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Copyright information Trademark information © 2014 MTS Systems Corporation. All rights reserved. MTS, Temposonics, FlexTest, and TestWare are registered trademarks of MTS Systems Corporation within the United States; AeroPro, MPT, Station Builder, Station Manager, and TestStar are trademarks of MTS Systems Corporation within the United States. These trademarks may be protected in other countries. Microsoft and Windows are registered trademarks of Microsoft Corporation.
Contents Contents 3 Technical Support 7 Preface 13 Conventions 14 Chapter 1 Safety Information 17 Safety Circuits Chapter 2 21 FlexTest Controller Configurations 27 FlexTest Controller Overview Installation 28 31 UPS System Requirements 43 FlexTest 40 Controller Configuration 47 Model 494.41 Single-Station System Board 52 Model 494.42 Single-Station System Board 67 Model 494.
Chapter 3 VME Bus Boards 113 VME Bus Board Overview Processor Connections 114 118 Model 494.40 I/O Carrier Board Model 494.43 Multibox Board Chapter 4 120 126 Mezzanine Cards 133 Digital Universal Conditioner Mezzanine Cards Model 494.25 Single DUC Card Model 494.26 Dual DUC Card 143 154 157 Model 494.16 VD/DUC Mezzanine Card 160 Model 494.21 Multi-Range DUC with Acceleration Compensation Card Model 494.45 8-Input A/D Converter Card Model 494.46 8-Output D/A Card 176 179 Model 494.
Model 494.76 8-Output BNC Transition Board Model 494.79 8-Channel Valve Driver Board Model 493.
Contents MTS FlexTest® Models 40/60/100/200 Controller Hardware
Technical Support Technical Support How to Get Technical Support Start with your manuals The manuals supplied by MTS provide most of the information you need to use and maintain your equipment. If your equipment includes software, look for online help and README files that contain additional product information. If you cannot find answers to your technical questions from these sources, you can use the internet, e-mail, telephone, or fax to contact MTS for assistance.
Technical Support Before You Contact MTS MTS can help you more efficiently if you have the following information available when you contact us for support. Know your site number and system number The site number contains your company number and identifies your equipment type (such as material testing or simulation). The number is typically written on a label on your equipment before the system leaves MTS. If you do not know your MTS site number, contact your sales engineer.
Technical Support Know relevant computer information Know relevant software information For a computer problem, have the following information available: • Manufacturer’s name and model number • Operating software type and service patch information • Amount of system memory • Amount of free space on the hard drive where the application resides • Current status of hard-drive fragmentation • Connection status to a corporate network For software application problems, have the following informati
Technical Support Identify system type Be prepared to troubleshoot Write down relevant information After you call 10 Technical Support To enable the Call Center agent to connect you with the most qualified technical support specialist available, identify your system as one of the following types: • Electromechanical material test system • Hydromechanical material test system • Vehicle test system • Vehicle component test system • Aero test system Prepare to perform troubleshooting while on
Technical Support Problem Submittal Form in MTS Manuals Use the Problem Submittal Form to communicate problems with your software, hardware, manuals, or service that are not resolved to your satisfaction through the technical support process. The form includes check boxes that allow you to indicate the urgency of your problem and your expectation of an acceptable response time. We guarantee a timely response—your feedback is important to us.
Technical Support 12 Technical Support MTS FlexTest® Models 40/60/100/200 Controller Hardware
Preface Before You Begin Safety first! Other MTS manuals Before you use your MTS product or system, read and understand the safety information provided with your system. Improper installation, operation, or maintenance can result in hazardous conditions that can cause severe personal injury or death, or damage to your equipment and specimen. Again, read and understand the safety information provided with your system before you continue.
Conventions Conventions Documentation Conventions The following paragraphs describe some of the conventions that are used in your MTS manuals. Hazard conventions Hazard notices may be embedded in this manual. These notices contain safety information that is specific to the activity to be performed. Hazard notices immediately precede the step or procedure that may lead to an associated hazard. Read all hazard notices carefully and follow all directions and recommendations.
Conventions Illustrations Electronic manual conventions Hypertext links Illustrations appear in this manual to clarify text. They are examples only and do not necessarily represent your actual system configuration, test application, or software. This manual is available as an electronic document in the Portable Document File (PDF) format. It can be viewed on any computer that has Adobe Acrobat Reader installed. The electronic document has many hypertext links displayed in a blue font.
Conventions 16 Preface MTS FlexTest® Models 40/60/100/200 Controller Hardware
Safety Information Chapter 1 Safety Information Contents Intended Use of MTS Series 494 Controllers 18 EC Declaration of Conformity for MTS Models 494.04 (FlexTest 40), 494.06 (FlexTest 60), 494.10 (FlexTest 100) and 494.
Safety Information Intended Use of MTS Series 494 Controllers MTS Series 494 Controllers vary from single-channel, single-station systems to multichannel, multistation systems. This increased flexibility of Series 494 Controllers permits their use in several industrial testing applications.
Safety Information EC Declaration of Conformity for MTS Models 494.04 (FlexTest 40), 494.06 (FlexTest 60), 494.10 (FlexTest 100) and 494.20 (FlexTest 200) Description of Models Manufacturer The MTS Series 494 Electronics Control Chassis’ are VMEbus chassis’ that can house up to twenty VMEbus modules in the front of the chassis and up to twenty MTS Systems Corporation transition modules in the rear panel of the chassis.
Safety Information DESCRIPTION BASIC STANDARD TEST SPECIFICATION Electrical surge immunity test EN 61000-4-5 2 kV mains line to earth 1 kV mains line to line .
Safety Circuits Safety Circuits Series 494 hardware includes a number of safety circuits that monitor and respond to potentially unsafe conditions. Shock Hazards To avoid shock hazards, users should not attempt to service any parts located inside any Series 494 Controller chassis. WARNING Controllers contain components that operate at hazardous voltage levels. Hazardous voltage levels inside the controller pose a danger. Contact with high-voltage electricity can result in injury or death.
Safety Circuits Input/Output Verification There are a number of ways that you can verify the integrity of controller input and output circuits. WARNING Improper use of controller outputs can result in damage to the controller and unexpected actuator movement. Unexpected actuator movement can result in injury to personnel or damage to the equipment. Outputs should be used to monitor controller functions within the specifications included in the MTS Series 494 Controller Hardware Manual.
Safety Circuits E-Stop Circuit Testing The E-Stop circuit should be tested periodically to help ensure that the system shuts down safely when the E-Stop button(s) is pressed. Note MTS recommends testing the E-Stop circuit at least once per month. 1. Remove any specimens from each station. 2. Apply power to the controller. 3. Start the HPU and each HSM associated with your test station(s). 4.
Safety Circuits Hardware Interlocks A Series 494 controller running Series 793 Control Software can have up to eight separate hardware interlock chains. Each test station configuration that you open must be assigned to a unique hardware interlock chain. This allows one controller to run up to eight test stations, each with its own hardware interlock chain. Note Some test configurations may only use one station that is assigned to a single hardware interlock chain.
Safety Circuits E-Stop and Hardware Interlocks The following table shows E-stop/interlock operation for a typical system that uses Series 793 Control Software. Interlock and E-stop operation on some test systems may vary. E-stop and Hardware Interlock Events/Actions (Series 793 Control Software) E-STOP GLOBAL (CONTROLLER) INTERLOCK STATION INTERLOCK An E-stop occurs when the operator presses an electromechanical E-stop switch.
Safety Circuits 26 Safety Information MTS FlexTest® Models 40/60/100/200 Controller Hardware
FlexTest Controller Configurations Chapter 2 FlexTest Controller Configurations This chapter describes the various components, specifications, and installation requirements for MTS FlexTest Controller hardware.
FlexTest Controller Overview FlexTest Controller Overview About MTS FlexTest Models 40/60/100/200 Controllers MTS FlexTest Models 40/60/100/200 Controllers are generally used in servohydraulic test systems. They provide real-time closed-loop control, with transducer conditioning and function generation to drive various types of servoactuators. A FlexTest Controller consists of: • One or more Series 494 Hardware chassis that contain controller hardware.
FlexTest Controller Overview FlexTest 40 FlexTest 60 Back (3 VME slots) FlexTest 100 Front (6 VME slots) Front (10 VME slots) Back (8 transition slots, 7 powered) Back (12 transition slots, 10 powered) FlexTest 200 Front (20 VME slots) Back (20 transition slots, 19 powered) FlexTest Models 40/60/100/200 Controllers MTS FlexTest® Models 40/60/100/200 Controller Hardware FlexTest Controller Configurations 29
FlexTest Controller Overview Typical Series 494 Chassis Connections (FT60, FT100, FT200) 494.40 I/O Carrier 1 2 3 4 5 6 7 8 494.16 VD/DUC HPU Station A Force Transducer Hydraulic Service Manifold (HSM) Hydraulic Power Unit (HPU) Servovalve E-Stop 494.26 Dual DUC LVDT 494.16 VD/DUC 494.74 HSM J49 AUX PWR 493.
Installation Installation This section includes a number of installation requirements for Series 494 Controller Hardware. Controller Installation Procedure The following procedure provides a basic outline for the installation of FlexTest controllers. 1. Unpack the controller. 2. Inspect the controller for any damage. Note Report any damage to the controller to the shipping agent and MTS. CAUTION Controller electronic components can be damaged during shipping.
Installation CAUTION The Model 494.06 Chassis has a removable front cover that could loosen when attempting to lift the chassis. Lifting the Model 494.06 Chassis without first removing the front cover can result in injury to personnel or equipment damage. Remove the front cover on the Model 494.06 Chassis before attempting to lift the Model 494.06 Chassis. 4. Connect power and cables as required.
Installation WARNING Unprotected cables can be damaged by hydraulic fluid, excessive temperature, excessive strain, and contact with sharp, abrasive, or heavy objects. A damaged cable can cause a rapid, unexpected system response which can result in severe personal injury, death, or damage to equipment. Protect all system cables as described below: • Protect electrical cables from spilled hydraulic fluid and from excessive temperatures that can cause the cables to harden and eventually fail.
Installation Installation Requirements–Series 494 Hardware Software settings Blank chassis panels Software is used to define the location (address) of each board used in the system. Controller software uses this information to locate and communicate with each board. In addition, there are other software settings that define hardware parameters. To help ensure proper ventilation, each blank slot in a Series 494 Chassis must have a blank chassis panel.
Installation Environmental Requirements—Series 494 Hardware All Series 494 hardware components are intended for indoor use only. This indoor environment must conform to the following environmental specifications. Note All Series 494 Controller must only be operated under the installation and ambient conditions (such as, temperature, moisture, and EMC) specified.
Installation Ventilation Requirements–Series 494 Chassis For proper ventilation for rack-mounted chassis, you must provide 51 mm (2 in) clearance on all sides of a Series 494 Chassis. Note The rear of the chassis requires a minimum clearance of 15.24 cm (6 in) for cable connections. 494.74 HSM 8 494.74 HSM 7 494.74 HSM 6 J3A STA 494.74 HSM J3B STA J49 AUX PWR J49 AUX PWR J49 AUX PWR J49 AUX PWR J3A STA 10 9 493.73 HPU SERVICE J23 E-STOP OUT J3B STA 5 4 3 2 1 B 494.
Installation Rack-Mounting Requirements–Series 494 Chassis To install a Series 494 Chassis in most 19-inch consoles you will need a console mounting kit. MOUNTING KIT PART NUMBER 494.04 Chassis Console Mounting Kit 100-152-784 494.06 Chassis Console Mounting Kit 100-174-282 494.10 Chassis Console Mounting Kit 100-183-825 494.20 Chassis Console Mounting Kit (Vertical Console) 56-819-501 494.
Installation WARNING Improper grounding can result in unexpected actuator movement and failure to meet EMC emission and susceptibility requirements. Unexpected actuator movement can result in injury or death and/or damage to the equipment. Ensure that each controller chassis is properly grounded. Stand-alone ground connections For stand-alone mounting, connect the shorting bar to both ground lugs. Tighten the two nuts that secure the shorting bar to the ground lugs. 10 9 493.73 HPU SERVICE 494.
Installation Use a cabinet ground cable (PN 569-278-xx) to connect each controllers Chassis Ground lug to the vertical ground rail. Ground Rail Shorting Bar Removed Ground Rail Series 494 Chassis Cabinet Wall Cabinet Ground Stud Series 494 Chassis Console Power Panel System Ground cable (PN 376-999-01) connects the cabinet ground stud to the Ground Rail. A System Ground cable (PN 376-999-xx) connects each ground lug on the power panel to the ground rail.
Installation AC Power Disconnect Requirements–Series 494 Chassis The Series 494 Chassis and the computer workstation should both be powered from the same electrical circuit. Note Self-Standing Enclosure Be sure to locate the chassis so that you have adequate access to disconnect the power cord from the chassis. 10 9 493.73 HPU SERVICE 494.74 HSM 8 7 6 494.74 HSM 494.74 HSM 494.74 HSM 5 4 3 2 1 B 494.76 ANALOG OUTPUT CH 1 - 8 A 494.
Installation Cable Requirements–Series 494 Hardware 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. WARNING Unprotected cables can be damaged by hydraulic fluid, excessive temperature, excessive strain, and contact with sharp, abrasive, or heavy objects.
Installation 42 FlexTest Controller Configurations MTS FlexTest® Models 40/60/100/200 Controller Hardware
UPS System Requirements UPS System Requirements UPS Systems for FlexTest 60, 100, 200, and GT Controllers To provide an increased level of safety, such as needed to address current European Machinery Directive, any system using an FT60, FT100, FT200, or FTGT servo controller must have an acceptable Uninterruptable Power Supply (UPS) properly integrated into the system.
UPS System Requirements UPS Systems for FlexTest 40 and FlexTest SE Servocontrollers To provide an increased level of safety and to address current European Machinery Directive, any system using an FT40, or FTSE servo controller must have an acceptable Uninterruptible Power Supply (UPS) properly integrated into the system.
UPS System Requirements The addition of a low battery warning relay contact out from the UPS will provide additional system safety protection by letting the controller know that the UPS battery is low. Specifications–UPS Systems Used with MTS Controllers Any UPS used with an MTS system must comply with these specifications.
UPS System Requirements Controller P0 Interlock Check Utility 793-based systems include a utility that uses Telnet commands to set and clear interlocks on various boards to identify boards that cannot set or clear interlocks. This is often the result of a bent P0 pin on the board connector. During normal startup, sysload will run this utility. If a problem is identified, 1. Sysload will not complete. 2. A results window lists the problem boards and the location of the log file that contains the results.
FlexTest 40 Controller Configuration FlexTest 40 Controller Configuration About the FlexTest 40 Controller The FlexTest 40 Controller is a fully digital proportional, integral, derivative, feed forward (PIDF) servocontroller that provides complete control of one station in a test system. A FlexTest 40 Controller consists of: • One Model 494.04 Chassis that contains controller hardware. • A computer workstation that runs MTS controller software applications.
FlexTest 40 Controller Configuration About the Model 494.04 Chassis The Model 494.04 Chassis is a four-slot VME chassis that you can rack mount or place on a desktop. All cabling is accessed through the rear panel. J28 HSM J25 Hpu J49 Aux Pwr Intlk J43 100-240 VAC 50-60 Hz, 1-2 A 1 2 3 4 5 6 7 8 J24 Power 1 2 3 4 5 6 7 8 DA Output E-stop J29 Two slots are reserved for Model 494.40 I/O Carrier boards. Each I/O carrier board can contain up to four mezzanine cards.
FlexTest 40 Controller Configuration Specifications–Model 494.04 Chassis All equipment related to the controller should be connected to the same fused power circuit. Note Electrical connections must be made by qualified personnel and conform to local codes and regulations. Local electrical codes supersede any information found here. Model 494.
FlexTest 40 Controller Configuration Model 494.04 Chassis Boards E-stop J29 DA Output J49 Aux Pwr Intlk J43 J54 Dig In Dig Out J55 The Model 494.04 Chassis includes three VME bus slots that contain the boards listed in the following table. Power J25 Hpu J28 HSM Slot 4-5 - 494.41 System I/O Slot 3 - 494.40 I/O Carrier 1 2 3 4 5 6 7 8 J24 Slot 2 - 494.
