugs.
Switch are not in same state /
condition.
Fault 2 - Guard The two Guard switch Check the Guard switch, cable and J12 connector. This fault
Switch contacts are not in same can also be caused by opening or closing the guard door very
state / condition. slowly.
Fault 3 - ESTOP A The ESTOP A chain The ESTOP A chain circuit has a fault. The driver and the
different states.

controller.
Fault 4 - ESTOP B The ESTOP B chain The ESTOP B chain circuit has a fault. The driver and the
different states.

controller.
Fault 5 - CRM1 The CRM1 chain sense The CRM1 chain circuit has a fault. The driver and the sense
Driver and driver are in different (feedback) are in different states.
states.
1. Check the CRM connectors and cables (J26) for loose

controller.
Fault 6 - CRM2 CRM2 is not currently Not currently used - if this fault is active individually, replace
Driver used. the controller.
Fault 7 - Drive The Drive Enable sense The Drive Enable signal is an output from the Interface board
Enable Driver and driver are in different to an input on the Yaskawa drive. If this fault is active, the
2. Check the Drive I/O cable (J22 & J23 & J24).

controller.

General failure
Fault 8 - The Controller Ready The Controller Ready signal is an output from the Interface
Controller Ready sense and driver are in board to an input on the Yaskawa drive. If this fault is active,
Driver different states. the driver output and the sense feedback are in a different
state.
2. Check the Drive I/O cable (J22 & J23 & J24).

controller.
Fault 9 - CRM The CRM Sense 1. Check the CRM relay and CRM sense contact for
Sense (feedback contact) on proper operation.
the CRM relay is not in
the correct state. 2. Check the J26 connector and CRM cables for loose
Fault A - Power The Interface board has Check the power supply DC output voltages for correct output
Fail detected power failure (+/- 0.5 volts).
on +5 v, +12 v, -12 v, or
+24 v* (* 30kN and
above frames)
Fault B - Velocity The velocity measured Check that TestSuite is configured for the correct frame type
Check by Interface board and default tuning is selected.
exceeded the 600
mm\min velocity limit
with guard door open.
Fault C - Velocity The analog velocity limit The Interface board outputs 0v (Interlocked) or 10 v (normal
Limit sense and driver are at operation, guard closed) to Yaskawa drive on J24, Pin 1. This
different voltages. is a velocity limit input for the Yaskawa drive.

controller.
Fault D - Guard The Guard configuration Not currently used on Exceed frame - if this fault is active
configuration is not currently used. individually, replace the controller.
Fault E - ESTOP The ESTOP OUT Sense Check the cable connected to J13 and any accessories
OUT sense (feedback contact) on an connected to the auxiliary ESTOP circuit (grip controllers,
auxiliary accessory is remote E-stop etc)
not in the correct state.
Fault F - Drive Yaskawa drive safety Yaskawa drive interlock. This should clear when Interlocks
EMD1 block active (does not are cleared. If it will not clear:
generate a fault)
1. Verify there are no ESTOPS active.
Check the Yaskawa drive using the SigmaWin+ software for
faults.

General failure
System faults (red Some system faults Exit TestSuite application and cycle frame power.
LED on have been detected by
controller) controller Observe the two (one green and one red) LED’s blinking
sequence after cycling frame power and check as follow:
Fault 1 - ESTOP One of the ESTOP 1. Check the ESTOP wiring, switch contacts, and jumper
switch fault switches or wires is not plugs.
functioning.
2. This fault can also be caused by pressing the ESTOP
button too slowly.
Fault 2 - Power A power supply has Check that:

fail fault failed or is out of
specification 1. The power supply DC output voltages for correct output
(within tolerance of about +/- 8%).
2. Check the Power In connector and cable (J27) for loose

connections breaks or shorts.
Fault 3 - OVER- The instantaneous Check that:

SPEED fault speed ever exceeds the
limit programmed in the 1. Check the Yaskawa drive parameter using the
speed ROM. SigmaWin+ software.
2. Re-download the firmware for controller.

Cycle 2 times
Fault 4 - ESTOP The feedback to Check that:

OUT fault accessary ESTOP chain
is not in the correct state 1. Check if an accessory ESTOP or jumper plug is
connected to the ESTOP OUT connector(J13).
2. Check the ESTOP wiring , switch contacts, and jumper

Cycle 3 times plugs.
3. Check the ESTOP function in the accessory is

functioning properly.
Fault 5 - DRIVE Yaskawa drive safety Yaskawa drive interlock. This should clear when Interlocks
EDM fault block active (does not are cleared. If it will not clear:
generate a fault). This is
normally active when 1. Verify there are no ESTOPS active.
any other fault is active.
2. Check the Yaskawa drive using the SigmaWin+
Cycle 4 times software for faults.
Fault 6 - ROM The ROM does not The ROM chip on Interface board poor contacted or damage
READ fault respond properly when may active ROM read fault.
being read.
1. Check the ROM chip on interface board for loose
contacted in the socket.
Cycle 5 times 2. If the ROM chip installed check OK, then replace the
controller.

General failure
Fault 7- ROM CRC The over-speed ROM The ROM chip on Interface board is not programmed
fault CRC check does not properly or damage may active fault.
pass.
1. Turn off frame power and re-install the chip, then cycle
the power.
Cycle 6 times 2. If after the re-install the issue still exists, then replace
the controller.
Fault 8- DRIVE The Drive Enable sense The Drive Enable signal is an output from the Interface board
ENABLE fault and driver are in different to an input on the Yaskawa drive. If this fault is active, the

Cycle 7 times 2. Check the Drive I/O cable (J22 & J23 & J24).

controller.

General failure

Appendix
Contents Clevis Adapter Dimension 200
Metric Threads Torque Chart 201
Additional Digital I/O Information 202
Concentricity Fixture 203
Electrical Diagrams for Exceed Systems with ICE Controllers 208
Electrical Diagrams for Exceed Systems with Insight Controllers 225
Notes 244
MTS Exceed® Series 40 FSE Manual Appendix 199

200
5(9,6,216

'(6&5,37,21
(&112
/(77(5
'5$:1 (1*5 '$7(

! !" #
Appendix
$%
! " "

! ! &
Clevis Adapter Dimension
# $%

! "! "
! !
! "! " $%
& !# !
&! ! && $&%
Clevis Adapter Dimension

6285&(5()
'5$:,1*

35235,(7$5<'$7$
7+(,1)250$7,21$1''(6,*16
',6&/26('+(5(,1$5(&21),'(17,$/
$1'7+(3523(57<2)0766<67(06
&25325$7,21$1'0$<127%(86('
5(352'8&('25',6&/26(',1$1<
)250(;&(37$6*5$17(',1:5,7,1*
%<0766<67(06&25325$7,217+,6
5(675,&7,21(;&/8'(6,1)250$7,21
7+$7,6,17+(38%/,&'20$,125
:$6/(*,7,0$7(/<,17+(35,25

3266(66,212)7+(5(&,3,(17
81/(6627+(5:,6(63(&,),('
0$7(5,$/'(6&5,37,21 ''' ()*( '5$:1 &+(&. (1*5 0)*
&$, /$1
29(5
0$7(5,$/6,=( # 72 '$7( '$7( '$7( '$7(
!+

