be certain.
Copyright information Trademark information © 2006, 2007, 2008, 2009 MTS Systems Corporation. All rights reserved. MTS, FlexTest, Temposonics, and TestWare are registered trademarks of MTS Systems Corporation; MPT, Station Builder, and Station Manager 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 Technical Support 9 How to Get Technical Support Before You Contact MTS 9 10 If You Contact MTS by Phone 11 Problem Submittal Form in MTS Manuals 12 Preface 15 Before You Begin Conventions 15 16 Documentation Conventions Chapter 1 Introduction 19 FlexTest GT Controllers 20 Model 493.10 Chassis Hydraulic Control Interlocks 20 22 22 Specifications FlexTest SE Controllers 23 24 Model 493.
Chapter 2 Installation 37 Installing the Model 493.10 Chassis (FTGT) Connecting Electrical Power Installing the Plug-in Modules VMEbus Modules 37 38 42 43 Installing the Transition Panels 47 Installing the 493.
Chapter 3 FlexTest GT Controller Connections 81 CE EMC Compliant Cabling Typical Cabling 83 84 Cable Part Numbers 85 Model 493.40 I/O Carrier Connections Sensor Connections 87 88 Model 493.
Cabling and Programming Series 407 Controllers 151 How to Provide Program to a Series 407 Controller Connecting Interlock Signals to 407 Controllers 151 156 Sending and Receiving Signals to a Model 407 Controller Connecting Interlock Signals to 458 Controllers 164 Eurotherm Temperature Controller Connection 165 Miscellaneous Conditioner Output Connections 167 Cabling for External Command Inputs 168 How to Enable and Run External Command Inputs Cabling and Using External Readout Devices J8 Inte
Cabling for External Command Inputs 210 How to Enable and Run External Command Inputs Cabling and Using External Readout Devices How to Send Signals to External Readout Devices Cable Part Numbers Chapter 5 213 216 FlexTest SE Controller Connections 217 Stand-alone Cabling Overview 218 Automated Cabling Overview 219 Multiple Controller Connections Cable Part Numbers 220 223 Model 493.
Appendix A Hydraulic Configurations 243 Model 493.02 Chassis Multiple Controller Interconnections Independent HSM (no HPU) Independent HSM (shared HPU) Shared HSM (with HPU) Shared HSM (no HPU) 246 246 247 247 248 Independent HSM with HPU (First On-Last Off) 249 Appendix B Model 493.
How to Get 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.
Before You Contact MTS 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.
If You Contact MTS by Phone Know relevant computer information Know relevant software information For a computer problem, have the following information available: • Manufacturer’s name and model number • Operating software type and service patch information • Amount of system memory • Amount of free space on the hard drive where the application resides • Current status of hard-drive fragmentation • Connection status to a corporate network For software application problems, have the following
Problem Submittal Form in MTS Manuals Identify system type Be prepared to troubleshoot Write down relevant information After you call To enable the Call Center agent to connect you with the most qualified technical support specialist available, identify your system as one of the following types: • Electromechanical material test system • Hydromechanical material test system • Vehicle test system • Vehicle component test system • Aero test system Prepare to perform troubleshooting while on the
Problem Submittal Form in MTS Manuals Access the Problem Submittal Form: • In the back of many MTS manuals (postage paid form to be mailed to MTS) • www.mts.
Problem Submittal Form in MTS Manuals 14 Technical Support Models FlexTest® IIm/GT/SE Controller Hardware
Before You Begin Preface Before You Begin Safety first! Other MTS manuals Before you use your MTS product or system, read and understand the Safety manual and any other safety information provided with your system. Improper installation, operation, or maintenance can result in hazardous conditions that can cause severe personal injury or death, or damage to your equipment and specimen. Again, read and understand the safety information provided with your system before you continue.
Documentation 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.
Documentation 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.