FlexTest 40 Controller Configuration Typical Model 494.04 Chassis Connections Force Transducer Hydraulic Service Manifold (HSM) Servovalve HPU To Valve Driver Card in 494.40 I/O Carrier Hydraulic Power Unit (HPU) LVDT Load Frame E-Stop To Digital Universal Conditioner (DUC) Card in 494.40 I/O Carrier J54 Digital Inputs (3) J43 Interlock Input/Output Analog Outputs (2) J24 E-stop J29 J28 HSM Power J25 Hpu J49 Aux Pwr Intlk J43 Slot 4-5 494.41 System I/O Slot 3 - 494.
Model 494.41 Single-Station System Board Model 494.41 Single-Station System Board J24 E-stop J29 J28 HSM J25 Hpu J49 Aux Pwr Intlk J43 Power 100-240 VAC 50-60 Hz, 1-2 A MOTOROLA LAN 2 Board features External Interfaces • Three digital inputs (J54) • Three digital outputs (J55) • Auxiliary power outputs for external devices (J49) • Two analog outputs (DA Output connector located on the 494.
Model 494.41 Single-Station System Board Model 494.41 System Board Specifications Model 494.41 Specifications (part 1 of 3) PARAMETER SPECIFICATION HSM Control* Connector J28 (CPC-4S) Off/Low/High Control Low Output +24 V DC, 1.0 A maximum High Output +24 V DC, 1.0 A maximum Proportional Control Signal Output 0–0.78 A Solenoid Impedance 20–25 Ω Ramp Time (0 to full scale) 2.1 s or 4.
Model 494.41 Single-Station System Board Model 494.41 Specifications (part 2 of 3) PARAMETER SPECIFICATION Program Interlock Input Connector J29 (D15S) Input Logic Switch Contact Closed = no program interlock Switch Contact Open = program interlock HPU Outputs (Start/Low/High) Connector J25 (D15P) HPU Output Output Voltage: 24 V DC at 10 mA HPU ON Input Trip Voltage: 0.9–5.
Model 494.41 Single-Station System Board Model 494.41 Specifications (part 3 of 3) PARAMETER SPECIFICATION Digital Output Relays Connector J55 (D9S) Voltage 30 V AC/DC maximum Current 1 A maximum Output logic Output 1: One normally open (NO) contact Open = Output is OFF Output 2: One normally open (NO) contact and one normally closed (NC) contact NO Contact: Open = Output is OFF NC Contact: Closed = Output is OFF Output 3: One normally open (NO) contact Open = Output is OFF Aux.
Model 494.41 Single-Station System Board J24 Emergency Stop Connections for the Model 494.41 System Board The Model 494.41 System board provides two E-Stop inputs that are available on the J24 E Stop connector (located on the rear panel of the Model 494.04 Chassis). J24 J28 HSM Power 100-240 VAC 50-60 Hz, 1-2 A 1 2 3 4 5 6 7 8 8 E-stop J29 DA Output J49 Aux Pwr Intlk J43 E-Stop Box J25 Hpu J24 1 2 3 4 5 6 7 8 494.41 System Board J54 Dig In Dig Out J55 494.
Model 494.41 Single-Station System Board J25 Hydraulic Power Unit Connections for the Model 494.41 System Board Connector J25 HPU provides 24-volt logic signals that control the hydraulic power unit (HPU). The connector can be connected directly to MTS Series 505 HPUs and similar HPUs with low-current, 24-volt input controls. Note 494.41 System Board Other MTS HPUs require the Model 493.07 HPU Converter Box to convert the low-current HPU output signal to a signal that can drive the HPU relay.
Model 494.41 Single-Station System Board CAUTION Control voltages for hydraulic power units vary between models. The interface between the Model 494.41 System board and an HPU consists of 24-volt logic signals. Connecting J25 to a non-compliant HPU can damage the board. Do not connect 24 V DC relay circuitry or 115 V AC circuitry to connector J25 on the Model 494.41 System board.
Model 494.41 Single-Station System Board J28 HSM Connections for the Model 494.41 System Board HSM control (off/low/high or proportional) is software configurable. The Model 494.41 Board provides separate 24-volt, low-pressure and high-pressure outputs that drive the HSM low- and high-pressure solenoids. Proportional control provides a current output from 0 to 0.78 A. Note The Model 494.41 Board cannot be used with 115 V AC HSMs.
Model 494.41 Single-Station System Board J29 Emergency Stop Connections for the Model 494.41 System Board Connector J29 E-STOP provides an output to external devices when an emergency stop signal is generated. You can also connect an external E-Stop to the J29 connector. 494.
Model 494.41 Single-Station System Board J43 Interlock Connections for the Model 494.41 System Board Connector J43 Interlock provides one optically isolated interlock input and a relay-contact interlock output. 494.
Model 494.41 Single-Station System Board J49 Auxiliary Power Connections for the Model 494.41 System Board The J49 Aux Pwr connector provides fused (self resetting) auxiliary power outputs for: +5 V DC, +15 V DC, -15 V DC, and +24 V DC. 494.
Model 494.41 Single-Station System Board J54 Digital Input Connections for the Model 494.41 System Board E-stop J29 J28 HSM J25 Hpu 100-240 VAC 50-60 Hz, 1-2 A 1 2 3 4 5 6 7 8 J24 494.41 System Board J54 Dig In Power 1 2 3 4 5 6 7 8 DA Output J49 Aux Pwr Intlk J43 J54 Dig In Dig Out J55 Connector J54 Dig In accepts up to three optically isolated digital-input signals from external devices. You can use these digital input signals to trigger test events in controller applications.
Model 494.41 Single-Station System Board J55 Digital Output Connections for the Model 494.41 System Board Connector J55 Dig Out provides three general-purpose digital outputs that can send digital-logic signals to external switches or logic devices. 494.
Model 494.41 Single-Station System Board Analog Output Connections for the Model 494.41 System Board The Model 494.41 System board provides two analog output signals that are available on the D/A Output connector (located on the rear panel of the Model 494.04 Chassis). Each D/A output is software defined. 494.04 Chassis 494.
Model 494.41 Single-Station System Board UPS Connections for the Model 494.41 System Board (FT40) The following drawing shows UPS connections for the Model 494.41 System board. Once connected, use your controller software to add the digital input resources and configure the digital inputs to perform various actions in response to the UPS signals. Note See your controller software user guide for information on how digital inputs are assigned and used. UPS 494.
Model 494.42 Single-Station System Board Model 494.42 Single-Station System Board Three digital inputs (J54) • Three digital outputs (J55) • Auxiliary power outputs for external devices (J49) • UPS inputs (J56) ACFail and low battery inputs (switch contacts) • Two analog outputs (DA Output connector on the 494.
Model 494.42 Single-Station System Board Model 494.42 System Board Specifications Model 494.42 Specifications (part 1 of 4) PARAMETER SPECIFICATION E-Stop/Run Output Relay Contacts Connector J23 (D9S) 30 V DC/AC maximum Voltage 1 A maximum Current Two (2) Normally Open Estop Relay Contacts: HPU E-Stop = Open Set of NO/NC Prog. Run Relay Contacts: Normally Open Contacts: Prog. Run = Closed Normally Closed Contacts: Prog.
Model 494.42 Single-Station System Board Model 494.42 Specifications (part 2 of 4) PARAMETER SPECIFICATION HSM Control* Connector J28 (D-9S) Off/Low/High Control Low Output +24 V DC, 1.0 A maximum High Output +24 V DC, 1.0 A maximum Proportional Control Signal Output 0–0.78 A Solenoid Impedance 20–25 Ω Ramp Time (0 to full scale) 2.1 s or 4.
Model 494.42 Single-Station System Board Model 494.42 Specifications (part 3 of 4) PARAMETER SPECIFICATION Interlock Input Connector J43 (D9S) Interlock Trip Voltage 0.8 V minimum, 3 V maximum Maximum Input Voltage +26 V DC Input Resistance 2700 Ω Interlock Power Output +24 V DC (current limited by a 15-KΩ resistor) Event SwitchContact Input Connector J43 (D9S) Event contacts open= Active event Event contacts closed= Inactive event 70 Auxiliary Power Outputs Connector J49 (D9S) +5 V DC 0.
Model 494.42 Single-Station System Board Model 494.42 Specifications (part 4 of 4) PARAMETER SPECIFICATION Digital Output Relays Connector J55 (D9S) Voltage 30 V AC/DC maximum Current 1 A maximum Output logic Output 1: One normally open (NO) contact Open = Output is OFF Output 2: One normally open (NO) contact and one normally closed (NC) contact NO Contact: Open = Output is OFF NC Contact: Closed = Output is OFF Output 3: One normally open (NO) contact Open = Output is OFF Aux.
Model 494.42 Single-Station System Board J23 E-Stop/Run Output Connections for the Model 494.42 System Board The Model 494.42 System Board provides E-Stop/Program Run outputs that are available on the J23 E-Stop/Run connector. 494.
Model 494.42 Single-Station System Board J24 Emergency Stop Connections for the Model 494.42 System Board The Model 494.42 System Board provides two optional E-Stop inputs that are available on the J24 E Stop connector (located on the rear panel of the Model 494.04 Chassis). J24 J28 HSM J29 Load Frame J25 HPU Power 100-240 VAC 50-60 Hz, 1-2 A 1 2 3 4 5 6 7 8 8 DA Output J43 INTLKJ56 UPS E-Stop Box J49 AuxJ23 PwrEstop/Run J24 1 2 3 4 5 6 7 8 494.42 System Board J54 Dig In J55 Dig Out 494.
Model 494.42 Single-Station System Board J25 Hydraulic Power Unit Connections for the Model 494.42 System I/O Board Connector J25 HPU provides 24-volt logic signals that control the hydraulic power unit (HPU). The connector may be connected directly to MTS Series 505 HPUs and similar HPUs that use low-current, 24-volt input controls. Note Other MTS HPUs require the Model 493.07 HPU Converter Box to convert the low-current HPU output signal to a signal that can drive the HPU relay. 494.
Model 494.42 Single-Station System Board CAUTION Control voltages for hydraulic power units vary between models The HPU interface between the Model 494.42 System I/O board and an HPU is 24-volt logic signals. Connecting J25 to a non-compliant HPU can damage the board. Do not connect 24 V DC relay circuitry or 115 V AC circuitry to connector J25 on the Model 494.42 System I/O board.
Model 494.42 Single-Station System Board J28 HSM Connections for the Model 494.42 System Board HSM control (off/low/high or proportional) is software configurable. The Model 494.42 board provides separate 24-volt, low-pressure and high-pressure outputs that drive the HSM low- and high-pressure solenoids. Proportional solenoid control provides a current output from 0 to 0.78 A. Note The Model 494.42 board can not be used with 115 V AC HSMs.
Model 494.42 Single-Station System Board J29 Load Frame Connections for the Model 494.42 System Board Connector J29 Load Frame provides an interface to connect one load frame. 494.
Model 494.42 Single-Station System Board Jumper plug required If connector J29 is not used, you must install a jumper plug to maintain the integrity of the interlocks. Use jumper plug part number 100-007-947 or jumper pins: 3-4, 5-7, 8-13, and 11-15. J43 Interlock Connections for the Model 494.42 System Board Connector J43 Intlk provides one optically isolated interlock input and a relaycontact interlock output per connector. 494.
Model 494.42 Single-Station System Board Jumper plug required If connector J43 is not used, you must install a jumper plug to maintain the integrity of the interlocks. Use jumper plug part number 100-057-245, or jumper pins: 1-2, 3-4, and 5-9. J49 Auxiliary Power Connections for the Model 494.42 System Board The J49 Aux Pwr connector provides fused (self resetting) auxiliary power outputs for: +5 V DC, +15 V DC, -15 V DC, and +24 V DC. 494.
Model 494.42 Single-Station System Board J54 Digital Input Connections for the Model 494.42 System Board J28 HSM J29 Load Frame J25 HPU J43 INTLKJ56 UPS J49 AuxJ23 PwrEstop/Run J54 Dig In 1 100-240 VAC 50-60 Hz, 1-2 A 1 2 3 4 5 6 7 8 J24 494.42 System Board Power 1 2 3 4 5 6 7 8 DA Output J54 Dig In J55 Dig Out Connector J54 Dig In accepts up to three optically isolated digital-input signals from external devices.
Model 494.42 Single-Station System Board J55 Digital Output Connections for the Model 494.42 System Board Connector J55 Dig Out provides three general-purpose digital outputs that can send digital-logic signals to external switches or logic devices. 494.
Model 494.42 Single-Station System Board J56 UPS Input Connections for the Model 494.42 System Board Connector J56 UPS provides dedicated inputs for an uninterruptible power supply (UPS). 494.
Model 494.42 Single-Station System Board Analog Output Connections for the Model 494.42 System Board The Model 494.42 System Board provides two analog output signals that are available on the D/A Output connector (located on the rear panel of the 494.04 chassis). Each D/A output is software defined. 494.04 Chassis 494.
Model 494.44 Two-Station System Board Model 494.44 Two-Station System Board External Interfaces • Eight digital inputs (J54*) • Eight digital outputs (J55*) • Auxiliary power outputs for external devices (J49) • Two analog outputs (DA Output connector on the 494.04 chassis) Hydraulic Control • 24-volt HPU control (J25) • 24-volt HSM control (Off/Low/High or proportional) for two HSMs (J28) HPU J25 J29A Load Frame J29B J28 HSM A-B Interlock J43B J43A Model 494.
Model 494.44 Two-Station System Board Model 494.44 System Board Specifications Model 494.44 Specifications (part 1 of 3) PARAMETER SPECIFICATION HSM Control* Connector J28A and 28B (D-15S) Off/Low/High Control Low Output +24 V DC, 1.0 A maximum High Output +24 V DC, 1.0 A maximum Proportional Control Signal Output 0–0.78 A Solenoid Impedance 20–25 Ω Ramp Time (0 to full scale) 2.1 s or 4.
Model 494.44 Two-Station System Board Model 494.44 Specifications (part 2 of 3) PARAMETER SPECIFICATION Interlock Input Connector J43 A/B (D9S) (one per J43 connector) Interlock Trip Voltage 0.
Model 494.44 Two-Station System Board Model 494.44 Specifications (part 3 of 3) PARAMETER SPECIFICATION Auxiliary Power Outputs Connector J49 (D9S) +5 V DC 0.75 A maximum +15 V DC 0.75 A maximum -15 V DC 0.75 A maximum +24 V DC 0.75 A maximum Digital Outputs Connector J55 (D9S) Note Digital Inputs Digital output signals must be routed through a Model 494.32 DI/O Breakout Box that includes drivers and connections for external devices.
Model 494.44 Two-Station System Board J23 E-Stop/Run Output Connections for the Model 494.44 System Board The Model 494.44 System Board provides E-Stop/Program Run outputs that are available on the J23 E-Stop/Run connector. 494.
Model 494.44 Two-Station System Board J24 Emergency Stop Connections for the Model 494.44 System Board The Model 494.44 System Board provides two optional E-Stop inputs that are available on the J24 E Stop connector (located on the rear panel of the Model 494.04 Chassis). J24 J28 HSM J49 AuxJ23 PwrEstop/Run Power 100-240 VAC 50-60 Hz, 1-2 A 1 2 3 4 5 6 7 8 8 DA Output J29 Load Frame J25 HPU E-Stop Box J43 INTLKJ56 UPS J24 1 2 3 4 5 6 7 8 494.44 System Board J54 Dig In J55 Dig Out 494.
Model 494.44 Two-Station System Board J25 Hydraulic Power Unit Connections for the Model 494.44 System I/O Board Connector J25 HPU provides 24-volt logic signals that control the hydraulic power unit (HPU). The connector may be connected directly to MTS Series 505 HPUs and similar HPUs that use low-current, 24-volt input controls. Note 494.44 System Board Other MTS HPUs require the Model 493.07 HPU Converter Box to convert the low-current HPU output signal to a signal that can drive the HPU relay.