),1,6+ 0$6. $1*/( 7,7/(
0 ;
< :25.67$7,21(0.16,1*
7+5($''(37+6$5(720,1)8//7+'6 6&$/( ; 63$&(7767'
'5,//'(37+6$5(72)8//',$ 121( ;;
*(1(5$/
5(029(%8556$1'6+$53('*(6 0$&+,1(' 1(;7/(9(/ 6,=( 180%(5 5(9

72/(5$1&(6
685)$&(6
'21276&$/(35,17 ;;;
$
7+,5' 352'8&7&2'( '
0766<67(06&25325$7,21
('(135$,5,(0,11(627$86$& $1*/(
352- 6+((72)
MTS Exceed® Series 40 FSE Manual

Metric Threads Torque Chart
Metric Threads Torque Chart

SUBJECT: SECTION:2.4
TORQUEVALUES ISSUE DATE:4Ͳ87
ͲMETRICTHREADSͲ REVISION:B

TENSILE SOCKETHEADCAPSCREWS HEXBOLTSGRADE8.8
GRADE12.9ORTHREADEDRODS ANDTHREADED
SIZE AREA OFEQUALSTRENGTH PRODUCTSPERNOTE
IN2 TORQUE(LUBE) TORQUE(LUBE)
WORKING WORKING
FORCLAMPͲ1.5X FORCLAMPͲ1.5X
FORCE FORCE
WORKINGFORCE WORKINGFORCE
KIP KN LBͲFT N.M KIP KN LBͲFT N.M
M3Ͳ.5 .00769 .461 2.05 1.0 1.4 .346 1.54 .77 1.0
M4Ͳ.7 .0134 .804 3.58 2.4 3.2 .603 2.68 1.8 2.4
M5Ͳ.8 .0217 1.3 5.79 4.8 6.5 .976 4.34 3.6 4.9
M6Ͳ1 .0307 1.84 8.21 8.2 11 1.38 6.15 6.1 8.3
M8Ͳ1.25 .056 3.36 14.9 20 27 2.52 11.2 15 20
M10Ͳ1.5 .0888 5.33 23.7 39 53 3.99 17.8 29 40
M12Ͳ1.75 .129 7.74 34.4 69 93 5.81 25.8 51 70
COARSE
M16Ͳ2 .24 14.4 64.2 170 230 10.8 48.1 130 170
M20Ͳ2.5 .376 22.5 100 330 450 16.9 75.2 250 340
M24Ͳ3 .541 32.4 144 570 780 24.3 108 430 580
M30Ͳ3.5 .861 51.6 230 1100 1600 38.7 172 860 1200
M36Ͳ4 1.25 75.3 335 2000 2700 56.5 251 1500 2000
M42Ͳ4.5 1.72 103 460 3200 4300 77.5 345 2400 3300
M48Ͳ5 2.26 136 604 4800 6500 102 453 3600 4900
M56Ͳ5.5 3.12 167 833 7700 10,000 140 625 5800 7900
M64Ͳ6 4.12 247 1100 12,000 16,000 185 824 8800 12,000

M8Ͳ1 .0601 3.61 16 21 29 2.7 12 16 22
M10Ͳ1.25 .0939 5.63 25.1 42 56 4.23 18.8 31 42
M12Ͳ1.25 .142 8.49 37.8 75 100 6.37 28.3 56 76
M12Ͳ1.5 .135 8.11 36.1 72 97 6.08 27.1 54 73
M16Ͳ1.5 .257 15.4 68.7 180 250 11.6 51.5 140 190
M20Ͳ1.5 .418 25.1 112 370 500 18.8 83.7 280 380
M20Ͳ2 .397 23.8 106 350 480 17.9 79.4 260 360
FINE
M24Ͳ2 .592 35.5 158 630 850 26.6 118 470 640
M27Ͳ2 .764 45.8 204 910 1200 34.4 153 690 930
M30Ͳ2 .958 57.5 256 1300 1700 43.1 192 950 1300
M36Ͳ3 1.33 79.9 355 2100 2000 59.9 267 1600 2200
M42Ͳ3 1.86 1.12 496 3500 4700 83.7 372 2600 3500
M48Ͳ3 2.47 148 660 5300 7100 111 495 3900 5300
M56Ͳ4 3.3 198 882 8200 11,000 149 662 6100 8300
M64Ͳ4 4.4 264 1170 12,000 17,000 198 880 9300 13,000

METRICSOCKETHEADCAPSCREWSGRADE12.9,SULTͲ177KSIͲ1220MPA
ĀWORKINGSTRESSā=50KSI=410MPA

THREADEDFASTENERSWITHSULT=125KSI=960MPA,ĀWORKINGSTRESSā=45KSI=310MPA

DEVIATION FROM RECOMMENDED VALUES IS PERMITTED IN APPLICATIONS WHERE OPTIMAL
CLAMPINGFORCES–VSͲBOLTSIZEAREREQUIRED.ATHOROUGHANALYSISISRECOMMENDED
WHENDEVIATINGFROMTHISSTANDARDPRACTICE.


Additional Digital I/O Information
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.
A typical example might be connecting an external switch.
202 Appendix MTS Exceed® Series 40 FSE Manual

Concentricity Fixture





Electrical Diagrams for Exceed Systems with ICE
Electrical Diagrams for Exceed Systems with ICE

Controllers
The following pages provide the electrical diagrams for Exceed systems with the
ICE controller.


E42.503 Electrical Diagram
















Electrical Diagrams for Exceed Systems with Insight
Electrical Diagrams for Exceed Systems with Insight

Controllers
The following pages provide the electrical diagrams for Exceed systems with the
Insight controller.
E42 Electrical Diagram 226

E43 10 kN or less Electrical Diagram 228
E43 20 kN 30 kN 50kN Electrical Diagram 230
E44 20 kN Or 30 kN Electrical Diagram 234

226
(;&((' (;&((' (/(&75,&$/ ',$*5$0 :,7+ ([ &21752//(5
7+,6 '5$:,1* ,6 )25 5()(5(1&( 21/<127 $1 $66(0%/< '5$:,1*
Appendix
(;7(5$/ &$%/(6 21/< $5( 6+2:1 21 7+,6 6+((76+((7
E42 Electrical Diagram
(;7(1620(7(5 +$1'6(7 :&$%/(

ď',*,7$/ 6(1625Đ $1' +$1'6(7 02817 $&&(625,(6
)851$&( &20081,&$7,21 &$%/(
$8; 6(1625
0$&+,1( (1&/2685( $1$/2* ,13876 *5,36 ď5()Đ
(7&
'6 ď5()Đ
'3
56
- (1&2'(5
- 5- -803(5
- ď5()Đ
ď5()Đ 86% 72 56 $'$37(5
- '&
/2$' &(// - 5- -803(5