Documentation Conventions 18 Preface Models FlexTest® IIm/GT/SE Controller Hardware
Chapter 1 Introduction This manual contains installation, cabling, jumpering, and hardware interfacing information for MTS 793 Controllers. This chapter describes the hardware components and specifications of FlexTest GT, FlexTest SE, and FlexTest IIm Controllers. Contents FlexTest GT Controllers 20 Model 493.10 Chassis Hydraulic Control Interlocks 22 22 Specifications 23 FlexTest SE Controllers 24 Model 493.
Model 493.10 Chassis FlexTest GT Controllers MTS FlexTest GT Controllers are fully digital Proportional, Integral, Derivative, Feedforward (PIDF) servocontrollers which use an identical chassis configuration. They provide complete control of up to eight channels distributed among up to eight stations. Optional station configurations are available (see “Hydraulic Configurations” on page 243). Model 493.10 Chassis FlexTest GT Controllers use the Model 493.10 Chassis. The Model 493.
Model 493.10 Chassis Front panel The Model 493.10 Chassis front panel has twelve slots; ten VMEbus slots and two slots (A and B) which are reserved. Rear panel The rear panel of the chassis has twelve transition bus slots. Two of these rear panel slots (slots A and B) can not be used with powered MTS transition modules. The chassis can be rack mounted or used in a floor standing configuration.
Hydraulic Control Cooling The chassis is cooled with a fan. An overtemperature sensor is part of the standard power supply assembly. If the internal chassis temperature exceeds 50ºC, this sensor will light an amber indicator located on the rear of the power supply module. Hydraulic Control Hydraulic control is handled with two transition modules: • The Model 493.73 HPU Transition module has a connection to control a hydraulic power unit.
Specifications Specifications FlexTest GT Specifications PARAMETER SPECIFICATION Environmental For indoor use only Temperature 5ºC–40ºC (41ºF–104ºF) Relative humidity 10%–85%, noncondensing Altitude For use at altitudes up to 2000 m (6500 ft) Power input Input voltage* 100–240 V AC Input frequency 47–63 Hz Input surge <100 A Power <1000 W Insulation over voltage Category II Pollution degree 2 Power supply #1 maximum draw is 400 W total +5 V DC 40 A ±15 V DC 7.
Specifications FlexTest SE Controllers The MTS Model 493.02 FlexTest SE Controller is a fully digital Proportional, Integral, Derivative, Feedforward (PIDF) servocontroller. It provides complete control of one servohydraulic channel or station in an MTS test system. FlexTest SE Controller FlexTest SE front panel controls The FlexTest SE may be operated in the standalone mode from its front panel controls, or in the automated mode with MTS Model 793.00 System Software running on a connected PC.
Specifications FlexTest SE stand-alone function generation A function generator (with a built-in cycle counter) in the controller provides basic sine, square, triangle, and ramp command waveforms. For tests requiring complex waveforms, the controller provides an external command input to receive externally generated commands. The function generator waveform can be output to another MTS FlexTest SE Controller (or any external device) for synchronization.
Model 493.02 Chassis Model 493.02 Chassis FlexTest SE Controllers use the Model 493.02 Chassis. The Model 493.02 Chassis is a single-station, single-channel VMEbus chassis which, in a typical configuration, houses three plug-in modules: Model 493.02 Chassis rear panel • A Series 498 Processor • A Model 493.40 I/O Carrier module • A Model 493.42 System I/O module Except for two front panel BNC connectors, all cabling is accessed through the controller’s rear panel.
Specifications Specifications FlexTest SE Specifications PARAMETER SPECIFICATION Environmental For indoor use only Temperature 5ºC–40ºC (41ºF–104ºF) Relative humidity 10%–85%, noncondensing Altitude For use at altitudes up to 2000 m (6500 ft) Power input Input voltage* 100–240 V AC Input frequency 47–63 Hz Input surge <50 A Insulation over voltage Category I Pollution degree 2 Weight * power factor corrected universal input approximately 8.
Specifications FlexTest IIm Controllers The MTS FlexTest IIm Controller is a fully digital Proportional, Integral, Derivative, Feedforward (PIDF) servocontroller. FlexTest IIm Controllers The FlexTest IIm configuration provides complete control of up to sixteen channels distributed among up to four stations in an MTS test system. The FlexTest IIm Controller is available in five standard configurations.