Model 494.44 Two-Station System Board CAUTION Control voltages for hydraulic power units vary between models The HPU interface between the Model 494.44 System I/O board and an HPU is 24-volt logic signals. Connecting J25 to a non-compliant HPU can damage the board. Do not connect 24 V DC relay circuitry or 115 V AC circuitry to connector J25 on the Model 494.44 System I/O board.
Model 494.44 Two-Station System Board J28 HSM Connections for the Model 494.44 System Board HSM control (off/low/high or proportional) for both HSMs is software configurable. The Model 494.44 board provides separate 24-volt, low-pressure and high-pressure outputs that drive the HSM low- and high-pressure solenoids. Proportional solenoid control provides a current output from 0 to 0.78 A. The Model 494.44 board can not be used with 115 V AC HSMs.
Model 494.44 Two-Station System Board Cable specification To maintain EMC compliance, J28 A/B HSM cables must comply with the following specifications: Connector—9-pin type D male EMI connector. Backshell—EMI metallized plastic or metal. Proportional Control Cable—18 AWG, 2-conductor with foil shield drain wire connected to conductive backshell. Off/low/high Control Cable—18 AWG, 3-conductor with foil shield drain wire connected to conductive backshell.
Model 494.44 Two-Station System Board J29 A/B Load Frame Connections for the Model 494.44 System Board Connector J29 A/B Load Frame provides interfaces to connect up to two load frames and optional UPS (J29A only). 494.
Model 494.44 Two-Station System Board Jumper plug required If connector J29 is not used, you must install a jumper plug to maintain the integrity of the interlocks. Use jumper plug part number 100-007-947 or jumper pins: 3-4, 5-7, 8-13, and 11-15. J43 A/B Interlock Connections for the Model 494.44 System Board Connector J43 A/B Interlock provides one optically isolated interlock input and a relay-contact interlock output per connector. 494.
Model 494.44 Two-Station System Board Jumper plug required If connector J43 is not used, you must install a jumper plug to maintain the integrity of the interlocks. Use jumper plug part number 100-057-245, or jumper pins: 1-2, 3-4, and 5-9. J49 Auxiliary Power Connections for the Model 494.44 System Board The J49 Aux Pwr connector provides fused (self resetting) auxiliary power outputs for: +5 V DC, +15 V DC, -15 V DC, and +24 V DC. 494.
Model 494.44 Two-Station System Board J54 Digital Input Connections for the Model 494.44 System Board Connector J54 Dig In accepts up to eight optically isolated digital-input signals from the Model 494.32 8-Channel DI/O Breakout Box. You can use these digital input signals to trigger test events in controller applications. Note 494.
Model 494.44 Two-Station System Board J55 Digital Output Connections for the Model 494.44 System Board Connector J55 Dig Out provides eight digital outputs that must be used with the Model 494.32 8-Channel High-Current DI/O Breakout Box. The breakout box provides high-current switching/isolation and device connections for each of the eight J55 outputs. Note External power for the output devices is brought into the breakout box through breakout-box connector J29. 494.
Model 494.44 Two-Station System Board Analog Output Connections for the Model 494.44 System Board The Model 494.44 System Board provides two analog output signals that are available on the D/A Output connector (located on the rear panel of the 494.04 chassis). Each D/A output is software defined. 494.04 Chassis 494.
Model 494.44 Two-Station System Board UPS Connections for the Model 494.44 System Board (FT40) The following drawing shows UPS connections for the Model 494.44 System Board. Once connected, you must use your controller software to configure the various UPS options. To 494.44 J29A D15S D15P D9S D9P 2 2 7 7 8 8 4 4 D15P Load Frame Cable 494.44 System I/O Board J29A L Frame UPS 1 +24V UPS AC Fail 4 3 UPS Battery Low Custom J29 Y Cable (PN 100-197-651) required for UPS systems.
FlexTest 60 Controller Configuration FlexTest 60 Controller Configuration About the FlexTest 60 Controller The MTS FlexTest 60 Digital Controller is a fully digital proportional, integral, derivative, feed forward (PIDF) servocontroller that provides complete control of up to six stations in a test system. A FlexTest 60 Controller consists of: • One Model 494.06 Chassis that contains controller hardware. • A computer workstation that runs MTS controller applications.
FlexTest 60 Controller Configuration About the Model 494.06 Chassis The Model 494.06 Chassis houses up to six MTS VME bus boards in its front panel and up to eight transition boards in its rear panel. The Model 494.06 Chassis can be rack mounted or mounted in a standalone enclosure. The physical board locations must match the board locations defined in your hardwaremapping software. Processor Board 1 I/O Carrier Boards 494.40 2 3 4 HPU Board 493.73 5 6 HSM Boards Unpowered Slot 494.
FlexTest 60 Controller Configuration Specifications–Model 494.06 Chassis All equipment related to the controller should be connected to the same fused power circuit. Note Electrical connections must be made by qualified personnel and conform to local codes and regulations. Local electrical codes supersede any information found here. Model 494.
FlexTest 100 Controller Configuration FlexTest 100 Controller Configuration About the FlexTest 100 Controller The MTS FlexTest 100 Digital Controller is a fully digital proportional, integral, derivative, feed forward (PIDF) servocontroller that provides complete control of up to eight stations in a test system. A FlexTest 100 Controller consists of: • One Model 494.10 Chassis that contains controller hardware. • A computer workstation that runs MTS controller applications.
FlexTest 100 Controller Configuration About the Model 494.10 Chassis The Model 494.10 Chassis houses up to 10 MTS VME bus boards in its front panel and up to 12 transition boards in its rear panel. The Model 494.10 Chassis can be rack mounted or mounted in a stand-alone enclosure. The physical board locations must match the board locations defined in the hardware-mapping software. Processor Boards I/O Carrier Boards 494.40 Digital I/O HPU 493.72 Board 493.73 HSM Boards 494.74 (1-slot) or 493.
FlexTest 100 Controller Configuration Specifications–Model 494.10 Chassis All equipment related to the controller should be connected to the same fused power circuit. Note Electrical connections must be made by qualified personnel and conform to local codes and regulations. Local electrical codes supersede any information found here. Model 494.
FlexTest 200 Controller Configuration FlexTest 200 Controller Configuration About the FlexTest 200 Controller The MTS FlexTest 200 Digital Controller is a fully digital proportional, integral, derivative, feed forward (PIDF) servocontroller that provides complete control of up to eight stations in a test system. A FlexTest 200 Controller consists of: • One Model 494.20 Chassis that contains controller hardware. • A computer workstation that runs MTS controller applications.
FlexTest 200 Controller Configuration About the Model 494.20 Chassis VME bus boards The Model 494.20 Chassis houses up to 20 MTS VME bus boards in its front card cage. The physical board locations must match the board locations defined in your hardware-mapping software.
FlexTest 200 Controller Configuration Transition boards The Model 494.20 Chassis houses up to 20 transition boards in its rear card cage. The physical board locations must match the board locations defined in your hardware-mapping software. Note Series 793 Software maps HSM interlock I/O connectors (J3 A/B on 494.74, J43 A/B on 493.74) to stations on a left-to-right basis. Digital I/O 493.73 HPU HSM 493.72 Board Boards 494.74 (1 slot) or 493.
FlexTest 200 Controller Configuration Transition Boards (Aero Structural Test Systems) For a detailed listing of Aero configuration options, see the FlexTest 200 Aero Configuration engineering drawing (Part number 700-004-113). 493.73 HPU Unpowered Board Slot BNC Boards 494.75 Input 494.76 Output 494.79 8-Channel Valve Driver Digital I/O HSM Boards 494.74 493.72 Spare Slots 1-2 3-4 19 18 17 16 15 14 13 494.79 494.79 494.79 494.79 494.79 494.79 494.
FlexTest 200 Controller Configuration Specifications–Model 494.20 Chassis All equipment related to the controller should be connected to the same fused power circuit. Note Electrical connections must be made by qualified personnel and conform to local codes and regulations. Local electrical codes supersede any information found here. Model 494.
FlexTest 200 Controller Configuration Cable–AWG and number of conductors as required. Braided shield with the shield connected to the metallized backshell at the chassis. 19 18 17 16 15 14 13 494.79 494.79 494.79 494.79 494.79 494.79 494.
VME Bus Boards Chapter 3 VME Bus Boards Contents About VME Bus Boards System Update Rates 114 114 How to Install and Remove a VME Bus Board Computer Workstation Connections 115 118 Wago Ethernet TCP/IP FieldBus Coupler Connections About the Model 494.40 I/O Carrier Board 120 How to Set Up a Model 494.40 I/O Carrier Board Model 494.40 I/O Carrier Board Settings 119 121 122 How to Set the Model 494.
VME Bus Board Overview VME Bus Board Overview About VME Bus Boards MTS VME Bus boards plug into the VME card cage located on the front of a Series 494 Chassis. VME Bus boards include processor boards and Model 494.40 I/O carrier boards. Processor board The chassis requires at least one VME bus processor board. The processor board provides PIDF processing and an interface between the controller and the computer workstation. I/O carrier board Each I/O carrier board can contain up to four mezzanine cards.
VME Bus Board Overview How to Install and Remove a VME Bus Board VME bus boards are inserted into a backplane connector and secured to the chassis with IEEE locking levers at the top and bottom of the faceplate. CAUTION The plug-in boards and cards contain static-sensitive components. Improper handling of boards and cards can cause component damage. Follow these precautions when handling boards and cards: • Turn off electrical power before installing or removing a board.
VME Bus Board Overview 5. Insert each VME bus board: A. Press and hold the buttons on each of the plastic levers (A). B. Rotate the levers (B) out (away from the board). C. Carefully insert the board (C) in the VME bus slot until it stops. D. Rotate the levers in (toward the board) (D) until the board is firmly seated in the backplane connector. E. Tighten the two screws (located in the levers) (E) to secure the board to the chassis. B D E A C A D B Board removal procedure E 1.
VME Bus Board Overview D. Carefully remove the board (D) from the VME bus slot.
Processor Connections Processor Connections Computer Workstation Connections The computer workstation is connected to the Model 494.96 Processor board installed in the VME bus of the chassis through an Ethernet 10/100 Base-T connection. The computer workstation must have a dedicated Ethernetcompatible connector.
Processor Connections Wago Ethernet TCP/IP FieldBus Coupler Connections The following drawing shows the controller processor connections for a Wago PLC (programmable logic controller). • The processor connection (LAN 2 or ENET 2) depends on the number of processors and the type of processor(s) used in your controller. • The Wago PLC connection is typically made to a Modbus FieldBus Coupler module intalled in a Wago PLC chassis. Note Only use interconnect cables supplied by MTS.
Model 494.40 I/O Carrier Board Model 494.40 I/O Carrier Board About the Model 494.40 I/O Carrier Board The Model 494.40 I/O Carrier board is a VME board where you can install up to four mezzanine cards. These cards perform a variety of functions, such as transducer conditioning, valve driving, and other I/O functions. Note The Model 494.40B board is a new generation release of the 494.40 board that is compatible with the old boards.
Model 494.40 I/O Carrier Board How to Set Up a Model 494.40 I/O Carrier Board 1. Turn off electrical power to the chassis before installing or removing boards and cards. CAUTION The plug-in boards and cards contain static-sensitive components. Improper handling of boards and cards can cause component damage. Follow these precautions when handling boards and cards: • Turn off electrical power before installing or removing a board.
Model 494.40 I/O Carrier Board Model 494.40 I/O Carrier Board Settings When you add or replace an I/O carrier board, you must set the board address. If DUC cards are used, you can add optional shunt calibration and bridgecompletion resistors to the I/O carrier board. The locations for these settings are shown below.
Model 494.40 I/O Carrier Board How to Set the Model 494.40 I/O Carrier Board Address The address setting for the I/O carrier board must match the settings used by the system control software. 1. Determine the I/O carrier address. 2. Locate address switches SW1 and SW2 on the I/O carrier circuit board and set the board address using the settings shown below.
Model 494.40 I/O Carrier Board How to Install a Shunt-Calibration Resistor on an I/O Carrier Board The Model 494.40 I/O Carrier board has a front-panel socket where you can insert shunt-calibration plug assembly for use with DUC cards. Each socket is associated with one of the eight RJ-50 connectors on the front panel. 1. Determine the RJ-50 connector(s) used by the transducer(s). Note Each mezzanine-card slot on the I/O carrier board connects to two RJ-50 connectors on the front of the I/O carrier board.
Model 494.40 I/O Carrier Board How to Install a Bridge-Completion Resistor on an I/O Carrier Board You can install bridge-completion resistors on the I/O Carrier board for use with DUC cards that condition 1/4-bridge transducers such as strain gages. The I/O Carrier circuit board has eight sockets for bridge completion resistors. Each resistor socket is associated with one of the eight RJ-50 connectors on the front panel. 1. Determine the RJ-50 connector used by the DC conditioner. 2.
Model 494.43 Multibox Board Model 494.43 Multibox Board About the Model 494.43 Multibox Board The Model 493.43 Multibox board allows multiple controllers to share a master hardware synchronization clock and pass station interlock state information between each other. In addition, this front panel module also provides user station interlock inputs and outputs.
Model 494.43 Multibox Board Specifications–Model 494.43 Multibox Board PARAMETER J9 Intlk Out SPECIFICATION Contact (Open = Interlock) Logic (0 = Interlock) Output Current: 1 A maximum at 30 V DC/AC. J8 Intlk In Input Debounce Time 12–16 ms Input Resistance 2.7 kΩ Minimum Input Off Voltage 0.
Model 494.43 Multibox Board J8 Interlock In Connections for the Model 494.43 Multibox Board Connector J8 Interlock IN provides four optically isolated station interlock inputs that can be connected to external interlock chains.
Model 494.43 Multibox Board J9 Interlock Out Connections for the Model 494.
Model 494.43 Multibox Board J51 Box In Connections for the Model 494.43 Multibox Board The J51 Box In connector provides an interface for connecting multiple MTS controller boxes together to allow sharing of station interlock status and a master synchronization clock.
Model 494.43 Multibox Board J52 Box Out Connections for the Model 494.43 Multibox Board The J52 Box Out connector provides an interface for connecting multiple MTS controller chassis together to allow sharing of station interlock status and a master synchronization clock. Last controller jumper The last controller box in a chain must have a jumper plug (MTS part number 100-079-126) on its J52 Box Out connector.
Model 494.
Mezzanine Cards Chapter 4 Mezzanine Cards Contents About Mezzanine Cards 134 How to Install a Mezzanine Card 138 How to Remove a Mezzanine Card 141 About Digital Universal Conditioners 143 About the Model 494.25 Single DUC Card Model 494.26 Dual DUC Card 154 157 Model 494.16 VD/DUC Mezzanine Card 160 Model 494.21 Multi-Range DUC with Acceleration Compensation Card 168 Model 494.45 8-Input A/D Converter Card Model 494.46 8-Output D/A Card 176 179 Model 494.
Mezzanine Cards About Mezzanine Cards You can install any of the mezzanine cards listed in the following table in one of the four card slots on the Model 494.40 I/O Carrier board. CAUTION Damage can occur if you connect a high-level signal to a mezzanine card when the chassis power is off. Improper operation can damage mezzanine cards. Do not apply a high-level signal to a mezzanine card when the chassis power is off.
Mezzanine Cards Mezzanine Cards (part 1 of 3) MODEL MEZZANINE CARD TYPE FUNCTION COMPATIBLE TRANSITION BOARDS 494.16 VD/DUC This card includes a digital universal conditioner (DUC) (upper RJ-50 connector–JXA) and a valve driver (lower RJ-50 connector–JXB). Not required The conditioner portion of this card is identical to the conditioners in the Model 494.26 Card.
Mezzanine Cards Mezzanine Cards (part 2 of 3) MODEL MEZZANINE CARD TYPE FUNCTION COMPATIBLE TRANSITION BOARDS 494.26 Dual DUC This card has two digital universal conditioners (DUCs) that you can independently configure (with software) as either an AC conditioner or a DC conditioner. Each conditioner on the DUC card connects to a front-panel RJ-50 connector on the I/O carrier board. Not required The AC configuration is typically used to condition an LVDT.