ď5()Đ
86%
86%
-
ď5()Đ
- '&
- 5- -803(5
- ď5()Đ
3&
,17(5/2&. - ,17/. -803(5
+$1'6(7 -
86% -
- ,QVLJKW
([ &21752//(5 ([ ,QWHUIDFH %RDUG
32:(5 &25'
'LJLWDO ,2 - 86(5 ' ,2 )25 $&&(625,(6
237,21$/ 5(027( (6723
(6723 2XWSXW - ď-803(5 3/8*Đ -
ď5()Đ
32:(5 6833/<
127(6 076 6\VWHPV&KLQD&R/WG

727$/ (/(&75,&$/ ',$*5$0
&$%/(6 ,1 7+,6 ',*5$0 $5( 6+2:1 )25 5()(5(1&( 21/<6(( '2&80(176 )25 3,1 72 3,1 &211(&7,216
0$5. &2817 3$57,7,21 5(9 12 6,*1 '$7(
'5$:1 67$1
( (/(&7520(&+$1,&$/ 6<67(0
3+$6( 0$5. :(,*+7 6&$/(
6 $
&+(&.
6 + (( 7 2)
$ -;
352& $335

)5$0( /2$' &(// &211(&725
(1&/2685( 6:,7&+ď5()Đ
6:
(;&((' (/(&75,&$/ ',$*5$0 :,7+ ([ &21752//(5
6: ,17(51$/ /2$' &(// &$%/(
7+,6 '5$:,1* ,6 )25 5()(5(1&( 21/<

<$6.$:$ 6*0-$)&6 ,17(51$/ &$%/(6 21/< $5( 6+2:1 21 7+,6 6+((76+((7
(6723ď5()Đ
32:(5
02725
(1&2'(5 ([ &21752//(5

833(5 /,0,7 6:,7&+ '5,9( $03
([ ,QWHUIDFH %RDUG
5(*(1(5$7,9( 5(6,6725 8 /6 -

6$)7< *5281' 6&5(: 6$)7< *5281' 6&5(:
/ /6
'& '& '&
% % /2:(5 /,0,7 6:,7&+ '3 '6 '3
- - -
'5,9( $03 ,QVLJKW %RDUG
ORDG &HOO 5($5
6*'65$$
32:(5 ,1387
&1
&1
&1
&1
72 3& 86% 3257 )25 3)%8/*,1
89:
/&
//
781,1* 6(592 3$5$0(7(5
-
-
-
-
-
-
-
-
-
(6723
/2$' 5(6,67(5 )3073;$%
2+0 :
&20 9'&
32:(5 6:,7&+
32:(5 6833/<
$535%)8-,
57%0($1 :(//
&50
&
.==4$%

32:(5
),/7(5
(3&25&20
127(6ġ
&$%/(6 ,1 7+,6 ',*5$0 $5( 6+2:1 )25 5()(5(1&( 21/<6(( '2&80(176 )25 3,1 72 3,1 &211(&7,216 076 6\VWHPV&KLQD&R/WG
727$/ (/(&75,&$/ ',$*5$0
$// '$6+(' /,1(6 21 6+((7 $5( 32:(5 :,5,1* &211(&7,216
0$5. &2817 3$57,7,21 5(9 12 6,*1 '$7(
3/($6( 5()(5 72 ',$*5$0 $66<3:5 72 6(( 7+( &211(&7216 2) 7+(6( 7:2 &5281',1* 6&5(:6 ( (/(&7520(&+$1,&$/ 6<67(0
'5$:1 67$1 3+$6( 0$5. :(,*+7 6&$/(
6 $
&+(&.
Appendix
6 + (( 7 2)
$ -;
352& $335
227
228
(;&((' ďN1 25 /(66Đ (;&((' ďN1 25 /(66Đ(/(&75,&$/ ',$*5$0 :,7+ ([ &21752//(5
Appendix
7+,6 '5$:,1* ,6 )25 5()(5(1&( 21/<
(;7(51$/ &$%/(6 21/< $5( 6+2:1 21 7+,6 6+((76+((7
$8; 6(1625 (;7(1620(7(5 +$1'6(7 :&$%/(

$1$/2* ,13876 ď',*,7$/ 6(1625Đ $1' +$1'6(7 02817 $&&(625,(6
)851$&( &20081,&$7,21 &$%/(
*5,36 ď5()Đ
(7&
E43 10 kN or less Electrical Diagram
/2$' &(// '6

'3 ď5()Đ
56
- (1&2'(5
0$&+,1( (1&/2685(
- 5- -803(5
- ď5()Đ
ď5()Đ 86% 72 56 $'$37(5
- '&
- 5- -803(5
ď5()Đ
86%
86%
-
ď5()Đ
- '&
- 5- -803(5
ď5()Đ 3&
-
,17(5/2&. - ,17/. -803(5
+$1'6(7 -
86% -
,QVLJKW
-
([ ,QWHUIDFH %RDUG
([ &21752//(5
32:(5 &25'
'LJLWDO ,2 - 86(5 ' ,2 )25 $&&(625,(6
237,21$/ 5(027( (6723

(6723 2XWSXW - ď-803(5 3/8*Đ -
32:(5 6833/<
ď5()Đ
127(6
&$%/(6 ,1 7+,6 ',*5$0 $5( 6+2:1 )25 5()(5(1&( 21/<6(( '2&80(176 )25 3,1 72 3,1 &211(&7,216
727$/ (/(&75,&$/ ',$*5$0
076 6\VWHPV&KLQD&R/WG
0$5. &2817 3$57,7,21 5(9 12 6,*1 '$7(
'5$:1 67$1
( (/(&7520(&+$1,&$/ 6<67(0
3+$6( 0$5. :(,*+7 6&$/(
6 $
&+(&.
6 + (( 7 2)
$ -;
352& $335

(;&((' N1 25 /(66(/(&75,&$/ ',$*5$0 :,7+ ([ &21752//(5
(1&/2685( 6:,7&+ď5()Đ 7+,6 '5$:,1* ,6 )25 5()(5(1&( 21/<

6: ,17(51$/ &$%/(6 21/< $5( 6+2:1 21 7+,6 6+((76+((7
6:
,17(51$/ /2$' &(// &$%/(

(6723ď5()Đ
<$6.$:$ 6*0-$)&6 )5$0( /2$' &(// &211(&725
32:(5 02725
(1&2'(5 ([ &21752//(5

'5,9( $03
833(5 /,0,7 6:,7&+ 8 /6 ([ ,QWHUIDFH %RDUG
-

/2:(5 /,0,7 6:,7&+ / /6 6$)7< *5281' 6&5(: 6$)7< *5281' 6&5(:
5(*(1(5$7,9( 5(6,6725 '& '& '&
'3 '6 '3
- - -
% % ,QVLJKW %RDUG
ORDG &HOO 5($5
'5,9( $03
6*'65$$ 32:(5 ,1387
3)%8/*,1
&1
&1
&1
&1
89:
/&
//
-
-
-
-
-
-
-
-
-
(6723
72 3& 86% 3257 )25 /2$' 5(6,67(5 )3073;$%
781,1* 6(592 3$5$0(7(5 2+0 :
&20 9'&
32:(5 6:,7&+
32:(5 6833/<
$535%)8-,
57%0($1 :(//
&50
&
.==4$%