Specifications FT IIm standard configurations Console • 4, 6, 8, 12, or 16 channels of control • 16 inputs and 16 outputs of user DIO • Per channel resources: – One valve driver output – One D/A output – One A/D input – One AC Conditioned input – Two DC conditioned inputs The FlexTest IIm Controller is available in a full-bay (vertical) console, a tabletop console, or a roll-around console.
Model 497.01 Analog Chassis Model 497.01 Analog Chassis The plug-in modules installed in the 497.01 Analog Chassis provide four main functions: • Interlock control—An interlock control plug-in module provides programmable interlock signal mapping between the test processor and the modules installed in this analog chassis. • Processor/Analog Chassis communications—A communications module provides data conversion between the test processor and the 497 analog plug-in modules.
Model 497.05 Hydraulic Control Panel Model 497.05 Hydraulic Control Panel The hydraulic control panel provides the following functions. • Control of up to four independent hydraulic service manifolds • Hydraulic power supply control • Interlock shutdown and latched indicators to show interlock status • Programmable interlock station assignment • Electrical power outputs to the hydraulic service manifolds and a 497.
Model 498.22 Chassis with Test Processor (FTIIm) Model 498.22 Chassis with Test Processor (FTIIm) The Model 498.22 test processor chassis is a VMEbus chassis that houses up to twelve plug-in modules (including processor modules, ADDA modules, digital I/O modules, and so forth). It also accommodates various rear-panel transition modules (for connections to other hardware chassis and external equipment). Note The test processor is covered by a tinted, removable front panel.
Specifications Specifications Model 497.01 Specifications PARAMETER SPECIFICATION Environmental For indoor use only Temperature 5ºC–40ºC (41ºF–104ºF) Relative humidity 10%–85%, relative, noncondensing Power requirements +15 V at 6 A; -15 V at 6 A; +5 V at 6 A (standard supply maximum output, actual load depends on installed modules) Dimensions Height 17.8 cm (7 in) Width 48.3 cm (19 in) Depth 31.1 cm (12.25 in) Model 497.
Specifications Model 497.05 Specifications (part 2 of 2) PARAMETER SPECIFICATION Interlock logic level inputs 0 = 0 V DC 1 = 3.2 to 24 V DC Dimensions 34 Introduction Height 8.9 cm (3.5 in) Width 48.3 cm (19 in) Depth 54.6 cm (21.
Specifications Model 498.22 Chassis Specifications PARAMETER SPECIFICATION Dimensions Height 40 cm (15.75 in) Width 48.3 cm (19 in) Depth 55.9 cm (22 in) Weight 18 kg (40 lb) plus 0.5 kg (1 lb) per module Rack mounting requirements: Clearance-each side 5.7 cm (2.25 in) for air flow Clearance-back 15.3 cm (6.
Specifications 36 Introduction Models FlexTest® IIm/GT/SE Controller Hardware
Chapter 2 Installation This chapter describes how to install the Controller chassis and connect it to system components. Contents Installing the Model 493.10 Chassis (FTGT) 37 Installing the 493.02 Chassis (FlexTest SE) 49 Installing 497/498 Electronics (FTIIm) 61 Installing the Model 493.10 Chassis (FTGT) The chassis can be installed in an equipment rack console or in a standalone configuration. CAUTION The Model 493.10 Chassis weighs about 45 kg (100 lb) in stand-alone configuration.
Connecting Electrical Power Stand-alone installation The stand-alone chassis can be placed on the floor. The chassis location is limited only by the length of the system cables. The front panel of the chassis can be removed to access the VMEbus plug-in modules. Console installation The rack-mounted chassis can be installed in any Model 490.8x console. Install the console with the 493.10 Rack Mounting kit (056-139-502 for FlexTest GT).