Mezzanine Cards Mezzanine Cards (part 3 of 3) MODEL MEZZANINE CARD TYPE FUNCTION COMPATIBLE TRANSITION BOARDS 494.47 Dual UART/ Encoder Interface This card provides two channels that allow the control software to communicate with and provide conditioning for two external devices. Each channel connects to the external device through an RJ-50 connector on the I/O carrier board.
Mezzanine Cards How to Install a Mezzanine Card Each Model 494.40 I/O Carrier board has four slots where you can install mezzanine cards. CAUTION The plug-in boards and cards contain static-sensitive components. Improper handling of boards and cards can cause component damage. Follow these precautions when handling boards and cards: • Turn off electrical power before installing or removing a board.
Mezzanine Cards 3. Align the mezzanine card. A. Place the I/O carrier board flat on an antistatic surface. If the I/O carrier board is not flat, you will not be able to properly install the mezzanine cards. B. Align the mezzanine card connectors with the mating connectors on the I/O carrier board. When properly aligned, you should be able to slightly move the mezzanine card back and forth (A) within the connector.
Mezzanine Cards 4. Insert the mezzanine card. A. Apply equal downward force (B) to all four corners of the mezzanine card so that both connectors seat at the same time. B. Make sure that both connectors are fully seated.
Mezzanine Cards How to Remove a Mezzanine Card CAUTION The plug-in boards and cards contain static-sensitive components. Improper handling of boards and cards can cause component damage. Follow these precautions when handling boards and cards: • Turn off electrical power before installing or removing a board. • Use a static ground strap to ground yourself to the chassis ground before touching the chassis or a board. • Keep unused boards and cards in conductive bags.
Mezzanine Cards B. Grasp the mezzanine card in all four corners and gently rock the mezzanine card while lifting it. Do not pry the edges of the card.
Digital Universal Conditioner Mezzanine Cards Digital Universal Conditioner Mezzanine Cards About Digital Universal Conditioners Some Series 494 mezzanine cards include digital universal conditioner (DUC) circuits that provide signal conditioning for AC and DC transducers. Each DUC circuit has the same features and specifications and is software configurable as an AC or DC conditioner. The following mezzanine cards include DUCs: • Model 494.26 Dual DUC mezzanine card • Model 494.
Digital Universal Conditioner Mezzanine Cards Digital Universal Conditioner (DUC) Features You can configure a DUC as either an AC conditioner or a DC conditioner. General Excitation DC configuration 144 Mezzanine Cards • Software-configurable conditioner gains allows the use of a wide range of transducers. • Each DUC channel has its own indicator LED (located on the I/O carrier board). • The conditioner includes a IEEE 1451.4, Class 2 smart transducer interface.
Digital Universal Conditioner Mezzanine Cards Specifications–Digital Universal Conditioner (DUC) Note The specifications for the DUC circuit in the Model 494.21 card are different than the specifications for the other Series 494 DUC cards. DUC Specifications (part 1 of 3) PARAMETER SPECIFICATION Input Types AC or DC (software configurable) Conditioner Analog Gain Analog gains: x.91, x1.75, x3.25, x6.28, x11.36, x21.92, x40.69, x78.60, x150.59, x290.64, x539.11, x1042.08, x1815.24, x3503.41, x6498.
Digital Universal Conditioner Mezzanine Cards DUC Specifications (part 2 of 3) PARAMETER SPECIFICATION DC Excitation 1–20 V DC (software configurable). Important If you use a 4-wire cable for a DUC that is configured for an 8-wire device, the excitation voltage will not be correct. Accuracy (1V to 20V): 0.10% of setting + 0.0001 VDC Loading Effects (100mA max.): 0.
Digital Universal Conditioner Mezzanine Cards DUC Specifications (part 3 of 3) PARAMETER SPECIFICATION Excitation Failure Interlocks An over- or under-current condition generates a system interlock. AC/DC over current: 105 mA typical AC/DC under current: 1–2 mA typical Note Undercurrent detection may not work properly for AC transducers with a DC resistance greater than 180 ohms. In this instance, the detection circuit may constantly report an undercurrent condition.
Digital Universal Conditioner Mezzanine Cards Digital Universal Conditioner (DUC) Bridge Connections The following figures show the full-, half-, and quarter-bridge configurations for a DUC that is configured as a DC conditioner. Shunt calibration The shunt-calibration resistor (R Shunt) sockets are located on the front of the I/O carrier board. Use system hardware-mapping software to specify which leg of the bridge is shunted during calibration.
Digital Universal Conditioner Mezzanine Cards Half-bridge configuration The following figure shows a half-bridge configuration. In this configuration, the transducer makes up half of the bridge circuit while the other half of the bridge is located on the DUC card. I/O Carrier Board Front-Panel RJ-50 Connector 1 IEEE 1451.4 Circuit DUC + IEEE 1451.4 Class 2 10 - IEEE 1451.
Digital Universal Conditioner Mezzanine Cards Quarter-bridge configuration The following figure shows a quarter-bridge configuration. In this configuration, one half of the bridge resides on the DUC card. When a quarter-bridge transducer is used, a bridge-completion resistor (R Completion) is required. The bridge-completion resistor is installed on the I/O carrier board. Once installed, you must physically set switch SW1A on the card to connect one end of R Completion to -FBR.
Digital Universal Conditioner Mezzanine Cards Digital Universal Conditioner (DUC) LVDT Connections I/O Carrier Board DUC Front-Panel RJ-50 Connector +Excitation 2 -FB 4 LVDT +FB 7 - Excitation 3 + IEEE 1451.4 Class 2 1 - IEEE 1451.4 Class 2 10 2 3 IEEE 1451.4 Circuit RJ-50 Cable Plug 1 Cable Shield Cable Grounding 1 The cable shield connects to the metal shielding on the RJ-50 cable plug. 2 The cable plug shielding connects to the I/O carrier board body.
Digital Universal Conditioner Mezzanine Cards How to Set Up a Digital Universal Conditioner (DUC) 1. Turn off electrical power to the chassis before installing or removing boards and cards. CAUTION The plug-in boards and cards contain static-sensitive components. Improper handling of boards and cards can cause component damage. Follow these precautions when handling boards and cards: • Turn off electrical power before installing or removing a board.
Digital Universal Conditioner Mezzanine Cards 3. Set up the mezzanine card(s). A. (Optional) For transducers that require a ground reference, set the card grounding DIP switch to the ON position. B. (Optional) For quarter-bridge transducers, set the bridgecompletion DIP switch on the card to the ON position and install a bridge completion resistor on the I/O carrier board. C. (Optional) Install shunt calibration resistor plug assemblies on the front panel of the I/O carrier board.
Model 494.25 Single DUC Card Model 494.25 Single DUC Card About the Model 494.25 Single DUC Card The Model 494.25 Single DUC is a mezzanine card that you can plug into one of the slots on the Model 494.40 I/O Carrier board. This card includes one digital universal conditioner (DUC) that you can configure as either an AC conditioner or a DC conditioner. Transducers connect to each conditioner through a front panel RJ-50 connector on the I/O carrier board.
Model 494.25 Single DUC Card Model 494.25 Single DUC Card Settings Hardware configuration Software configuration The conditioner on this card has a two-position switch that is used to set up the following DC conditioner functions: • Switch A connects a bridge completion resistor to -FBR to complete a quarter-bridge circuit. • Switch B provides a ground reference for an external transducer by connecting -FBR to ground.
Model 494.25 Single DUC Card Model 494.25 Single DUC Card Pin Assignments Signals are routed to and from each conditioner through an RJ-50 connector located on the front of the I/O carrier board. CAUTION The front-panel sockets on the I/O carrier board only accept cabling with 10-pin, shielded, RJ-50 connectors with a gray boot. The use of other RJ connector types (less than 10 pins or unshielded with a black boot) with the I/O carrier board can cause component damage.
Model 494.26 Dual DUC Card Model 494.26 Dual DUC Card About the Model 494.26 Dual DUC Card The Model 494.26 Dual DUC is a mezzanine card that you can plug into one of the slots on the Model 494.40 I/O Carrier board. This card includes two digital universal conditioners (DUCs) that you can independently configure as either an AC conditioner or a DC conditioner. Transducers connect to each conditioner through a front panel RJ-50 connector on the I/O Carrier board. Accelerometer Compensation The Model 494.
Model 494.26 Dual DUC Card Model 494.26 Dual DUC Card Settings Hardware configuration Software configuration Each of the two conditioners on this card has a two-position switch that is used to set up the following DC conditioner functions: • Switch A connects a bridge completion resistor to -FBR to complete a quarter-bridge circuit. • Switch B provides a ground reference for an external transducer by connecting -FBR to ground.
Model 494.26 Dual DUC Card Model 494.26 Dual DUC Card Pin Assignments Signals are routed to and from each conditioner through an RJ-50 connector located on the front of the I/O carrier board. CAUTION The front-panel sockets on the I/O carrier board only accept cabling with 10-pin, shielded, RJ-50 connectors with a gray boot. The use of other RJ connector types (less than 10 pins or unshielded with a black boot) with the I/O carrier board can cause component damage.
Model 494.16 VD/DUC Mezzanine Card Model 494.16 VD/DUC Mezzanine Card About the Model 494.16 VD/DUC Card The Model 494.16 VD/DUC card combines a valve driver (VD) and a digital universal conditioner (DUC) on a single mezzanine card. You can install this card in one of the four slots in the Model 494.40 I/O Carrier board. 2-stage valve applications The valve driver can drive single or dual 2-stage servovalves.
Model 494.16 VD/DUC Mezzanine Card Specifications–Model 494.16 Valve Driver Card PARAMETER SPECIFICATION Output Current 100 mA maximum per output (software configurable) Valve Outputs per Card 2 Dither Frequency 1 Hz–4915.2 Hz (software adjustable) Amplitude 0–5 V DC (software adjustable) Valve Clamping Software configurable valve clamping setting performs the following actions when a hydraulic interlock occurs. Valve Balance Offset • Disabled—Valve does not clamp.
Model 494.16 VD/DUC Mezzanine Card How to Set Up a Model 494.16 VD/DUC Card 1. Turn off electrical power to the chassis before installing or removing boards and cards. CAUTION The plug-in boards and cards contain static-sensitive components. Improper handling of boards and cards can cause component damage. Follow these precautions when handling boards and cards: • Turn off electrical power before installing or removing a board.
Model 494.16 VD/DUC Mezzanine Card 4. Install the VD/DUC card(s) on the I/O carrier board. 5. (Optional) Install shunt-calibration-resistor plug assemblies on the front panel of the I/O carrier board(s). Note If you use MTS TEDS modules or MTS transducers with integrated shunt-calibration resistors, you must insert a jumper plug (MTS part number 100-188-097) into the socket for each transducer input where you will use the integrated shunt-calibration resistor. 6. Install the I/O carrier board(s). A.
Model 494.16 VD/DUC Mezzanine Card Model 494.16 VD/DUC Card Settings Software configuration Most configuration and setup of the valve driver (VD) and digital universal conditioner (DUC) is done through software. Note Hardware settings For detailed information on software configuration, calibration, and tuning, see the control software and tuning/calibration manuals.
Model 494.16 VD/DUC Mezzanine Card Model 494.16 VD/DUC Card Pin Assignments Signals are routed to and from the DUC and valve driver through two RJ-50 connectors located on the front of the I/O carrier board. CAUTION The front-panel sockets on the I/O carrier board only accept cabling with 10-pin, shielded, RJ-50 connectors with a gray boot. The use of other RJ connector types (less than 10 pins or unshielded with a black boot) with the I/O carrier board can cause component damage.
Model 494.16 VD/DUC Mezzanine Card Two-Stage Servovalve Connections for the Model 494.16 VD/DUC Card Single two-stage valve With a two-stage servovalve, you can use the DUC portion of the card to provide control feedback for a channel while the valve driver provides the drive signal for the servovalve. I/O Carrier Board JXB + VD1 2 A Mezzanine Card - VD1 3 B 494.
Model 494.16 VD/DUC Mezzanine Card Three-Stage Servovalve Connections for the Model 494.16 VD/DUC Card With a three-stage servovalve, the inner-loop LVDT uses the DUC portion of the card while the valve driver portion provides the drive signal for a Series 252 Servovalve which controls a Series 256 or 257 Servovalve. I/O Carrier Board JXA Mezzanine Card 494.
Model 494.21 Multi-Range DUC with Acceleration Model 494.21 Multi-Range DUC with Acceleration Compensation Card About the Model 494.21 Multi-Range DUC /Acceleration Compensation Card The Model 494.21 Mezzanine Card plugs into one of the slots on the Model 494.40 I/O Carrier. This card combines a multi-range digital universal conditioner (DUC) input and an accelerometer compensation input on a single card.
Model 494.21 Multi-Range DUC with Acceleration Transducer input This card includes a multi-range digital universal conditioner (DUC) that you can configure as either an AC conditioner or a DC conditioner. Transducers connect to the card through a front-panel RJ-50 connector on the I/O carrier board. The DUC circuit is similar to other Series 494 DUCs with the addition of an AC transducer demodulator (located before the summing amp).
Model 494.21 Multi-Range DUC with Acceleration Specifications–Model 494.21 Multi-Range DUC/Acceleration Compensation Card Model 494.21 Specifications (part 1 of 3) PARAMETER SPECIFICATION Input Types AC or DC (software configurable) Conditioner Analog Gain Analog gains: x.91, x1.75, x3.25, x6.28, x11.36, x21.92, x40.69, x78.60, x150.59, x290.64, x539.11, x1042.08, x1815.24, x3503.41, x6498.55, x12379.91 The analog gain settings are software configurable. DC Gain Accuracy Gain 1 to 20k: 0.
Model 494.21 Multi-Range DUC with Acceleration Model 494.21 Specifications (part 2 of 3) PARAMETER SPECIFICATION DC Excitation 1–20 V DC (software configurable) Accuracy (1V to 20V): 0.10% of setting + 0.001 VDC† Loading Effects (100mA max.): 0.02% of setting‡ Anti Alias Filter 5 pole Butterworth 3dB = 25 kHz A/D Resolution 16 bit Excitation Stability AC: 30 ppm/ °C typical AC Excitation Excitation voltage: 0.
Model 494.21 Multi-Range DUC with Acceleration Model 494.21 Specifications (part 3 of 3) PARAMETER SPECIFICATION Excitation Failure Interlocks An over- or under-current condition generates a system interlock. AC/DC overcurrent: 105 mA typical AC/DC undercurrent: 1–2 mA typical Note Undercurrent detection may not work properly for AC transducers with a DC resistance greater than 180 ohms. In this instance, the detection circuit may constantly report an undercurrent condition.
Model 494.21 Multi-Range DUC with Acceleration Model 494.21 Multi-Range DUC/Acceleration Compensation Card Settings Software configuration Most configuration and setup of this card is done through software. Note Hardware settings For detailed information on software configuration, calibration, and tuning, see the control software and tuning/calibration manuals.
Model 494.21 Multi-Range DUC with Acceleration Model 494.21 Multi-Range DUC/Acceleration Compensation Card Pin Assignments Signals are routed to and from each input through an RJ-50 connector located on the front of the I/O carrier board. CAUTION The front-panel sockets on the I/O carrier board only accept cabling with 10-pin, shielded, RJ-50 connectors with a gray boot.
Model 494.21 Multi-Range DUC with Acceleration Model 494.21 Multi-Range DUC/Acceleration Compensation Card Configuration The following drawing shows a basic configuration for acceleration compensation using the Model 494.21 Card. Note The Model 494.21 Card can be configured for a number of custom applications. For custom applications, refer to the system configuration drawings for analog bus routing, interconnects, cable part numbers, and other information.
Model 494.45 8-Input A/D Converter Card Model 494.45 8-Input A/D Converter Card About the Model 494.45 8-Input A/D Card The Model 494.45 8-Input A/D Card is a mezzanine card that you can plug into one of the slots on the Model 494.40 I/O Carrier board. Each A/D card accepts up to eight analog input signals that must be within ± 12.5 V DC. The A/D card also includes a software-configurable digital filter for each input.