32:(5
),/7(5

(3&25&20
127(6ġ
&$%/(6 ,1 7+,6 ',*5$0 $5( 6+2:1 )25 5()(5(1&( 21/<6(( '2&80(176 )25 3,1 72 3,1 &211(&7,216 076 6\VWHPV&KLQD&R/WG
727$/ (/(&75,&$/ ',$*5$0
$// '$6+(' /,1(6 21 6+((7 $5( 32:(5 :,5,1* &211(&7,216
0$5. &2817 3$57,7,21 5(9 12 6,*1 '$7(
3/($6( 5()(5 72 ',$*5$0 $66<3:5 72 6(( 7+( &211(&7216 2) 7+(6( 7:2 &5281',1* 6&5(:6 ( (/(&7520(&+$1,&$/ 6<67(0
'5$:1 67$1 3+$6( 0$5. :(,*+7 6&$/(
6 $
Appendix
&+(&.
6 + (( 7 2)
$ -;
352& $335
229
230
(;&((' ďN1 25 /(66Đ (;&((' ďN1 25 /(66Đ(/(&75,&$/ ',$*5$0 :,7+ ([ &21752//(5
Appendix
7+,6 '5$:,1* ,6 )25 5()(5(1&( 21/<
(;7(51$/ &$%/(6 21/< $5( 6+2:1 21 7+,6 6+((76+((7
$8; 6(1625 (;7(1620(7(5 +$1'6(7 :&$%/(

$1$/2* ,13876 ď',*,7$/ 6(1625Đ $1' +$1'6(7 02817 $&&(625,(6
)851$&( &20081,&$7,21 &$%/(
*5,36 ď5()Đ
(7&
/2$' &(// '6

'3 ď5()Đ
56
E43 20 kN 30 kN 50kN Electrical Diagram
- (1&2'(5
0$&+,1( (1&/2685(
- 5- -803(5
- ď5()Đ
ď5()Đ 86% 72 56 $'$37(5
- '&
- 5- -803(5
ď5()Đ
86%
86%
-
ď5()Đ
- '&
- 5- -803(5
ď5()Đ 3&
-
,17(5/2&. - ,17/. -803(5
+$1'6(7 -
86% -
,QVLJKW
-
([ ,QWHUIDFH %RDUG
([ &21752//(5
'LJLWDO ,2 - 86(5 ' ,2 )25 $&&(625,(6

32:(5 &25' 237,21$/ 5(027( (6723
(6723 2XWSXW - ď-803(5 3/8*Đ -
ď5()Đ
32:(5 6833/<
127(6 727$/ (/(&75,&$/ ',$*5$0

&$%/(6 ,1 7+,6 ',*5$0 $5( 6+2:1 )25 5()(5(1&( 21/<6(( '2&80(176 )25 3,1 72 3,1 &211(&7,216 0$5. &2817 3$57,7,21 5(9 12 6,*1 '$7(
'5$:1 67$1
( (/(&7520(&+$1,&$/ 6<67(0
3+$6( 0$5. :(,*+7 6&$/(
6 $
&+(&.
6 + (( 7 2)
$ -;
352& $335

(;&((' N1 25 /(66(/(&75,&$/ ',$*5$0 :,7+ ([ &21752//(5
7+,6 '5$:,1* ,6 )25 5()(5(1&( 21/<

(1&/2685( 6:,7&+ )5$0( /2$' &(// &211(&725
,17(51$/ &$%/(6 21/< $5( 6+2:1 21 7+,6 6+((76+((7
5()Đ
6: '6
6:
,17(51$/ /2$' &(// &$%/(
(6723ď5()Đ
([ &21752//(5
72 &86720(5
<$6.$:$ 6833/,(' 32:(5

6*0*$)&
833(5 /,0,7 6:,7&+ 8 /6
([ ,QWHUIDFH %RDUG
5(*(1(5$7,9( 5(6,6725 /2:(5 /,0,7 6:,7&+ / /6 -
'5,9( $03
02725 '& '& '&
% % '3 '6 '3 6$)7< *5281' 6&5(:
- - -
32:(5 &25'
ORDG &HOO
6*'65$$
32:(5(
(1&2'(5
6$)7< *5281' 6&5(:
&25' *5,3
&1
&1
&1
&1
89:
/&
//
0*$%$9&
-
-
-
-
-
-
-
-
-
72 3& 86% 3257 )25

781,1* 6(592 3$5$0(7(5 (6723
)3073;$%
32:(5 6:7,&+
&50 &
32:(5 6833/< $535%)8-,
43 '0 ($1 :(//
.==4$%

&217$&725 &
/&'%'6&+1(,'(5
32:(5
),/7(5

(3&25&20
127(6ġ
&$%/(6 ,1 7+,6 ',*5$0 $5( 6+2:1 )25 5()(5(1&( 21/<6(( '2&80(176 )25 3,1 72 3,1 &211(&7,216 076 6\VWHPV&KLQD&R/WG
727$/ (/(&75,&$/ ',$*5$0
$// '$6+(' /,1(6 21 6+((7 $5( 32:(5 :,5,1* &211(&7,216
0$5. &2817 3$57,7,21 5(9 12 6,*1 '$7(
3/($6( 5()(5 72 ',$*5$0 $66<3:5 72 6(( 7+( &211(&7216 2) 7+(6( 7:2 &5281',1* 6&5(:6 ( (/(&7520(&+$1,&$/ 6<67(0
'5$:1 67$1 3+$6( 0$5. :(,*+7 6&$/(
6 $
&+(&.
6 + (( 7 2)
$ -;
352& $335
Appendix
231
232
(;&((' ďN1 25 /(66Đ(/(&75,&$/ ',$*5$0 :,7+ ([ &21752//(5
Appendix
(ďN1 25 /(66Đ
7+,6 '5$:,1* ,6 )25 5()(5(1&( 21/<
(;7(51$/ &$%/(6 21/< $5( 6+2:1 21 7+,6 6+((76+((7
/2$' &(// '6

'3
(;7(1620(7(5 +$1'6(7 :&$%/(

ď',*,7$/ 6(1625Đ $1' +$1'6(7 02817 $&&(625,(6
)851$&( &20081,&$7,21 &$%/(
$8; 6(1625
$1$/2* ,13876 *5,36 ď5()Đ
(7&
E44 10 kN Or Less Electrical Diagram
ď5()Đ
56
- (1&2'(5
0$&+,1( (1&/2685( - 5- -803(5
- ď5()Đ
ď5()Đ 86% 72 56 $'$37(5
- '&
- 5- -803(5
ď5()Đ
86%
86%
-
ď5()Đ
- '&
- 5- -803(5
ď5()Đ 3&
-
,17(5/2&. - ,17/. -803(5
+$1'6(7 -
86% -
- ,QVLJKW
$& 32:(5 &25'
([ ,QWHUIDFH %RDUG
([ &21752//(5
'LJLWDO ,2 - 86(5 ' ,2 )25 $&&(625,(6
237,21$/ 5(027( (6723