Connecting Electrical Power Note Grounding Local electrical codes supersede any information found here. The chassis will not function correctly if it is not grounded as shown. Be sure your power source is also properly grounded. The chassis includes two grounds: a chassis ground and a signal ground. The two grounding lugs are connected together with an external shorting bar when the chassis is manufactured.
Connecting Electrical Power CAUTION Proper grounding is required for safe operation. It is also required to meet EMC emission and susceptibility requirements. Power All equipment related to the chassis should be connected on the same fused power circuit. The power supply can accept single-phase voltages within 90–264 V AC at frequencies between 47–63 Hz. AC power disconnect 40 Installation • The maximum continuous power usage is approximately 1000 W.
Connecting Electrical Power Note Be sure to locate the chassis so you have adequate access to disconnect the power cord from the chassis.
Installing the Plug-in Modules Installing the Plug-in Modules This section describes how to install the plug-in modules into the chassis. The modules plug into a backplane connector and are secured to the chassis with a screw at the top and at the bottom of the module faceplate. A hardware interface file (.hwi file extension) defines each type of module and maps each module location for the system software. The .hwi file and the physical locations for each type of module must match.
VMEbus Modules VMEbus Modules The VMEbus compatible modules should be installed in the front panel chassis slots according to the following guidelines. Placement of VMEbus modules in the front panel chassis • The processor module(s) must be located in the first (and second) slots. • The GRESIII module (if used) should be located in slot 10. It may also be located in slot 2 if a second processor is not used. • I/O carrier modules and/or ADDA II modules can be installed in slots 3 to 10.
VMEbus Modules Setting I/O Carrier addresses Use the dipswitch (S1) and rotary dipswitch (S2) on each I/O Carrier module to set its address in accord with its installed chassis slot as follows: SLOT 2 ADDRESS 1 PPC Setting I/O Carrier module addresses 3 4 5 6 7 8 9 10 C20 C22 C24 C26 C28 C2A C2C C2E The dipswitch settings for address C20 is shown below. Increment the rotary dipswitch as required to complete I/O Carrier module addressing.
VMEbus Modules The rotary dipswitch settings for address C40 are shown below. Increment the front panel dipswitch as required to complete ADDA II module addressing. E C A 9 F 8 0 7 S3 1 6 2 3 4 5 E C A 9 F 8 0 1 6 7 E C A 9 2 3 4 5 S2 F 8 0 7 1 6 2 3 4 5 On ADDA II Front Panel Front Panel VMEbus Modules MODEL MODULE NAME FUNCTION 493.40 I/O Carrier Supports up to four mezzanine cards. 493.
VMEbus Modules I/O Carrier Mezzanine Cards (part 2 of 2) MODEL MODULE NAME FUNCTION 493.46 D/A Converts up to six internal digital signals to analog signals for use by external devices. 493.47 Encoder Processes the signals from an encoder or a Temposonics III transducer with an SSI interface. 493.48 Acceleration Conditioner Processes the signals from an accelerometer. Each Acceleration Conditioner mezzanine card can support up to three accelerometers.
Installing the Transition Panels Installing the Transition Panels The transition panels need to be installed in specific slots of the rear panel chassis. This is done to allow proper air flow in the chassis. For consistency, install the modules according to the following guidelines. Starting from the left chassis slot (slot 10) and working to the right, install the modules as shown. If you do not have one of the modules, install the next one you do have.
Installing the Transition Panels Note Other transition modules may be used, contact MTS Systems Corporation for additional information. Rear Panel Transition Panels MODEL 48 MODULE NAME FUNCTION 493.71 RS485 Provides four channels of RS-485 interface, four channels of station stop interlocks, and four channels of emergency stop interlocks. The RS-485 interface channels are used for the Remote Station Controller and/or temperature controller. 493.
Installing the Plug-in Modules Installing the 493.02 Chassis (FlexTest SE) This section describes how to install the MTS FlexTest 493.02 chassis and connect it to your system components. Contents Installing the Plug-in Modules VMEbus Modules 42 50 Chassis Installation Options 51 Connecting Electrical Power Installing the Handle Kit 53 58 Installing the Plug-in Modules This section describes how to install the plug-in modules into the chassis.