Model 494.45 8-Input A/D Converter Card Model 494.45 8-Input A/D Card Pin Assignments Analog input signals are typically routed to the A/D card through a Model 494.75 8-Input BNC transition board. Signals are routed to the A/D card through RJ-50 connectors located on the front of the I/O carrier board that contains the A/D card. CAUTION The front-panel sockets on the I/O carrier board only accept cabling with 10-pin, shielded, RJ-50 connectors.
Model 494.45 8-Input A/D Converter Card Model 494.45 8-Input A/D Card Connections Analog input signals are typically routed to the A/D converter card through a Model 494.75 8-Input BNC Transition Board. The two transition board outputs (J11, J12) connect to the I/O carrier board RJ-50 connectors used with the A/D Converter card slot (J3A and J3B). CAUTION The front-panel sockets on the I/O carrier board only accept cabling with 10-pin, shielded, RJ-50 connectors.
Model 494.46 8-Output D/A Card Model 494.46 8-Output D/A Card About the Model 494.46 8-Output D/A Card The Model 494.46 8-Output D/A Card is a mezzanine card that you can plug into one of the slots on the Model 494.40 I/O Carrier board. Each D/A converter card provides up to eight analog output signals. Analog output signals are typically routed from the D/A card to a Model 494.76 8-Output BNC transition board.
Model 494.46 8-Output D/A Card Model 494.46 8-Output D/A Card Pin Assignments Analog output signals are typically routed from the D/A card through a Model 494.76 8-Output BNC transition board. Signals are routed from the D/A card through RJ-50 connectors located on the front of the I/O carrier board. CAUTION The front-panel sockets on the I/O carrier board only accept cabling with 10-pin, shielded, RJ-50 connectors.
Model 494.46 8-Output D/A Card Model 494.46 8-Output D/A Connections Analog output signals are typically routed to external devices through a Model 494.76 8-Output BNC transition board. The transition board (J11, J12) connects to the front-panel I/O carrier board connectors associated with the D/A mezzanine card slot (J2A and J2B in the following figure). VME Card Cage Transition Card Cage 494.76 ANALOG OUTPUT CH 1 - 8 Analog Outputs First Output 1 Output 2 1 2 3 4 5 6 7 8 494 D/A .
Model 494.46 8-Output D/A Card Servo valve driver You can use the analog output signals from the Model 494.46 D/A card to drive a Model 494.79 8-Channel Valve Driver transition board. The transition board (J11, J12) connects to the front-panel I/O carrier board connectors associated with the D/A converter mezzanine card slot (J2A and J2B in the following figure). VME Card Cage Transition Card Cage Servovalves 494.
Model 494.47 Dual UART/Encoder Interface Card Model 494.47 Dual UART/Encoder Interface Card About the Model 494.47 Dual UART/Encoder Card The Model 494.47 UART/Encoder is a mezzanine card that you can plug into one of the slots on the Model 494.40 I/O Carrier board. The UART/ Encoder card includes two interfaces that you can configure for two UART devices or two digital transducers. The device mode and other parameters are software configurable.
Model 494.47 Dual UART/Encoder Interface Card Specifications–Model 494.
Model 494.47 Dual UART/Encoder Interface Card UART Pin Assignments for the Model 494.47 Dual UART/Encoder Card Signals are routed to and from the Model 494.47 card through two RJ-50 connectors located on the front of the I/O carrier board. The device type that you set for the card determines the pin assignments. The following figure shows the pin assignments for RS-485/UART devices (such as the Model 494.
Model 494.47 Dual UART/Encoder Interface Card UART Connections for the Model 494.47 Dual UART/Encoder Card Model 409 Temperature Controller Connections I/O Carrier Board JXA Mezzanine Card 494.47 Dual UART/ Encoder Conditioner + Tx/Rx 2 - Tx/Rx 3 Model 409 Temperature Controller JXB + Tx/Rx 2 - Tx/Rx 3 Model 409 Temperature Front-panel RJ-50 Connectors JXA and JXB Controller Cable Grounding 1 The cable shield connects to the metal shielding on the RJ50 cable plug.
Model 494.47 Dual UART/Encoder Interface Card Incremental Encoder/Counter Pin Assignments for the Model 494.47 Card Signals are routed to and from the Model 494.47 card through two RJ-50 connectors located on the front of the I/O carrier board. The device type that you set for the card determines the pin assignments. The following figure shows the pin assignments for incremental encoders with quadrature outputs.
Model 494.47 Dual UART/Encoder Interface Card Incremental Encoder Connections for the Model 494.47 Card I/O Carrier Board JXA Mezzanine Card 494.
Model 494.47 Dual UART/Encoder Interface Card Counter Connections for the Model 494.47 Card I/O Carrier Board JXA Mezzanine Card 494.47 Dual UART/ Encoder Conditioner + Enc A 2 - Enc A 3 + Power* 4 - Power* 7 Counter JXB + Enc A 2 - Enc A 3 + Power* 4 - Power* 7 Front-Panel RJ-50 Connectors JXA and JXB Counter *494.47 card supplies 15 V DC at 200 mA Cable Grounding 1 The cable shield connects to the metal shielding on the RJ-50 cable plug.
Model 494.47 Dual UART/Encoder Interface Card SSI Encoder Pin Assignments for the Model 494.47 Card The device type that you set for the UART/digital transducer card determines the pin assignments. The following figure shows the pin assignments for SSI devices (such as Temposonics R transducers). Signals are routed to and from the UART/digital transducer card through two RJ-50 connectors located on the front of the I/O carrier board.
Model 494.47 Dual UART/Encoder Interface Card SSI Encoder (Temposonics R) Connections for the Model 494.47 Card I/O Carrier Board Mezzanine Card 494.
Model 494.47 Dual UART/Encoder Interface Card Pulse-Width-Modulated Output Pin Assignments for the Model 494.47 Card The device type that you set for the UART/digital transducer card determines the pin assignments. The following figure shows the pin assignments for devices with a pulse-width-modulated output (such as Temposonics G transducers). Signals are routed to and from the UART/digital transducer card through two RJ-50 connectors on the front of the I/O carrier board.
Model 494.47 Dual UART/Encoder Interface Card Pulse-Width-Modulated (PWM) Connections for the Model 494.47 Card Temposonics G (PWM) Connections (9- to 28-volt power option) I/O Carrier Board JXA Mezzanine Card 494.
Model 494.47 Dual UART/Encoder Interface Card External Clock Connections for the Model 494.47 Card The Model 494.47 card can be configured to provide differential RS-485 external clock and external-trigger outputs to synchronize external systems (such as data acquisition systems) to the controller clocks. I/O Carrier Board Mezzanine Card Model 494.
Model 494.49 Quad Encoder Interface Card Model 494.49 Quad Encoder Interface Card About the Model 494.49 Quad Encoder Interface Card The Model 494.49 Quad Encoder Interface is a mezzanine card that resides in one of the slots on the Model 494.40 I/O Carrier board. The Model 494.49 card can accept up to four digital transducer (encoder) signals from a Model 493.80 Quad Encoder transition board. Encoder Inputs Transition Card Cage VME Card Cage 493.
Model 494.49 Quad Encoder Interface Card Specifications–Model 494.49 Quad Encoder Interface Card PARAMETER SPECIFICATION Digital Transducer/ Encoder Electrical Interface TTL transceivers. Supported Digital Transducer/ Encoder Interfaces Use hardware-mapping software to select the type of interface: The Model 493.80 Quad Encoder transition board converts four channels of differential RS-422 encoder signals (J3-J8) into TTL encoder signals (J11, J12) that are compatible with the Model 494.
Model 494.49 Quad Encoder Interface Card Model 494.49 Quad Encoder Interface Card Connections Encoder signals are routed to the Model 494.49 card through a Model 493.80 Quad Encoder Transition Board. Transition board connectors J11 and J12 connect to the I/O carrier board RJ-50 connectors. CAUTION The front-panel sockets on the I/O carrier board only accept cabling with 10-pin, shielded, RJ-50 connectors.
Model 494.49 Quad Encoder Interface Card Incremental Encoder/Counter Pin Assignments for the Model 494.49 Card The device type that you set in your hardware-mapping software determines the pin assignments. The following figure shows the pin assignments for incremental encoders with quadrature outputs. Note Signals are routed to and from the Quad Encoder card through two RJ-50 connectors located on the front of the I/O carrier board.
Model 494.49 Quad Encoder Interface Card Incremental Encoder Connections for the Model 494.
Model 494.49 Quad Encoder Interface Card Counter Connections for the Model 494.
Model 494.49 Quad Encoder Interface Card SSI/Gurley Encoder Pin Assignments for the Model 494.49 Card The device type that you set in your hardware-mapping software determines the pin assignments. The following figure shows the pin assignments for SSI devices (such as Temposonics R transducers). Note Signals are routed to and from the Quad Encoder card through two RJ-50 connectors located on the front of the I/O carrier board.
Model 494.49 Quad Encoder Interface Card SSI/Gurley Encoder (Temposonics R) Connections for the Model 494.
Model 494.49 Quad Encoder Interface Card PWM Input Pin Assignments for the Model 494.49 Quad Encoder Card The device type that you set in your hardware-mapping software determines the pin assignments. The following figure shows the pin assignments for devices that provide a pulse-width-modulated output (such as Temposonics G transducers). Note Signals are routed to and from the Quad Encoder card through two RJ-50 connectors located on the front of the I/O carrier board.
Model 494.49 Quad Encoder Interface Card Temposonics G Connections for the Model 494.49 Quad Encoder Card The Model 493.80 transition board converts the differential signals from the Temposonics G transducers into single-ended signals that are compatible with the Model 494.49 Quad Encoder Interface card. The transition board also supplies DC power to each transducer.
Model 494.49 Quad Encoder Interface Card External Clock Connections for the Model 494.49 Quad Encoder Card The device type that you set in your hardware-mapping software determines the pin assignments. The following figure shows the pin assignments for single-ended TTL external clock and external-trigger outputs used to synchronize external systems (such as data acquisition systems) to the controller clocks I/O Carrier Board Mezzanine Card Model 494.
TEDS Transducer ID Module TEDS Transducer ID Module About the TEDS Transducer ID Module The TEDS Transducer ID module (TEDS module) includes a chip that can store TEDs IDs used to identify the transducer, and optional shuntcalibration resistors. The controller communicates with the TEDS module through a IEEE 1451.4, Class 2 smart transducer interface. Transducer connections TEDS Module options include different connectors that allow the TEDS module to connect directly to the transducer.
Digital I/O and Transition Boards Chapter 5 Digital I/O and Transition Boards Digital I/O Hardware About Digital I/O Hardware 208 Model 493.72 Digital I/O Board 209 Model 493.31 16-Channel Low-Current DI/O Breakout Box 212 Model 494.31 16-Channel High-Current DI/O Breakout Box 216 Model 494.32 8-Channel DI/O Breakout Box Model 494.33 Digital I/O Power Supply Transition Boards About Transition Boards 221 227 237 Model 493.73 HPU Interface Board 238 Model 493.
Digital I/O Hardware Devices Digital I/O Hardware Devices About Digital I/O Hardware Digital I/O hardware allows the controller to drive output devices and monitor input devices. The following digital I/O hardware is compatible with MTS FlexTest 40/60/100/200 Controllers. Digital I/O Hardware TRANSITION BOARD FUNCTION Model 493.72 Digital I/O Board The Model 493.72 Digital I/O board is a transition board that provides 16 digital inputs and 16 digital outputs. The Model 493.
Model 493.72 Digital I/O Board Model 493.72 Digital I/O Board About the Model 493.72 Digital I/O Board The Model 493.72 Digital I/O board is a transition board that provides 16 digital inputs and 16 digital outputs. The Model 493.72 board is typically used with the Model 494.31 (high current) or the Model 493.31 (low current) breakout boxes. Digital I/O Transition Board Cables connected to J3 and J4 connect digital input and output circuits on the Model 493.72 board to the DI/O breakout box. 493.
Model 493.72 Digital I/O Board Specifications–Model 493.72 Digital I/O Board Model 493.72 Digital I/O Board Specifications PARAMETER SPECIFICATION Digital Inputs Connector J3 (D-37S) Provides 16 optically isolated digital inputs: Input ON Voltage = 2.7–26 V DC (at 0.5 mA minimum) Input OFF Voltage = <0.8 V DC Input Resistance = 2 Kohm Jumper Selectable Debounce Times: 20 ms, 10 ms, 1 ms, 0.
Model 493.72 Digital I/O Board How to Change the Debounce Settings on the Model 493.72 Digital I/O Board If necessary, install jumpers on the Model 493.72 Digital I/O board to change the debounce time for each group of four digital inputs. Note The board ships with no jumpers installed, which provides a default debounce time of 20 ms for each input. 1. Locate the four jumper sockets (X2-X5) on the Model 493.72 Digital I/O board. Each jumper socket sets the debounce time for a group of four inputs.
Model 493.31 16-Channel Low-Current DI/O Breakout Box Model 493.31 16-Channel Low-Current DI/O Breakout Box About the Model 493.31 DI/O Breakout Box The Model 493.31 16-Channel Low-Current DI/O Breakout Box provides a terminal plug interface to external devices that are monitored and controlled directly by the Model 493.72 Digital I/O board. The breakout box connects to the digital I/O board through two cables, one for the digital inputs and one for the digital outputs. 493.
Model 493.31 16-Channel Low-Current DI/O Breakout Box Digital I/O Connections for the Model 493.31 DI/O Breakout Box 493.
Model 493.31 16-Channel Low-Current DI/O Breakout Box Digital Input Connections for the Model 493.31 DI/O Breakout Box The J3 In connector on the Model 493.72 board accepts up to sixteen digital-input signals from external devices that are connected to the Model 493.31 DI/O Breakout Box. These signals are monitored by controller software. Breakout box connections Each input device connects to a terminal plug that is inserted into one of the 16 input sockets on the D I/O breakout box. Model 493.
Model 493.31 16-Channel Low-Current DI/O Breakout Box Digital Output Connections for the Model 493.31 Breakout Box The J4 Out connector provides up to sixteen digital output signals that can control external devices. These digital-output signals are controlled by controller software. Breakout box connections Device connections–each output device connects to a terminal plug that is inserted into one of the 16 output sockets on the digital I/O breakout box.
Model 494.31 16-Channel High-Current DI/O Breakout Box Model 494.31 16-Channel High-Current DI/O Breakout Box About the Model 494.31 DI/O Breakout Box The breakout box connects to the Model 493.72 Digital I/O board through two cables, one for the digital inputs and one for the digital outputs. + 12 V J3 IN J10 IN 493.72 D I/O Device connections–each input/output device connects to a terminal plug that is inserted into one of the 16 input/output sockets on the DI/O breakout box.
Model 494.31 16-Channel High-Current DI/O Breakout Box Specifications–Model 494.31 DI/O Breakout Box Model 494.31 DI/O Breakout Box Specifications PARAMETER SPECIFICATION Model 494.31 Breakout Box Output Circuits The high-current digital I/O breakout box includes 16 power MOSFETS (one for each output) that provide the high-current output for output devices. The low-current opto isolators on the Model 493.72 board drive high-current MOSFETS on the digital I/O breakout box.
Model 494.31 16-Channel High-Current DI/O Breakout Box Digital I/O Connections for the Model 494.
Model 494.31 16-Channel High-Current DI/O Breakout Box Digital Input Connections for the Model 494.31 DI/O Breakout Box The J3 In connector accepts up to sixteen digital-input signals from external devices. These signals are monitored by controller software. Breakout box connections Device connections–each input device connects to a terminal plug that is inserted into one of the 16 input sockets on the D I/O breakout box.
Model 494.31 16-Channel High-Current DI/O Breakout Box Digital Output Connections for the Model 494.31 Breakout Box The J4 Out connector provides up to sixteen digital output signals that can control external devices. These digital-output signals are controlled by controller software. Breakout box connections Device connections–each output device connects to a terminal plug that is inserted into one of the 16 output sockets on the digital I/O breakout box.
Model 494.32 8-Channel DI/O Breakout Box Model 494.32 8-Channel DI/O Breakout Box About the Model 494.32 DI/O Breakout Box The Model 494.32 DI/O Breakout Box is used to connect input and output devices to the Model 494.44 System Board. Replaceable fuses for each output. • Fuse-status LEDs for each output. • Connections for one or two external output supply voltages (J29).