(6723 2XWSXW - ď-803(5 3/8*Đ -
ď5()Đ
727$/ (/(&75,&$/ ',$*5$0

127(6
32:(5 6833/< 0$5. &2817 3$57,7,21 5(9 12 6,*1 '$7(
&$%/(6 ,1 7+,6 ',*5$0 $5( 6+2:1 )25 5()(5(1&( 21/<6(( '2&80(176 )25 3,1 72 3,1 &211(&7,216 ( (/(&7520(&+$1,&$/ 6<67(0
'5$:1 67$1 3+$6( 0$5. :(,*+7 6&$/(
6 $
&+(&.
6 + (( 7 2)
$ -;
352& $335

(;&((' N1 25 /(66(/(&75,&$/ ',$*5$0 :,7+ ([ &21752//(5
(1&/2685( 6:,7&+ď5()Đ 7+,6 '5$:,1* ,6 )25 5()(5(1&( 21/<

6: ,17(51$/ &$%/(6 21/< $5( 6+2:1 21 7+,6 6+((76+((7
6:
,17(51$/ /2$' &(// &$%/(

(6723ď5()Đ
)5$0( /2$' &(// &211(&725
([ &21752//(5

833(5 /,0,7 6:,7&+ 8 /6 '5,9( $03
([ ,QWHUIDFH %RDUG
/2:(5 /,0,7 6:,7&+ / /6 -

6$)7< *5281' 6&5(: 6$)7< *5281' 6&5(:
<$6.$:$ 6*0-$)&6 5(*(1(5$7,9( 5(6,6725 '& '& '&
'3 '6 '3
- - -
% % ,QVLJKW %RDUG
'5,9( $03 ORDG &HOO 5($5
02725
6*'65$$
32:(5 ,1387
3)%8/*,1
32:(5
&1
&1
&1
&1
(1&2'(5
89:
/&
//
-
-
-
-
-
-
-
-
-
(6723
72 3& 86% 3257 )25 /2$' 5(6,67(5 )3073;$%
781,1* 6(592 3$5$0(7(5 2+0 :
&20 9'&
32:(5 6:,7&+
32:(5 6833/<
$535%)8-,
57%0($1 :(//
&50
&
.==4$%

32:(5
),/7(5

(3&25&20
127(6ġ
&$%/(6 ,1 7+,6 ',*5$0 $5( 6+2:1 )25 5()(5(1&( 21/<6(( '2&80(176 )25 3,1 72 3,1 &211(&7,216 076 6\VWHPV&KLQD&R/WG
727$/ (/(&75,&$/ ',$*5$0
$// '$6+(' /,1(6 21 6+((7 $5( 32:(5 :,5,1* &211(&7,216
0$5. &2817 3$57,7,21 5(9 12 6,*1 '$7(
3/($6( 5()(5 72 ',$*5$0 $66<3:5 72 6(( 7+( &211(&7216 2) 7+(6( 7:2 &5281',1* 6&5(:6 ( (/(&7520(&+$1,&$/ 6<67(0
'5$:1 67$1 3+$6( 0$5. :(,*+7 6&$/(
6 $
&+(&.
Appendix
6 + (( 7 2)
$ -;
352& $335
233
234
(;&((' ďN1N1Đ(/(&75,&$/ ',$*5$0 :,7+ ([ &21752//(5
(;&((' N1N1
Appendix
7+,6 '5$:,1* ,6 )25 5()(5(1&( 21/<
(;7(51$/ &$%/(6 21/< $5( 6+2:1 21 7+,6 6+((76+((7
/2$' &(// '6

'3
(;7(1620(7(5 +$1'6(7 :&$%/(

ď',*,7$/ 6(1625Đ $1' +$1'6(7 02817 $&&(625,(6
)851$&( &20081,&$7,21 &$%/(
$8; 6(1625
$1$/2* ,13876 *5,36 ď5()Đ
(7&
E44 20 kN Or 30 kN Electrical Diagram
ď5()Đ
56
- (1&2'(5
0$&+,1( (1&/2685( - 5- -803(5
- ď5()Đ
ď5()Đ 86% 72 56 $'$37(5
- '&
- 5- -803(5
ď5()Đ
86%
86%
-
ď5()Đ
- '&
- 5- -803(5
ď5()Đ 3&
-
,17(5/2&. - ,17/. -803(5
+$1'6(7 -
86% -
- ,QVLJKW
32:(5 &25' ([ ,QWHUIDFH %RDUG
([ &21752//(5
'LJLWDO ,2 - 86(5 ' ,2 )25 $&&(625,(6
237,21$/ 5(027( (6723

(6723 2XWSXW - ď-803(5 3/8*Đ -
ď5()Đ
32:(5 6833/<
727$/ (/(&75,&$/ ',$*5$0

127(6
0$5. &2817 3$57,7,21 5(9 12 6,*1 '$7(
&$%/(6 ,1 7+,6 ',*5$0 $5( 6+2:1 )25 5()(5(1&( 21/<6(( '2&80(176 )25 3,1 72 3,1 &211(&7,216 ( (/(&7520(&+$1,&$/ 6<67(0
'5$:1 67$1 3+$6( 0$5. :(,*+7 6&$/(
6 $
&+(&.
6 + (( 7 2)
$ -;
352& $335

(;&((' N1N1(/(&75,&$/ ',$*5$0 :,7+ ([ &21752//(5
7+,6 '5$:,1* ,6 )25 5()(5(1&( 21/<

(1&/2685( 6:,7&+ )5$0( /2$' &(// &211(&725
,17(51$/ &$%/(6 21/< $5( 6+2:1 21 7+,6 6+((76+((7
5()Đ
6: '6
6:
,17(51$/ /2$' &(// &$%/(
(6723ď5()Đ
([ &21752//(5
72 &86720(5
6833/,(' 32:(5

833(5 /,0,7 6:,7&+ 8 /6
<$6.$:$ ([ ,QWHUIDFH %RDUG
5(*(1(5$7,9( 5(6,6725 /2:(5 /,0,7 6:,7&+ / /6 -
6*0*$)&
'5,9( $03
'& '& '&
% % '3 '6 '3 6$)7< *5281' 6&5(:
- - -
32:(5 &25'
02725 ORDG &HOO

6*'65$$
6$)7< *5281' 6&5(:
&25' *5,3
&1
&1
&1
&1
89:
/&
//
32:(5(
(1&2'(5
0*$%$9&
-
-
-
-
-
-
-
-
-
72 3& 86% 3257 )25

781,1* 6(592 3$5$0(7(5 (6723
)3073;$%
32:(5 6:7,&+
&50 &
32:(5 6833/< $535%)8-,
43 '0 ($1 :(//
.==4$%

&217$&725 &
/&'%'6&+1(,'(5
32:(5
),/7(5

(3&25&20
127(6ġ
&$%/(6 ,1 7+,6 ',*5$0 $5( 6+2:1 )25 5()(5(1&( 21/<6(( '2&80(176 )25 3,1 72 3,1 &211(&7,216 076 6\VWHPV&KLQD&R/WG
727$/ (/(&75,&$/ ',$*5$0
$// '$6+(' /,1(6 21 6+((7 $5( 32:(5 :,5,1* &211(&7,216
0$5. &2817 3$57,7,21 5(9 12 6,*1 '$7(
3/($6( 5()(5 72 ',$*5$0 $66<3:5 72 6(( 7+( &211(&7216 2) 7+(6( 7:2 &5281',1* 6&5(:6 ( (/(&7520(&+$1,&$/ 6<67(0
'5$:1 67$1 3+$6( 0$5. :(,*+7 6&$/(
6 $
&+(&.
$ -;
Appendix
352& $335 6 + (( 7 2)
235
236
(;&((' N1 25 /(66 (;&((' ďN1 25 /(66Đ(/(&75,&$/ ',$*5$0 :,7+ ([ &21752//(5
Appendix
7+,6 '5$:,1* ,6 )25 5()(5(1&( 21/<
(;7(51$/ &$%/(6 21/< $5( 6+2:1 21 7+,6 6+((76+((7
(;7(1620(7(5 +$1'6(7 :&$%/(

ď',*,7$/ 6(1625Đ $1' +$1'6(7 02817 $&&(625,(6
0$&+,1( (1&/2685( )851$&( &20081,&$7,21 &$%/(
$8; 6(1625
$1$/2* ,13876 *5,36 ď5()Đ
(7&
ď5()Đ
56
- (1&2'(5
/2$' &(//
-
'6 5- -803(5
'3 ď5()Đ
-
ď5()Đ 86% 72 56 $'$37(5
- '&
- 5- -803(5
ď5()Đ
86%
86%
-
ď5()Đ
- '&
- 5- -803(5
ď5()Đ 3&
-
,17(5/2&. - ,17/. -803(5
+$1'6(7 -
86% -
- ,QVLJKW
( ,QWHUIDFH %RDUG
'LJLWDO ,2 - 86(5 ' ,2 )25 $&&(625,(6
( &21752//(5
237,21$/ 5(027( (6723
(6723 2XWSXW - ď-803(5 3/8*Đ -
ď5()Đ
32:(5 &25'
32:(5 6833/<
727$/ (/(&75,&$/ ',$*5$0

127(6 0$5. &2817 3$57,7,21 5(9 12 6,*1 '$7(
'5$:1 67$1
( (/(&7520(&+$1,&$/ 6<67(0
&$%/(6 ,1 7+,6 ',*5$0 $5( 6+2:1 )25 5()(5(1&( 21/<6(( '2&80(176 )25 3,1 72 3,1 &211(&7,216 3+$6( 0$5. :(,*+7 6&$/(
6 $
&+(&.
6 + (( 7 2)
$ -;
352& $335

(;&((' N1 25 /(66(/(&75,&$/ ',$*5$0 :,7+ ([ &21752//(5
7+,6 '5$:,1* ,6 )25 5()(5(1&( 21/<

(1&/2685( 6:,7&+ )5$0( /2$' &(// &211(&725
,17(51$/ &$%/(6 21/< $5( 6+2:1 21 7+,6 6+((76+((7
5()Đ
6: '6
6:
,17(51$/ /2$' &(// &$%/(
(6723ď5()Đ
([ &21752//(5
72 &86720(5

6833/,(' 32:(5
833(5 /,0,7 6:,7&+ 8 /6

<$6.$:$ ([ ,QWHUIDFH %RDUG
5(*(1(5$7,9( 5(6,6725 /2:(5 /,0,7 6:,7&+ / /6 -
6*0*$)&
'5,9( $03
'& '& '&
% % '3 '6 '3 6$)7< *5281' 6&5(:
- - -
32:(5 &25'
02725 ORDG &HOO

6*'6$$
6$)7< *5281' 6&5(:
&25' *5,3
&1
&1
&1
&1
89:
/&
//
32:(5(
(1&2'(5
0*$%$9&
-
-
-
-
-
-
-
-
-
72 3& 86% 3257 )25

781,1* 6(592 3$5$0(7(5 (6723
)3073;$%
32:(5 6:7,&+
&50 &
32:(5 6833/< $535%)8-,
43 '0 ($1 :(//
.==4$%

&217$&725 &
/&'%'6&+1(,'(5
32:(5
),/7(5

(3&25&20
127(6ġ
&$%/(6 ,1 7+,6 ',*5$0 $5( 6+2:1 )25 5()(5(1&( 21/<6(( '2&80(176 )25 3,1 72 3,1 &211(&7,216 076 6\VWHPV&KLQD&R/WG
727$/ (/(&75,&$/ ',$*5$0
$// '$6+(' /,1(6 21 6+((7 $5( 32:(5 :,5,1* &211(&7,216
0$5. &2817 3$57,7,21 5(9 12 6,*1 '$7(
3/($6( 5()(5 72 ',$*5$0 $66<3:5 72 6(( 7+( &211(&7216 2) 7+(6( 7:2 &5281',1* 6&5(:6 ( (/(&7520(&+$1,&$/ 6<67(0
'5$:1 67$1 3+$6( 0$5. :(,*+7 6&$/(
6 $
&+(&.
$ -;
Appendix
352& $335 6 + (( 7 2)
237
238
(;&((' N1N1 (;&((' N1N1(/(&75,&$/ ',$*5$0 :,7+ ([ &21752//(5
Appendix
7+,6 '5$:,1* ,6 )25 5()(5(1&( 21/<
(;7(51$/ &$%/(6 21/< $5( 6+2:1 21 7+,6 6+((76+((7
(;7(1620(7(5 +$1'6(7 :&$%/(

ď',*,7$/ 6(1625Đ $1' +$1'6(7 02817 $&&(625,(6
0$&+,1( (1&/2685( )851$&( &20081,&$7,21 &$%/(
$8; 6(1625
$1$/2* ,13876 *5,36 ď5()Đ
(7&
E45 200 kN 300 kN Electrical Diagram
ď5()Đ
56
- (1&2'(5
/2$' &(//
-
'6 5- -803(5
'3 ď5()Đ
-
ď5()Đ 86% 72 56 $'$37(5
- '&
- 5- -803(5
ď5()Đ
86%
86%
-
ď5()Đ
- '&
- 5- -803(5
ď5()Đ 3&
-
,17(5/2&. - ,17/. -803(5
+$1'6(7 -
86% -
- ,QVLJKW
( ,QWHUIDFH %RDUG
'LJLWDO ,2 - 86(5 ' ,2 )25 $&&(625,(6
( &21752//(5
237,21$/ 5(027( (6723
(6723 2XWSXW - ď-803(5 3/8*Đ -
ď5()Đ
32:(5 &25'
32:(5 6833/<
727$/ (/(&75,&$/ ',$*5$0

127(6 0$5. &2817 3$57,7,21 5(9 12 6,*1 '$7(
'5$:1 67$1
( (/(&7520(&+$1,&$/ 6<67(0
&$%/(6 ,1 7+,6 ',*5$0 $5( 6+2:1 )25 5()(5(1&( 21/<6(( '2&80(176 )25 3,1 72 3,1 &211(&7,216 3+$6( 0$5. :(,*+7 6&$/(
6 $
&+(&.
6 + (( 7 2)
$ -;
352& $335