Model 494.32 8-Channel DI/O Breakout Box Specifications–Model 494.32 DI/O Breakout Box Device connections Individual input and output connections require a four-position terminal plug (included with the breakout box). Input and output terminal plugs have different keying. Output circuits PARAMETER SPECIFICATION Maximum Output Voltage 30 V DC Maximum Output Current 2 A (per channel) Output Fuse 3 A, fast-blow fuse (one per channel) Output Fuse Voltage Drop 0.15 V typical Output-On Resistance 0.
Model 494.32 8-Channel DI/O Breakout Box Power Connections for the Model 494.32 DI/O Breakout Box Input and output channels are grouped into banks that can be independently powered. Input Bank 1 Power 1(J19) Inputs 1-4 Inputs DI1 + IN PWR DI5 Outputs DI4 DO1 DI7 DI6 DI8 DO3 DO5 DO7 + OUT PWR 1 2 3 4 - IN PWR DI2 Output Bank 1 Output Bank 2 Power 3 (J29) Power 4 (J29) Outputs 1-4 Outputs 5-8 494.
Model 494.32 8-Channel DI/O Breakout Box Digital Input Connections for the Model 494.32 DI/O Breakout Box The Model 494.32 DI/O Breakout Box includes eight opto-isolators that accept signals from input devices (switch contacts, logic inputs). The optoisolators convert the input signals to signals that are compatible with the input circuits (J54) on the Model 494.44 System Board.
Model 494.32 8-Channel DI/O Breakout Box HPU J25 J29A Load Frame J29B J49 Aux Pwr Estop/Run J23 J28 HSM A-B Power 1 2 3 4 5 6 7 8 J24 J43A J55 Dig Out DA Output Interlock J43B 494.32 DI/O Breakout Box J19 Input Power Dig In J54 Digital Input Connections for Switches or Dry Contacts 1 2 3 4 5 6 7 8 100-240 VAC 50-60 Hz, 1-2 A External DC Voltage Source(s) (3.
Model 494.32 8-Channel DI/O Breakout Box Digital Output Connections for the Model 494.32 DI/O Breakout Box Output signals from the Model 494.44 System Board drive high-current opto-isolators on the DI/O breakout box. These high-current opto-isolators supply the higher voltage and current required by output devices. Device connections Each output device connects to a terminal plug that is inserted into one of the eight output sockets on the DI/O breakout box.
Model 494.33 Digital I/O Power Supply Model 494.33 Digital I/O Power Supply About the Model 494.33 Digital I/O Power Supply The Model 494.33 DI/O Power Supply can provide 24 V DC power to the following DI/O breakout boxes: • Model 494.31 16-Channel LowCurrent DI/O Breakout Box 494.33 Power Supply • Model 494.32 8-Channel DI/O Breakout Box DIO Remote Power Supply Power Output Connections J1 Output Pwr—supplies two separate 24 V DC, 7-amp power feeds for breakoutbox output devices.
Model 494.33 Digital I/O Power Supply Specifications–Model 494.33 DI/O Power Supply Electrical PARAMETER SPECIFICATION Input Voltage 100–240 V AC, 5–2 A, single phase “J1 Output Pwr” Output 24 V DC, 14 A maximum (7 A per output)* Fuse: 7 A, 250 V, Slo-Blo “J3 Input Pwr” Output 24 V DC, 1 A maximum* Fuse:1 A, 250 V, Slo-Blo * The maximum cable length for all power cables is 6 m (20 ft).
Model 494.33 Digital I/O Power Supply Environmental requirements PARAMETER SPECIFICATION Temperature 5ºC–40ºC (41ºF–104ºF) Humidity 5–85%, non-condensing Ventilation For proper ventilation, allow 51 mm (2 in) clearance on each end (fan intake and exhaust) of the power supply. The top side of the power supply (where the cables connect) requires a minimum clearance of 15.24 cm (6 in). Dimensions PARAMETER SPECIFICATION Length 29.2 cm (11.5 in) Width 13.3 cm (5.25 in) Height 14.0 cm (5.
Model 494.33 Digital I/O Power Supply Fuse Replacement—Model 494.33 DI/O Power Supply The Model 494.33 DI/O Power Supply includes output fuses and a resettable circuit breaker that is built into the power switch. Fuse replacement 1. If required, shut down system hydraulics. 2. Switch the Power switch on the front of the power supply to the off position. ON OFF 3. Check the fuses.
Model 494.33 Digital I/O Power Supply Circuit Breaker Reset—Model 494.33 DI/O Power Supply The Model 494.33 DI/O Power Supply includes a circuit breaker that is built into the power switch. Important Reset procedure You should develop a circuit breaker reset procedure based on a risk assessment for your system. 1. If required, shut down system hydraulics. 2. Switch the Power switch on the front of the power supply to the off position. ON OFF 3.
Model 494.33 Digital I/O Power Supply Overtemperature Reset—Model 494.33 DI/O Power Supply The Model 494.33 DI/O Power Supply includes an overtemperature circuit. This circuit removes all power outputs if the internal temperature is too high. Important Reset procedure You should develop an overtemperature reset procedure based on a risk assessment for your system. Perform the following procedure to reset the overtemperature circuit and restore DC power output: 1.
Model 494.33 Digital I/O Power Supply Power Connections for the Model 494.31 DI/O Breakout Box To maintain EMC compliance, power cables must comply with the following specifications. Note The maximum cable length for all power cables is 6 m (20 ft). For cable pin assignments, see “Power Connections Model 494.31 DI/O Breakout Box” on page 234. Output Pwr cable Input Pwr cable Model 494.31 DI/O Breakout Box PARAMETER TO J1, 494.
Model 494.33 Digital I/O Power Supply Power Connections Model 494.31 DI/O Breakout Box Model 494.31 DI/O Breakout Box OUTPUT PWR DIO Remote Power Supply J11 J21 INPUT PWR 494.33 Power Supply J1 Output Pwr Maximum Cable Length: 6 m (20 ft) J3 Input Pwr Input Power 494.33 DI/O Pwr Supply J3 Input Pwr 494.31 DI/O Breakout Box J11 Input Power + 24 V DC 2 1 - 24 V DC 6 3 F1 Output Pwr Power F2 Output Pwr Maximum Input Pwr current: 62.5 mA per input device (1 A total). Output Power 494.
Model 494.33 Digital I/O Power Supply Power Connections for the Model 494.32 DI/O Breakout Box To maintain EMC compliance, power cables must comply with the following specifications. Note The maximum cable length for all power cables is 6 m (20 ft). For cable pin assignments, see “Power Connections Model 494.32 DI/O Breakout Box” on page 236. Output Pwr cable Input Pwr cable Model 494.32 DI/O Breakout Box PARAMETER TO J1, 494.
Model 494.33 Digital I/O Power Supply Power Connections Model 494.32 DI/O Breakout Box Input and output channels are grouped into banks that are independently powered. Model 494.32 DI/O Breakout Box Input Power J19 Digital Inputs J10 Output Power J29 Digital Outputs J20 494.33 Power Supply DIO Remote Power Supply J1 Output Pwr Maximum Cable Length: 6 m (20 ft) 494.33 DI/O Pwr Supply J3 Input Pwr Input Power 494.
Transition Boards Transition Boards About Transition Boards Transition boards plug into the transition card cage located in the rear of the chassis. Each transition board allows external devices to interface with the controller. Note The Model 494.04 Chassis does not use transition boards. Series 494 Transition Boards TRANSITION BOARD FUNCTION Model 493.72 Digital I/O Contains sixteen general purpose digital input channels and sixteen general purpose digital output channels. Model 493.
Model 493.73 HPU Interface Board Model 493.73 HPU Interface Board About the Model 493.73 HPU Interface Board The Model 494.73 HPU Interface board is a single-width transition board that plugs into the transition card cage on a Series 494 Chassis. This board provides 24-volt logic signals that control the hydraulic power unit (HPU). Note The emergency stop (E-Stop) inputs and outputs are part of a controller-wide E-Stop system. 493.
Model 493.73 HPU Interface Board Specifications–Model 493.73 HPU Interface Board Model 493.73 Specifications PARAMETER SPECIFICATION E-Stop Output* Connector J23 (D9S) Voltage 24 V DC/AC maximum Current 1 A maximum Normally Open Contacts: Open = E-Stop Active Normally Closed Contacts: Closed = E-Stop Active * The E-Stop relay is de-energized when an E-Stop is active.
Model 493.73 HPU Interface Board J23 E-Stop Output Connections for the Model 493.73 HPU Interface Board Connector J23 E-STOP Out provides a set of E-Stop relay contacts that can be used with external devices. An E-Stop on any of the E-Stop buttons connected to the chassis will de-energize the E-Stop relay. Cable specifications 4 4 5 5 6 6 To maintain EMC compliance, 23 E-STOP Out cables must comply with the following specifications: Connector —9-contact, type D, female EMI connector.
Model 493.73 HPU Interface Board J24 E-Stop Input Connections for the Model 493.73 HPU Interface Board Connector J24 E-STOP In provides an input for an external emergency stop switch. Note Emergency stop inputs are part of a controller-wide E-Stop system. 493.73 HPU SERVICE J29 E-STOP OUT J24 E-STOP IN J24 E-STOP IN 493.
Model 493.73 HPU Interface Board J25 HPU Connections for the Model 493.73 HPU Interface Board Connector J25 HPU provides 24-volt logic signals that control the hydraulic power unit (HPU). The connector can be connected directly to MTS Series 505 HPUs and similar HPUs with low-current (8 mA or less), 24-volt controls. Note Other MTS HPUs require the Model 493.07 HPU Converter Box to convert the low-current HPU output signal to a high-current signal that can drive the HPU relay.
Model 493.73 HPU Interface Board J25 HPU Connections 493.73 HPU Board J25 HPU 493.
Model 493.73 HPU Interface Board J54 DI/O Connections for the Model 493.73 HPU Interface Board Connector J54 SYS DI/O provides three digital inputs and one digital output. Inputs can be external switches or logic inputs. The inputs are connected to the high and low inputs of an opto-isolator that includes a debounce circuit for use with mechanical switch contacts. 493.73 493.
Model 493.73 HPU Interface Board UPS Connections for the Model 493.73 HPU Board (FT60, FT100, FT200, FTGT) The following drawing shows UPS connections for the Model 493.73 HPU board. Once connected, use your controller software to add UPS hardware resources and configure the various UPS options. Note Systems that use Series 793 Control Software have Hwi Editor and station setup settings for UPS systems. 493.73 HPU SERVICE UPS 493.
Model 493.74 Two-Station HSM Interface Board Model 493.74 Two-Station HSM Interface Board About the Model 493.74 Two-Station HSM Interface Board The Model 493.74 Two-Station HSM Interface board is a double-width board that plugs into the transition card cage on a Series 494 Chassis. Each Model 493.74 HSM transition board controls up to two stations. 493.
Model 493.74 Two-Station HSM Interface Board Specifications–Model 493.74 Two-Station HSM Board Model 493.74 Specifications (part 1 of 2) PARAMETER SPECIFICATION HSM Control* Connector J28 (CPC-4S) Off/Low/High Control Low Output +24 V DC, 1.0 A maximum High Output +24 V DC, 1.0 A maximum Proportional Control Signal Output 0–0.78 A Solenoid Impedance 20–25 Ω Ramp Time (0 to full scale) 2.1 s or 4.
Model 493.74 Two-Station HSM Interface Board Model 493.
Model 493.74 Two-Station HSM Interface Board J28 HSM Connection for the Model 493.74 HSM Board Connector J28 HSM controls a hydraulic service manifold (HSM). HSM control (off/low/high or proportional) is software configurable. Off/low/high control provides separate 24-volt, low-pressure and highpressure outputs that drive the HSM low- and high-pressure solenoids. Proportional control provides a current output from 0 to 0.78 A. Note 493.74 HSM Station J43-1 J44-1 Intlk The Model 493.
Model 493.74 Two-Station HSM Interface Board J28 Proportional HSM Output Configuration The proportional HSM output option provides a current source that drives a proportional solenoid on the HSM. The proportional output is configured with the controller software. Pressure settings This board supports software-selectable HSM High and Low pressure settings. HSM rate settings This board supports the following software-selectable HSM rate settings: Fast (2 seconds) or Slow (4 seconds).
Model 493.74 Two-Station HSM Interface Board J29 Load Frame Connections for the Model 493.74 HSM Board Connector J29 Load Frame connects to the load unit control module. Load frame signals include E-Stop and crosshead controls for each station. 493.74 HSM Board 493.
Model 493.74 Two-Station HSM Interface Board Station stop The Emergency Stop connection can also be configured as a station stop. When this is done, be sure that you have other Emergency Stop boxes near by. Pressing Station Stop will shut down the hydraulics to an individual station without shutting down power to the hydraulic power unit. Note A Model 493.73 HPU Transition Board must be installed for the Emergency Stop connection to be enabled. J43 Interlock Connections for the Model 493.
Model 493.74 Two-Station HSM Interface Board Cable specification To maintain EMC compliance, J43 Interlock cables must comply with the following specifications: Connector–9-contact, type D, male EMI connector. Backshell–EMI metallized plastic or metal. Cable–AWG and number of conductors as required. Braided shield with shield connected to the metallized backshell at the chassis. Jumper plug If connector J43 is not used, you must install a jumper plug to maintain the integrity of the interlocks.
Model 493.74 Two-Station HSM Interface Board J44 Run/Stop Connections for the Model 493.74 HSM Board Run/Stop status output Connector J44 Run/Stop provides the run/stop status of the controller to external devices. • Two form C contacts provide the run/stop status. • The contacts are rated 1.0 A at 30 V (AC or DC). 493.74 HSM Station J43-1 Intlk 493.
Model 493.74 Two-Station HSM Interface Board J49 Auxiliary Power Connections for the 493.74 HSM Board Connector J49 Aux Pwr provides auxiliary power outputs for: +5 V DC, +15 V DC, -15 V DC, and +24 V DC. 493.74 HSM Board 493.
Model 493.80 Encoder Interface Board Model 493.80 Encoder Interface Board About the Model 493.80 Encoder Interface Board The Model 493.80 Encoder Interface board converts four channels of differential RS-422 encoder signals into TTL encoder signals that are compatible with the Model 494.49 Quad Encoder Interface card. In addition, the Model 493.80 board can supply DC power to each of the four encoders. The Model 493.
Model 493.80 Encoder Interface Board Specifications–Model 493.80 Encoder Interface Board PARAMETER SPECIFICATION Digital Transducer/ Encoder Electrical Interface The Model 493.80 Encoder Interface board converts four channels of differential RS-422 encoder signals (J3-J8) into TTL encoder signals (J11, J12) that are compatible with the Model 494.49 Quad Encoder Interface card. Supported Digital Transducer/ Encoder Interfaces The Model 493.
Model 493.80 Encoder Interface Board Power Settings for the Model 493.80 Encoder Interface Board Power for the encoders can be supplied from the Model 493.80 board. Three voltage levels (+5 V DC, +/- 15 V DC, and +24 V DC) are available and can be selected by the jumper settings in the following table. Power Settings for the Model 493.
Model 493.80 Encoder Interface Board Jumper Settings and Locations for the Model 493.80 Encoder Interface Board Each channel on the Model 493.80 board includes jumpers that you can configure for various voltages. When used with the Model 494.49 Quad Encoder board, the jumper setting for each channel’s mode must be the same (all SSI or all non-SSI). 493.
Model 493.80 Encoder Interface Board Mode Settings for the Model 493.80 Encoder Interface Board Each channel on the Model 493.80 board includes jumpers that you can configure for various modes. Note When used with the Model 494.49 Quad Encoder board, the jumper setting for each channel’s mode must be the same (all SSI or all non-SSI).