(;&((' N1N1(/(&75,&$/ ',$*5$0 :,7+ ([ &21752//(5
(1&/2685( '6
6:,7&+ď5()Đ
7+,6 '5$:,1* ,6 )25 5()(5(1&( 21/<
6: ,17(51$/ &$%/(6 $5( 21/< 6+2:1 21 7+,6 6+((76+((7
6:
)5$0( /2$' &(// &211(&725
,17(51$/ /2$' &(// &$%/(
(6723ď5()Đ
([ &21752//(5

833(5 /,0,7 6:,7&+ 8 /6
/2:(5 /,0,7 6:,7&+ / /6 ([ ,QWHUIDFH %RDUG
-
5(*(1(5$7,21 5(6,67(1&(
$6= :5 ) 1 '& '& '&
<$6.$:$ '3 '6 '3
=+(1*<$1*;,1* - - -
6*0*$)& ,QVLJKW %RDUG
ORDG &HOO
% %
'5,9( $03
02725 6*'6$$
-
-
-
-
-
-
-
-
-
&1
&1
&1
&1
//
89:
/&
32:(5
(1&2'(5
(6723
72 3& 86% 3257 )25 )3073;$%
781,1* 6(592 3$5$0(7(5
32:(5 6833/<
&50 &
43'0($1 :(//
.==4$%
&217$&725 &
/&'%'6&+1(,'(5
127(6
&$%/(6 ,1 7+,6 ',*5$0 $5( 6+2:1 )25 5()(5(1&( 21/<6(( '2&80(176 )25 3,1 72 3,1 &211(&7,216 727$/ (/(&75,&$/ ',$*5$0
0$5. &2817 3$57,7,21 5(9 12 6,*1 '$7(
'5$:1 67$1
( (/(&7520(&+$1,&$/ 6<67(0
3+$6( 0$5. :(,*+7 6&$/(
6 $
&+(&.
$ -;
Appendix
352& $335 6 + (( 7 2)
239
240Appendix
([ &21752//(5 32:(5 6833/<
8/ $:* *51 <(/ 43'0($1 :(//
([ ,QWHUIDFH %RDUG 32:(5 6833/<
- 3( 1 /
32:(5 6833/< * 8/ $:* *51 <(/
<$6.$:$ '5,9( 8/ $:* *51 <(/

,QVLJKW %RDUG -
),/7(5 8/ $:* *51 <(/
6$)7< *5281' 9$&
<$6.$:$ 02725 8/ $:* %/. 25 9$&
6*0*$)& 8/ $:* :+7 +=
$PSV
72 &86720(5
6833/,('
32:(5 6:,7&+ ',6&211(&725
02725 $535%)8-,
<$6.$:$ '5,9(
32:(5
6*'6$$
(1&2'(5
32:(5 &25'
/
/
/
/&
/&
&1
*1'
89:
6$)7< *5281'
$:* *51 <(/ &25' *5,3
0*$%$9&

$:* %/.
$:* %/.
$:* %/.
8/ $:* %/.

8/ $:* %/.
8/ $:* %/.
8/ $:* %/.
8/ $:* %/.
/ $:* %/.
8
8/ $:* :+7

&,5&8,7 %5($.(5
0'$%

&217$&(725
&
7 / 8/ $:* %/. D $$ 8/ $:* %/. 8 8 8/ $:* %/.
7 / 8/ $:* %/. E %% 8/ $:* %/. 9 9 8/ $:* %/.
/,1(
/2$'
/2$'
/,1(
7 / 8/ $:* %/. F && 8/ $:* %/. : : 8/ $:* %/.
/&'%'6&+1(,'(5 75$16)250(5 ),/7(5

6*.9$;,*(0$7$, )16&+$))1(5
127(6
727$/ (/(&75,&$/ ',$*5$0

&$%/(6 ,1 7+,6 ',*5$0 $5( 6+2:1 )25 5()(5(1&( 21/<6(( '2&80(176 )25 3,1 72 3,1 &211(&7,216
86( 7,(:5$36 21 08/7,&$%/(6 $6 5(48,5(' 0$5. &2817 3$57,7,21 5(9 12 6,*1 '$7(
'5$:1 67$1
( (/(&7520(&+$1,&$/ 6<67(0
3+$6( 0$5. :(,*+7 6&$/(
3/($6( 5()(5 72 ',$*5$0 $66<3:5 72 6(( 7+( &211(&7,216 2) 7+(6( 7:2 *5281',1* 6&5(:6
6 $
7+(5( $5( 7:2 237,21$/ ,13876 )25 7+( 75$16)250(5$%&,6 )25 9$& 32:(5 ,1387$1' $%&,6 )25 9$& ,1387 &+(&.
6 + (( 7 2)
$ -;
352& $335

(;&((' N1 25 /(66 (;&((' N1 25 /(66(/(&75,&$/ ',$*5$0 :,7+ ([ &21752//(5
7+,6 '5$:,1* ,6 )25 5()(5(1&( 21/<

(;7(51$/ &$%/(6 21/< $5( 6+2:1 21 7+,6 6+((76+((7
(;7(1620(7(5 +$1'6(7 :&$%/(

ď',*,7$/ 6(1625Đ $1' +$1'6(7 02817 $&&(625,(6
0$&+,1( (1&/2685( )851$&( &20081,&$7,21 &$%/(
$8; 6(1625
$1$/2* ,13876 *5,36 ď5()Đ
(7&

ď5()Đ
56
- (1&2'(5
/2$' &(//
-
'6 5- -803(5
'3 ď5()Đ
-
ď5()Đ 86% 72 56 $'$37(5
- '&
- 5- -803(5
ď5()Đ
86%
86%
-
ď5()Đ
- '&
- 5- -803(5
ď5()Đ 3&
-
,17(5/2&. - ,17/. -803(5
+$1'6(7 -
86% -
- ,QVLJKW
( ,QWHUIDFH %RDUG
'LJLWDO ,2 - 86(5 ' ,2 )25 $&&(625,(6
( &21752//(5
237,21$/ 5(027( (6723
(6723 2XWSXW - ď-803(5 3/8*Đ -
ď5()Đ
32:(5 &25'
32:(5 6833/<
727$/ (/(&75,&$/ ',$*5$0

127(6 0$5. &2817 3$57,7,21 5(9 12 6,*1 '$7(
'5$:1 67$1
( (/(&7520(&+$1,&$/ 6<67(0
&$%/(6 ,1 7+,6 ',*5$0 $5( 6+2:1 )25 5()(5(1&( 21/<6(( '2&80(176 )25 3,1 72 3,1 &211(&7,216 3+$6( 0$5. :(,*+7 6&$/(
6 $
&+(&.
6 + (( 7 2)
$ -;
352& $335
Appendix
241
242
(;&((' N1 25 /(66(/(&75,&$/ ',$*5$0 :,7+ ([ &21752//(5
(1&/2685( '6
Appendix
6:,7&+ď5()Đ
7+,6 '5$:,1* ,6 )25 5()(5(1&( 21/<
6: ,17(51$/ &$%/(6 $5( 21/< 6+2:1 21 7+,6 6+((76+((7
6:
)5$0( /2$' &(// &211(&725
,17(51$/ /2$' &(// &$%/(
(6723ď5()Đ
([ &21752//(5
833(5 /,0,7 6:,7&+ 8 /6

/2:(5 /,0,7 6:,7&+ / /6 ([ ,QWHUIDFH %RDUG
-
5(*(1(5$7,21 5(6,67(1&(
$6= :5 ) 1 '& '& '&
<$6.$:$ '3 '6 '3
=+(1*<$1*;,1* - - -
6*0*$)& ,QVLJKW %RDUG
ORDG &HOO
% %
'5,9( $03
02725 6*'6$$
-
-
-
-
-
-
-
-
-
&1
&1
&1
&1
//
89:
/&
32:(5
(1&2'(5
(6723
72 3& 86% 3257 )25 )3073;$%
781,1* 6(592 3$5$0(7(5
32:(5 6833/<
&50 &
43'0($1 :(//
.==4$%
&217$&725 &
/&'%'6&+1(,'(5
127(6
&$%/(6 ,1 7+,6 ',*5$0 $5( 6+2:1 )25 5()(5(1&( 21/<6(( '2&80(176 )25 3,1 72 3,1 &211(&7,216 727$/ (/(&75,&$/ ',$*5$0
0$5. &2817 3$57,7,21 5(9 12 6,*1 '$7(
'5$:1 67$1
( (/(&7520(&+$1,&$/ 6<67(0
3+$6( 0$5. :(,*+7 6&$/(
6 $
&+(&.
6 + (( 7 2)
$ -;
352& $335

([ &21752//(5 32:(5 6833/<
8/ $:* *51 <(/ 43'0($1 :(//
([ ,QWHUIDFH %RDUG 32:(5 6833/<
- 3( 1 /
32:(5 6833/< * 8/ $:* *51 <(/
<$6.$:$ '5,9( 8/ $:* *51 <(/

,QVLJKW %RDUG -
),/7(5 8/ $:* *51 <(/
6$)7< *5281' 9$&
<$6.$:$ 02725 8/ $:* %/. 25 9$&
6*0*$)& 8/ $:* :+7 +=

$PSV
72 &86720(5
6833/,('
32:(5 6:,7&+ ',6&211(&725
02725 $535%)8-,
<$6.$:$ '5,9(
32:(5
6*'6$$
(1&2'(5
32:(5 &25'
/
/
/
/&
/&
&1
*1'
89:
6$)7< *5281'
$:* *51 <(/ &25' *5,3
0*$%$9&

$:* %/.
$:* %/.
$:* %/.
8/ $:* %/.

8/ $:* %/.
8/ $:* %/.
8/ $:* %/.
8/ $:* %/.
/ $:* %/.
8
8/ $:* :+7

&,5&8,7 %5($.(5
0'$%

&217$&(725
&
7 / 8/ $:* %/. D $$ 8/ $:* %/. 8 8 8/ $:* %/.
7 / 8/ $:* %/. E %% 8/ $:* %/. 9 9 8/ $:* %/.
/,1(
/2$'
/2$'
/,1(
7 / 8/ $:* %/. F && 8/ $:* %/. : : 8/ $:* %/.
/&'%'6&+1(,'(5 75$16)250(5 ),/7(5

6*.9$;,*(0$7$, )16&+$))1(5
127(6
727$/ (/(&75,&$/ ',$*5$0

&$%/(6 ,1 7+,6 ',*5$0 $5( 6+2:1 )25 5()(5(1&( 21/<6(( '2&80(176 )25 3,1 72 3,1 &211(&7,216
86( 7,(:5$36 21 08/7,&$%/(6 $6 5(48,5(' 0$5. &2817 3$57,7,21 5(9 12 6,*1 '$7(
'5$:1 67$1
( (/(&7520(&+$1,&$/ 6<67(0
3+$6( 0$5. :(,*+7 6&$/(
3/($6( 5()(5 72 ',$*5$0 $66<3:5 72 6(( 7+( &211(&7,216 2) 7+(6( 7:2 *5281',1* 6&5(:6
6 $
7+(5( $5( 7:2 237,21$/ ,13876 )25 7+( 75$16)250(5$%&,6 )25 9$& 32:(5 ,1387$1' $%&,6 )25 9$& ,1387 &+(&.
6 + (( 7 2)
$ -;
352& $335
Appendix
243
Notes
Notes

Notes
Notes

Notes
Notes

Notes
Notes

Notes

m
MTS Systems Corporation
http://www.mts.com/en/Global/index.asp
ISO 9001 Certified QMS

100303151D Exceed40FSE EN

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

100303151D Exceed40FSE EN

Uploaded by

Copyright:

Available Formats

MTS Exceed® Series 40

100-303-151 B October 2015

100-303-151 C December 2015

100-303-151 C (reissue) June 2020

100-303-151 D July 2021

2 MTS Exceed ® Series 40 FSE Manual

MTS Exceed ® Series 40 FSE Manual 3

TEDS Devices Window 116

Operator maintenance 126

Removing Panels 144

4 MTS Exceed ® Series 40 FSE Manual

Spare Parts List 151

Systems with the ICE Controller 187

Clevis Adapter Dimension 200

MTS Exceed ® Series 40 FSE Manual 5

6 MTS Exceed ® Series 40 FSE Manual

MTS Exceed Series 40 Material Test System is the latest generation of

MTS Exceed® Series 40 FSE Manual Introduction 7

Low-Capacity Mid-Capacity High-Capacity

8 Introduction MTS Exceed® Series 40 FSE Manual

• Provides main data and signal processing power

• Detects the activation of limit switches

• Provides digital servocontrol- for speed and position accuracy

• Automatically identifies accessories including load cells and extensometers

• Communicates with handset interface

• Provides programmable data acquisition rate (up to 1000 Hz maximum for

• Commands the motor

Many additional features can be purchased to meet your company’s specific

MTS Exceed® Series 40 FSE Manual Introduction 9

Load Frame Components

Ball Screw Cover

Upper Limit Stop

Load Cell Limit Switch Actuator

Lower Limit Stop

Model E42.503 Rated Force Capacity 5 kN

10 Introduction MTS Exceed® Series 40 FSE Manual

Ball Screw Cover

Adapter Limit Switch Actuator

Lower Limit Stop

Model E43 Rated Force Capacity 10 kN

MTS Exceed® Series 40 FSE Manual Introduction 11

Column Cover Top Beam

Upper Limit Stop

Limit Switch Actuator

Lower Limit Stop

Model E43.304 / E43.504 - Rated Force Capacity 30 kN, 50 kN

12 Introduction MTS Exceed® Series 40 FSE Manual

Ball Screw Cover

Crosshead Upper Limit Stop

Lower Test Space

Power Switch Power Cord

Model E44.104 / E44.304 - Rated Force Capacity 10 kN, 30 kN

MTS Exceed® Series 40 FSE Manual Introduction 13

Ball Screw Cover

Upper Test Space

Crosshead Upper Limit Stop

Lower Test Space Handset

Model E45.105 - Rated Force Capacity 100 kN

14 Introduction MTS Exceed® Series 40 FSE Manual

Ball Screw Cover

Upper Limit Stop

Adapter Limit Switch Actuator

Base Adapter Lower Limit Stop