Model 494.74 Two-Station HSM Interface Board Model 494.74 Two-Station HSM Interface Board About the Model 494.74 Two-Station HSM Interface Board The Model 494.74 Two-Station HSM transition board is a single-width board that plugs into the transition card cage on a Series 494 Chassis. AUX Power (J49)–the J49 connector provides fused (self resetting) auxiliary power outputs for: +5 V DC, +15 V DC, -15 V DC, and +24 V DC.
Model 494.74 Two-Station HSM Interface Board Specifications–Model 494.74 Two-Station HSM Interface Board Model 494.74 Specifications (part 1 of 2) PARAMETER SPECIFICATION HSM Outputs Connectors 28A and 28B (D9S)) Low Output 1.0 A maximum High Output 1.0 A maximum HSM Command State Monitoring: Each HSM channel monitors and compares the HSM command state against the actual HSM Low and High output states to help sense failed HSM relay contacts.
Model 494.74 Two-Station HSM Interface Board Model 494.74 Specifications (part 2 of 2) PARAMETER SPECIFICATION Run/Stop Output Relays Connectors J3A and J3B (D15S) Voltage Rating 30 V DC/AC maximum Current Rating 1 A maximum Normally Open Relay Contacts: Open = Program is stopped Normally Closed Relay Contacts: Closed = Program is stopped Auxiliary Power Outputs Connector J49, (D9S) +5 V DC 0.75 A maximum +15 V DC 0.75 A maximum -15 V DC 0.75 A maximum +24 V DC 0.
Model 494.74 Two-Station HSM Interface Board J3 Interlock Connections for the Model 494.74 HSM Board Each HSM channel has interlock inputs and outputs that are available through connector J3A or J3B (one channel per connector). Interlock output contacts can control external devices. Interlock inputs from external devices can initiate station and program interlocks. Interlock Input Options 494.
Model 494.74 Two-Station HSM Interface Board Interlock output J3 Run/Stop output J3 Each HSM channel has a set of interlock output contacts that are available through connector J3A and J3B (one channel per connector). These interlock contacts change state when an interlock line goes active and can be used to control external devices.
Model 494.74 Two-Station HSM Interface Board Cable specification To maintain EMC compliance, J3 Interlock cables must comply with the following specifications: Connector–15-contact, type D, male EMI connector. Backshell–EMI metallized plastic or metal. Cable–AWG and number of conductors as required. Braided shield with shield connected to the metallized backshell at the chassis.
Model 494.74 Two-Station HSM Interface Board J28 HSM Connections for the Model 494.74 HSM Board The control cable for each HSM plugs into a separate J28 connector on the 494.74 HSM board. Each HSM channel has separate 24-volt, low-pressure and high-pressure outputs that drive the HSM low- and high-pressure solenoids. Note The Model 494.74 HSM board cannot be used directly with 115 V AC HSMs. Applications that use 115 V AC HSMs require an external converter box (such as a Model 413.
Model 494.74 Two-Station HSM Interface Board J49 Auxiliary Power Connections for the Model 494.74 HSM Board The J49 connector provides auxiliary power outputs for: +5 V DC, +15 V DC, -15 V DC, and +24 V DC. 494.
Model 494.75 8-Input BNC Transition Board Model 494.75 8-Input BNC Transition Board About the Model 494.75 8-Input BNC Transition Board Analog input signals are typically routed to the Model 494.45 A/D Converter mezzanine card through a Model 494.75 8-Input BNC Transition Board. The two outputs of this transition board connect to the front-panel RJ-50 connectors on the I/O carrier board associated with the A/D converter mezzanine card (J3A and J3B).
Model 494.76 8-Output BNC Transition Board Model 494.76 8-Output BNC Transition Board About the Model 494.76 8-Output BNC Transition Board Analog output signals are typically routed to external devices through a Model 494.76 8-Output BNC transition board. The transition board connects to the front-panel I/O carrier board connectors associated with the D/A converter mezzanine card slot (J3A and J3B).
Model 494.79 8-Channel Valve Driver Board Model 494.79 8-Channel Valve Driver Board About the Model 494.79 8-Channel Valve Driver Board The Model 494.79 8-Channel Valve Driver is a transition board that contains eight separate valve drivers. Each valve driver requires an external valvedrive signal. Valve drive signals are typically provided by a Model 494.46 8Output D/A mezzanine card.
Model 494.79 8-Channel Valve Driver Board Specifications–Model 494.79 8-Channel Valve Driver Board The Model 494.79 8-Channel Valve Drive board only supports two-stage valves. PARAMETER SPECIFICATION Output Current Software-configurable output current settings: 25 mA, 50 mA, or 75 mA. Note If other output currents are required, call MTS about board modifications. Valve Outputs per Channel 1 Dither Frequency 1–4915.
Model 494.79 8-Channel Valve Driver Board Model 494.79 8-Channel Valve Driver Board Pin Assignments The following figure shows the pin assignments for each of the eight valve driver outputs. CAUTION The front-panel sockets on the Model 494.79 board only accept cabling with 10-pin, shielded, RJ-50 connectors with a gray boot. The use of other RJ connector types (less than 10 pins or unshielded with a black boot) with the Model 494.79 board can cause component damage.
Model 494.79 8-Channel Valve Driver Board Two-Stage Servovalve Connections for the Model 494.79 Valve Driver You can use the analog output signals from the D/A converter card to drive a Model 494.79 8-Channel Valve Driver board. The transition board connects to the D/A converter card through front-panel I/O carrier board connectors. Note Single two-stage valve The following diagrams show wiring for systems where compression is positive. 494.
Model 493.07 HPU Converter Box Model 493.07 HPU Converter Box About the Model 493.07 Converter Box This section describes how to jumper the Model 493.07 Converter Box to connect a Series 494 Chassis and other controller types to a hydraulic power unit (HPU). The converter box converts logic-level signals to and from the Series 494 Chassis to relay signals used by the HPU pump. For pumps that are 24 V PLC compliant, the converter box is not needed. This includes all Series 505 HPUs and 506.52–.92 HPUs.
Model 493.07 HPU Converter Box WARNING When connected to a 120-volt HPU, the Model 493.07 Converter Box contains dangerous voltages. Removing the cover from the Model 493.07 Converter Box without first disconnecting all cables can expose you to a dangerous electrical shock hazard that can cause series personal injury or death. Disconnect all cables from the Model 493.07 Converter Box before removing the cover. Jumper settings As shipped, the HPU interface on the Model 493.
Model 493.07 HPU Converter Box The Model 493.07 Converter Box can be connected to other controllers (as shown in the following table) using a “Y” cable. Note If the Series 494 Chassis is the only device connected to the HPU, the jumper settings are not necessary. COMPATIBLE WITH JUMPERS Model 458.05/.10/.20/.40 Model 490.01 Model 497.05 Standard jumper setting: Model 413.05 Model 436.11 Model 407.
Model 493.07 HPU Converter Box Connections for the Model 493.07 Converter Box This section describes how to connect a Series 494 Chassis to a variety of MTS hydraulic configurations. Cable specifications Use the following connectors and cables to connect the Series 494 Chassis to your HPU with a Model 493.07 Converter Box: Series 494 Chassis to Model 493.07 Converter Box J25 Connector–15-contact, type D, female EMI connector at J25 of the Model 493.
Model 493.07 HPU Converter Box Converter box connections The following three configurations have cables to support both 24 V DC and 115 V AC control voltages. A Model 493.07 Converter Box is available for each voltage (not both). Be sure the cables and converter box are rated for the same voltage. Single Series 494 Chassis with a non-PLC pump 494 Chassis 039-713-8XX (24 V DC) 039-714-6XX (115 V AC) J25 HPU J1 HPU 493.
Model 493.07 HPU Converter Box Controller compatibility You can mix Model 493.07, 458, 490, and 497.05 Controllers directly on the same HPU (without the use of an HPU isolation box). You cannot mix Model 493.07, 458, 490, and/or 497.05 Controllers with 436, 413.05, or 413.8x Controllers unless you use an isolation box. You can jumper the Model 493.07 Converter box so you can use it directly with 436 and 413.05 Controllers.
Cables Chapter 6 Cables Series 494 Cable Part Numbers For a complete listing of Series 494 cable part numbers, see the System Cable/Jumper Plug Guide engineering drawing (part number 700-003-814). How to Identify Series 494 RJ-50 Connectors All Series 494 cables equipped with 10-pin RJ-50 connectors have a gray boot. Do not use cables with black connector boots with Series 494 hardware.
Cables Series 494 Cable Connections Follow these precautions when connecting cables to a controller. WARNING Unprotected cables can be damaged by hydraulic fluid, excessive temperature, excessive strain, and contact with sharp, abrasive, or heavy objects. A damaged cable can cause a rapid, unexpected system response which can result in severe personal injury, death, or damage to equipment.
Cables MTS FlexTest® Models 40/60/100/200 Controller Hardware Cables 283
Cables 284 Cables MTS FlexTest® Models 40/60/100/200 Controller Hardware
Troubleshooting and Maintenance Appendix A Troubleshooting and Maintenance Chassis Troubleshooting J39 Service Test Points The J39 Power Monitor connector (located on the rear panel of the Model 494.06, 494.10, and 494.20 Chassis) provides service test points. Test points include all of the power supply voltages and the status of the overtemperature sensor and the power-fail circuit. 494.xx Chassis J39 Power Monitor 8 15 1 * Temperature = (degrees C) 9 Vout (pin 14) 0.005 Note - 273.
Chassis Troubleshooting Overcurrent Protection for Series 494 Hardware Series 494 hardware includes the following overcurrent protection: • Self-resetting fuses for each auxiliary power output. • AC circuit breaker built into the chassis power switch. Note There are no user-replaceable fuses in any Series 494 Controller. How to Reset the Chassis Circuit Breaker Each Series 494 Hardware chassis has a circuit breaker built into the power switch.
Chassis Troubleshooting 3. For proper ventilation, make sure that there is 51 mm (2 in) clearance on all sides of the chassis. 4. Let the chassis cool down and restart the system. If the Over Temp indicator is on, shut down the system. CAUTION The chassis Over Temp indicator (located on the front of the Model 494.06 chassis and on the back of the Models 494.10 and 494.20 chassis) turns on when the chassis temperature is too hot–over 50ºC (122ºF).
Service Connections Service Connections About Service Connections A Series 494 Chassis can have several service connectors. There are two types of connectors: J3 I/O carrier service connection • The chassis connection monitors the power supply. • The connection on the I/O carrier board monitors the output of each card. The J3 Service connector on the Model 494.40 I/O Carrier board provides the monitor output from each of the four I/O option cards installed. It is an 8pin RJ-45 connector.
Chassis Maintenance Chassis Maintenance This section describes how to maintain your MTS controller chassis. How to Clean the Chassis Remove dust from the chassis with appropriate electronics cleaner. How to Clean the Air Filter Be sure the cooling fan is operational and not clogged. Clean or replace the filter as required. The filter is typically located in the top of the chassis, and can be accessed from the rear. To clean the air filter: 1. Remove the filter from the chassis. 2.
Chassis Maintenance CAUTION An improperly installed chassis filter will not filter the air properly. This can result in excessive amounts of dust and debris on the inside of the controller. Excessive amounts of dust and debris on the inside of the controller can result in an over-temp condition. Install the filter so that the arrow on the side of the filter points in the direction of air flow through the chassis.
Optional Station Configurations Appendix B Optional Station Configurations About Optional Station Configurations You can configure the Series 494 Chassis to support an optional six or eight stations. When configuring your system for a six or eight stations, consider the following: • Ensure that the .hwi file is correctly set for the desired multistation configuration, especially the interlock and HSM board settings. • Power to each HSM is limited.
Optional Station Configurations Eight-Station Configurations The eight-station configuration can provide eight channels of control. A typical 8-Channel/8-Station configuration requires 16 Digital Universal Conditioners and 8 two-stage valve drivers. HSM power limits Interlocks HSM power current is limited to 1.6 A per HSM. For 8-station configurations, the .hwi file must contain the line INTERLOCKS=8. This line must be a discrete entry, not part of any other hwi section.
Aero Multibox Systems Appendix C Aero Multibox Systems This section describes the basic tasks required to set up Aero Multibox systems. Aero Multibox Overview 294 Task 1 – Set Up Multibox Hardware Task 2 – Make Multibox Connections 297 304 Task 3 – Use the CMT to Configure the Multibox System Task 4 – Create an Hwi File for Each Box Important 310 317 The procedures in this section should only be performed by MTStrained personnel.
Aero Multibox Overview Aero Multibox Overview About Multibox Systems A multibox system consists of up to 12 networkable 20-slot controller chassis (boxes) that can be combined to create various test systems. • Series 493 Hardware can provide up to 30 control channels per box for a maximum of 360 control channels for a 12-box system. • Series 494 Hardware can provide up to 40 control channels per box for a maximum of 480 control channels for a 12-box system.
Aero Multibox Overview Multibox Hardware Multibox Hardware ITEM DESCRIPTION Dual Processor Systems CPU 0 SUP processor board–this processor board includes a Gigabit Ethernet connnection for the controller network. CPU 1 DSP processor board–this processor board includes a VMIC reflective memory mezzanine card. Single Processor Systems Newer systems use a single dual-core 7100 processor board equipped with a SCRAMNet GT reflective memory module. Model 49x.
Aero Multibox Overview Single Processor 7100 Processor Dual Processors Model 49x.43 Multibox Model 498.96 Model 49x.43 Model 498.
Aero Multibox Overview Task 1 Set Up Multibox Hardware The following procedure outlines the basic steps required to set up the hardware used in a multibox system. 1. “AeroPro Workstation Requirements” on page 298. 2. “Add HPU and HSM Boards to the Master Controller Box” on page 299. 3. “Reflective Memory Module Node Address Jumper Settings” on page 300. 4. “Multibox Processor Settings” on page 301. 5. “Multibox Chassis Address Settings” on page 302. 6.
Aero Multibox Overview AeroPro Workstation Requirements Hardware requirements WORKSTATION RECOMMENDED REQUIREMENTS* AeroPro Server Intel Quad Core Xeon, 2.34 GHz processor, or faster 4 GB RAM 256 MB video card, PCIe Two PCI network cards (Gigabit). Depending on controller hardware, additional network cards may be required. DVD+R/+RW drive 250 GB Hard drive, RAID 1 AeroPro Client Intel Dual Core, 2.
Aero Multibox Overview Add HPU and HSM Boards to the Master Controller Box Each multibox system requires an HPU board and a HSM board. These boards must only be installed in the first box in the chain (Master box). • Model 493.73 HPU board with E-Stop input • Model 493.74 (or 494.74) HSM board with Station-Stop input Important Board locations If reconfiguring a system, you must remove any HPU and HSM boards from the dependent boxes. The HPU/HSM board locations depend on the type of HSM board used.
Aero Multibox Overview Reflective Memory Module Node Address Jumper Settings Each box in a dual-processor multibox system must have a reflective memory module (VMIC) installed on the DSP processor board located in VME slot 3. Each VMIC module must have a discrete Node ID number. The Node ID number is set on the VMIC module using the E1 jumpers (see table below). Note 7100 processors do not use the VMIC card. SCRAMNet GT memory cards do not require any jumper settings.
Aero Multibox Overview Multibox Processor Settings When used in a multibox system, both processors in each box must have Switch 1 Bit 6 set to the off position. Note If you remove a box from a multibox system and use it as a standalone controller (without a Model 49x.43 Multibox board), you must set Switch 1 Bit 6 on both processor boards to the on position. Typically, when a box is removed from a multibox system, the Model 49x.
Aero Multibox Overview Multibox Chassis Address Settings Each chassis (box) in a multibox system requires a Model 49x.43 Multibox board with a front-panel address switch that sets the TCP/IP address setting for the box.
Aero Multibox Overview Verify the I/O Carrier Address Settings Each I/O Carrier board installed in the VME bus must have a unique address. This address is set using switches SW1 and SW2 on the I/O Carrier board. I/O Carrier boards should be installed from left-to-right starting with the lowest address. Any blank slots in the VME bus should have addresses reserved as part of this low-to-high addressing sequence.
Aero Multibox Overview Task 2 Make Multibox Connections Once the hardware is installed and configured, you can make the box-to-box connections and set up the various networks used in the multibox system. Connect Multibox Hardware (dual processors) 1. Connect the Fiber-Optic cables as show below. 2. Connect the Box In/Box Out cables as shown below. 3. Install a Box Out jumper plug on the last box.
Aero Multibox Overview Connect Multibox Hardware (single 7100 processor) 1. Connect the Fiber-Optic cables as show below. 2. Connect the Box In/Box Out cables as shown below. 3. Install a Box Out jumper plug on the last box. Note Single 7100 processor configurations require the installation of SCRAMNet GT memory modules on each processor board. Box 2 (Dependent) Box 1 (Master) B O X A D R S J8 Intlk In A D R S J8 Intlk In PMC 1 PMC 1 J9 Intlk Out B O X Box Address Switch = 0 148.150.203.
Aero Multibox Overview Single-Box Multibox Chassis Connections Typically, when a box is removed from a multibox system, the Model 49x.43 Multibox board remains in the box and Switch 1 Bit 6 on both processor boards are left in the off position. Dual-processor systems If you use a single multibox chassis to run a test, you must connect it as shown in the following drawing. CPU 0 Multibox Board CPU 1 Cabling J8 Interlock Jumper Plug B O X A D R S J8 Intlk In E F 0 12 172.16.20.
Aero Multibox Overview 7100 Processors 7100 processors do not have processor switch settings. • If used in a single-box configuration that includes a Multibox board, the processor IP address is determined by the front-panel address switch setting on the Multibox board. When this switch is set to 0, the IP address is 148.150.203.8. • If used in a single-box configuration without a Multibox board, the processor IP address defaults to 148.150.203.191. 7100 Processor Model 49x.
Aero Multibox Overview Multibox Network Address Settings Box 2 Box 1 (Dependent) (Master) B O X B O X A D R S Box 3 (Dependent) A D R S B O X A D R S J8 Intlk In J8 Intlk In J8 Intlk In J9 Intlk Out J9 Intlk Out J9 Intlk Out J52 Box Out Box Out RX TX J52 Box Out Box Out J52 Box Out RX TX J51 Box In J51 Box In J51 Box In RX TX Box In Box In Client 1 Controller NIC 148.150.203.190 Gigabit Ethernet Subnet: 255.255.255.0 Switch 1629 Console Server PC Client NIC 172.16.20.
Aero Multibox Overview Client PC Each Client PC requires a network interface card (NIC) that connects to a Gigabit Ethernet switch. Client Multibox Network Interface Card Settings NETWORK INTERFACE CARD TCP/IP ADDRESS SUBNET Client 1 172.16.20.101 255.255.255.0 Client 2 172.16.20.102 255.255.255.0 Client 3 172.16.20.103 255.255.255.0 Client n 172.16.20.10n 255.255.255.
Aero Multibox Overview Task 3 Use the CMT to Configure the Multibox System The Controller Management Tool (CMT) procedures are performed when you are combining two or more controller chassis (boxes) into a multibox system. These procedures must be performed in the following order: 1. “Delete the Old Single-Box Controller Folder” on page 311. 2. “Install System Controller Files” on page 312. 3. “Use the CMT to Configure the Controller” on page 313. 4. “Reboot the Controllers” on page 315. 5.
Aero Multibox Overview Delete the Old Single-Box Controller Folder When switching from a single controller to a multibox controller or if you are configuring a new system as a multibox, you must first remove the existing single-box controller folder. This folder (“793 for Aero” for an AeroST controller or “MTS Flex Test 200” for the Flex Test controller) is created when the 793 software is installed and must be removed for a multibox configuration.
Aero Multibox Overview B. Highlight the old single-box controller folder and click Delete. The default names for the controller folders are “793 for Aero” for an AeroST controller or “MTS Flex Test 200” for the Flex Test controller. Install System Controller Files Note This step is not required when using the Controller Management Tool (CMT) with 793 software version 5.20 and later. 1. Turn ON the power to all the controllers (boxes) in the multibox configuration. 2.
Aero Multibox Overview Use the CMT to Configure the Controller Use the Controller Management Tool (CMT) application to rename each box and set the Controller Type to define the Master and Dependent controllers. As you rename each controller, the various folders in the Controllers directory will also be renamed with the new controller name (Box 1, Box 2, ...). 1. If necessary, start the Controller Management Tool application. 2. Configure the Master controller.
Aero Multibox Overview 3. Configure the Dependent controllers. A. Select the next controller and click Options. B. In the Controller Options window: In the Controller Name text box, type Box 2. In the Controller Type list, click Dependent. C. Click OK. 4. Repeat Step 3 for all other Dependent controllers in the multibox configuration incrementing the “Box x” number each time and setting the Controller Type for each box to Dependent.
Aero Multibox Overview Reboot the Controllers Once you have used the Controller Management Tool (CMT) to name all the controllers and define their Controller Type (master or dependent) you must use the CMT to reboot all the controllers. 1. In the CMT window, select each controller one at a time and click Reboot. The CMT window will go blank until the controllers have completed their reboots and come on line again. 2.
Aero Multibox Overview Use the CMT to Register Multiple Controllers 1. Make sure that all controllers are connected properly (including all network connections). 2. Apply power to each controller. 3. Allow the CMT to detect each controller. Each controller that is detected appears in the CMT window. The Controller Name typically appears as Unregistered_0 and Unregistered_1. 4. In the Controller Management Tool (CMT) window, click Register Multiple Controllers. 5.
Aero Multibox Overview Task 4 Create an Hwi File for Each Box Each controller (box) in a multibox configuration requires an Hwi file that maps all the hardware in that box to specific locations in the chassis. You must perform the following procedures for each box in a multibox system. 1. “Select a Controller and run the Detect Hardware Feature to Help Build an Hwi file” on page 318. 2. “Define the VME Slot Locations” on page 320. 3. “Configure Servo Valve Outputs” on page 324. 4.
Aero Multibox Overview Select a Controller and run the Detect Hardware Feature to Help Build an Hwi file 1. Start the Hwi Editor application. All Programs > MTS 793 Software > Service Tools > Hwi Editor The following window will open showing all the controllers that are available on the controller network (only two in this example). 2. Select the Controller that you want to create an Hwi file for and click OK. 3. In the Hwi File Editor window, set the Controller Type. 4.
Aero Multibox Overview 5. Select the TCP/IP address for the box that you want to create an Hwi file. Each box in a multibox system has a unique TCP/IP address. See the table below. . Controller TCP/IP Addresses BOXES 1-6 BOXES 7-12 Box 1: 148.150.203.8 Box 7: 148.150.203.56 Box 2:148.150.203.16 Box 8: 148.150.203.64 Box 3: 148.150.203.24 Box 9 : 148.150.203.72 Box 4: 148.150.203.32 Box 10 : 148.150.203.80 Box 5: 148.150.203.40 Box 11: 148.150.203.88 Box 6: 148.150.203.48 Box 12: 148.150.203.
Aero Multibox Overview Define the VME Slot Locations The Hwi Editor application can detect the hardware in the controller but cannot detect the exact VME slot where the various VME boards are installed. You must verify the slot number where each VME board is installed and make changes as necessary. Important I/O carriers should be physically installed (left-to-right) based on their address settings starting with the lowest address setting. 1. Click Search to detect the hardware installed in the box.
Aero Multibox Overview Note If the I/O carriers were physically installed (left-to-right) starting with the lowest address setting, most of their slot numbers should be correct. In this example, the 49x.43 Multi-Box I/O is located in VME Slot 2 and the last three 494.40 I/O Carriers are located in VME Slots 18, 19 and 20. VME slots 14, 15, 16, and 17 were left empty.
Aero Multibox Overview 3. Click Sort. The hardware will be reordered to match the physical locations set in the previous step. See the example below. 4. Verify that the slot locations shown match the physical location of the hardware and click OK.
Aero Multibox Overview About Servovalve Drive Outputs for Aero Applications Aero applications use a combination of a Model 49x.46 D/A cards and Model 49x.79 MUD boards to provide the servo valve drive outputs. Four D/A cards provide 32 outputs (eight outputs per card) for a Flex Test 200 controller and 24 outputs (six outputs per card) in an AeroST controller.
Aero Multibox Overview Configure Servo Valve Outputs Perform this procedure to define which D/A card is connected to which MUD board. 1. Navigate to 494.40 IO carrier [20] and click + to expand the tree. 2. Click + for the first Model 494.46 8-Output D/A Converter to expand the tree to show the eight analog outputs as shown below. 3. Assign the D/A outputs to a Model 494.79 MUD board. A. In the right-hand side of the window, click the Channels tab. B. From the Analog Output 1 list, click 494.
Aero Multibox Overview D. Click OK. The Hwi Editor will assign all 8 outputs (6 for the Model 493.79) to the MUD board located in Transition Slot 19. 4. Repeat this procedure for each D/A and MUD board combination. The next MUD board in the sequence is located in Transition Slot 18.
Aero Multibox Overview Configure the Model 494.79 Multiple Universal Driver (MUD) Board 1. In the Hwi File Editor window, expand the hardware tree to display the 494.79 Multiple Universal Valve Driver [19] settings. 2. In the Interlock Enable list, click False. Note Standard MTS servo valve cables do not support the cable-loss interlock detection circuit so the Interlock Enable setting must be set to False. 3.
Aero Multibox Overview Configure Each Model 493.25 / 494.26 DUC For Hwi Editor versions 5.20 and above, use the Show Hwi Defaults feature to make universal changes to the DUC default settings that you can apply to all the DUCs in the controller. 1. Disable the analog input filter. A. Starting at the 494.40 IO Carrier in VME Slot 4 expand the hardware tree down to the level of “Analog Input x”. B. In the Filter Type list, click Disabled.
Aero Multibox Overview 2. Configure the DUC. A. Expand the hardware tree down and select the DUC icon. The default values for the type of cable connected (4 or 8 wires) and the polarity of the applied shunt are shown below. B. If necessary, make changes to match the bridge type, shunt excitation and shunt polarity. 3. Repeat this procedure for each DUC in the controller chassis.
Aero Multibox Overview Save the Hwi File in the Correct Folder The Hwi file must be saved in the folder that the CMT application created for the controller box. These folders (named “Box 1”, “Box 2” ... “Box ‘n’”) are located in the C:\MTS 793\Controllers directory. 1. Make sure the Hwi file is named: “793 Controller.hwi”. 2. Save the Hwi file in the folder with the controller’s name. For example: C:\MTS 793\Controllers\Box 1.
Aero Multibox Overview 330 Aero Multibox Systems MTS FlexTest® Models 40/60/100/200 Controller Hardware
Model 793 Multibox Systems Appendix D Model 793 Multibox Systems This section provides a general overview on how to set up Model 793 Multibox Systems. Perform the following procedures in the order shown: 1. “Connect the Multibox System” on page 332. 2. “Use the CMT to Register Multiple Controllers” on page 333. 3. “Use the CMT to Configure the Controller” on page 335. 4. “Create an .hwi File for Each Box” on page 337. 5. “Use the Station Builder Application to Create a Multibox Configuration” on page 338.
Model 793 Multibox Systems Task 1 Connect the Multibox System Model 793 Multibox System Connections Each multibox system requires an HPU board and a HSM board. These boards must only be installed in the first box in the chain (Master box). Box 2 (Dependent) Box 1 (Master) B O X A D R S B O X Box Address Switch = 0 148.150.203.8 J8 Intlk In PMC 1 PMC 1 J8 Interlock Jumper Plug J9 Intlk Out J9 Intlk Out Box Address Switch = 1 148.150.203.
Model 793 Multibox Systems Task 2 Register the Controllers Use the CMT to Register Multiple Controllers 1. Make sure that all controllers are connected properly (including all network connections). 2. Apply power to each controller. 3. Allow the CMT to detect each controller. Each controller that is detected appears in the CMT window. The Controller Name typically appears as Unregistered_0 and Unregistered_1.
Model 793 Multibox Systems Optional–Delete the default single-box controller folder When you register multibox controllers, the CMT will also display the default single-box controller that was installed in the initial installation. (The controller type depends on the controller product that was installed. For example, MTS FlexTest 200). • This default controller is not required for multibox systems but is required if you want to run in demo mode.
Model 793 Multibox Systems Task 3 Configure the Controllers Use the CMT to Configure the Controller Use the Controller Management Tool (CMT) application to rename each box and set the Controller Type to define the Master and Dependent controllers. As you rename each controller, the various folders in the Controllers directory will also be renamed with the new controller name (Box 1, Box 2, ...). 1. If necessary, start the Controller Management Tool application. 2. Configure the Master controller.
Model 793 Multibox Systems 3. Configure the Dependent controllers. A. Select the next controller and click Options. B. In the Controller Options window: In the Controller Name text box, type Box 2. In the Controller Type list, click Dependent. C. Click OK. 4. Repeat Step 3 for all other Dependent controllers in the multibox configuration incrementing the “Box x” number each time and setting the Controller Type for each box to Dependent.
Model 793 Multibox Systems Task 4 Create an .hwi File for Each Box Each controller (box) in a multibox configuration requires an .hwi file that maps all the hardware in that box to specific locations in the chassis. 1. Start the Hwi Editor application. All Programs > MTS 793 Software > Service Tools > Hwi Editor The following window will open showing all the controllers that are available on the controller network (only two in this example). 2. Select the Controller that you want to create an .
Model 793 Multibox Systems Task 5 Use the Station Builder Application to Create a Multibox Configuration Once you have use the Controller Management Tool (CMT) application to register and configure the multibox system and created Hwi files for each box, you can use the Station Builder application to create the configurations required for your test.
Index Index Numerics 493.07 HPU Converter box 275 493.31 DI/O Breakout Box 212 493.72 Digital I/O board 209 493.73 HPU Interface board 238 e-stop connections, J24 241 HPU connections 242 493.73 HPU Interface, DIO, J54 244 493.74 Two-Station HSM Interface board (2-slot) 246 493.74, run/stop, J44 254 493.80 ADDA Encoder board 256 494.04 Chassis 48 494.05 Handset connections 186 494.06 Chassis 102 494.10 Chassis 106 494.16 VD/DUC card 160 494.20 Chassis 111 494.25 Single DUC card 154 494.
Index digital input 493.31 DI/O breakout box 214 494.31 DI/O breakout box 219 494.32 DI/O breakout box 224 494.42, J54 80 494.44, J54 97 digital output 493.31 DI/O breakout box 215 494.31 DI/O breakout box 220 494.32 DI/O breakout box 226 494.42, J55 81, 82 494.44, J55 98 digital transducer card 183 dual DUC 157 dual valves 166 DUC 494.16 VD/DUC 160 494.21 Multi-Range DUC with Acceleration Compensation Card 168 494.25 Single DUC 154 494.
Index interlock 493.43 Multi-Chassis I/O board, J8 intlk in 128 493.74, J43 252 494.41, J43 61 494.42, J43 78 494.43 Multi-Chassis I/O board, J9 intlk out 129 494.44, J43 95 overtemperature 286 P load frame 494.42, J29 77 494.44, J29 94 LVDT connections 151 power 493.80 ADDA Encoder board 258 494.32 DIO Breakout box 223 AC disconnect 40 grounding 37 UPS requirements 45 power supply 494.31 connections 233 494.32 connections 235 494.33 DI/O power supply 227 494.
Index specifications 493.73 HPU Interface board 239 493.74 Two-Station HSM board 247 493.80 ADDA Encoder board 257 494.04 Chassis 49 494.06 Chassis 103 494.10 Chassis 106 494.16 Valve Driver card 161 494.20 Chassis 111 494.21 Multi-Range DUC with Acceleration Compensation Card 170 494.31 DI/O Breakout Box 217 494.32 DI/O Breakout Box 222 494.32 DIO Breakout box 222 494.33 DI/O power supply 228 494.41 System board 85 494.41 System I/O board 53 494.42 system board 68 494.43 Multi-Chassis I/O board 127 494.
m MTS Systems Corporation 14000 Technology Drive Eden Prairie, Minnesota 55344-2290 USA Toll Free Phone: 800-328-2255 (within the U.S. or Canada) Phone: 952-937-4000 (outside the U.S. or Canada) Fax: 952-937-4515 E-mail: info@mts.com Internet: www.mts.