VMEbus Modules VMEbus Modules The VMEbus compatible modules should be installed in chassis slots according to the following guidelines. • The processor module is installed in slot 1 • The I/O carrier module is installed in slot 2. • The System I/O module is installed in slots 4 and 5.
Chassis Installation Options Model 493.40 I/O Carrier Mezzanine Cards MODEL MODULE NAME FUNCTION 493.14 Valve Driver Produces the control signal for a Series 252 Servovalve. 493.15 3–Stage Valve Driver Produces the control signal for a Series 256 or 257 Servovalve. 493.25 Universal Conditioner Processes the signals from either an AC or DC-type sensors. 493.45 A/D Converts up to six external analog signals to digital signals for use by the controller. 493.
Chassis Installation Options Rack mounting requirements When installing the chassis in an equipment rack allow a minimum of 2 in. (5.1 cm) on either side of the controller for air flow. There are no spacing requirements for the top or bottom of the controller. If the equipment rack is equipped with doors, allow adequate clearance for the front and rear of the controller. The rear of the controller requires a minimum clearance of 6 in. (15.24 cm) to accommodate cables.
Connecting Electrical Power Connecting Electrical Power Electrical connections must be made by qualified personnel and conform to local codes and regulations. An electrical service panel to provide the electrical power feed (line voltage) to the chassis is not necessary, but may be required by local electrical codes. Note Grounding Local electrical codes supersede any information found here. The chassis will not function correctly if it is not grounded as shown.
Connecting Electrical Power Rack Mount Configuration Chassis ground cable (PN 037-766-102) connected to the vertical conductive rail. Signal common cable (PN 037-766-101) connected to the power panel. System ground cable (PN 005-402-3xx) connected to the test frame or other components. The AC power ground is through the power cord. The power cord must be plugged into both the chassis and the power source for proper grounding. CAUTION Proper grounding is required for safe operation.
Connecting Electrical Power Power AC power disconnect All equipment related to the chassis should be connected on the same fused power circuit. • The power supply can accept single-phase voltages within 90–264 V AC at frequencies between 47–63 Hz. • The maximum continuous power usage is approximately 300 W. The current draw depends on the local voltage supply. A 15 amp line will be adequate for the chassis and the computer.
Connecting Electrical Power Note Be sure to locate the chassis so you have adequate access to disconnect the power cord from the chassis.
Connecting Electrical Power Rack Mounted Configuration Outlet Strip or Power 100–240 VAC 50–60 Hz, 12–6A R UN 6TS ABT TYPE E PC-M IP TYP E EP C-M IP BFL RST DEBUG PC I M E ZZ AN NE C ARD Power Panel Models FlexTest® IIm/GT/SE Controller Hardware Installation 57
Installing the Handle Kit Installing the Handle Kit The controller may be equipped with an optional handle kit. The following procedure provides assembly and installation instructions for the handle kit (MTS PN 100-061-494). The following table and figure show the handle kit assembly components described in the procedure.
Installing the Handle Kit 9 8 2 1 4 3 5 12 (handle-not shown) 6 7 10 11 13 Handle Kit 1. Place one support arm (1) into one handle side leg (2), as shown in the handle kit assembly figure. 2. Set one of the clips (3) in place over the slender, straight portion of the support arm (1), just behind the circular end of the support arm. 3. Insert two washers (4) and a screw (5) through the mounting hole in the handle side leg (2). 4.
Installing the Handle Kit 7. Insert a Phillips screwdriver through the hole in the button (7) and lightly tighten the screw (5). 8. Assemble the remaining handle kit components to the other handle side leg (2) according to steps 1 through 7 and mount the side leg to the mounting holes on the opposite side of the controller. 9. Insert a lock washer (10) and handle screw (11) through the mounting hole at the end of one handle side leg (2) and lightly tighten to handle (12).
Connecting the Console and Chassis Power Installing 497/498 Electronics (FTIIm) Contents Connecting the Console and Chassis Power Grounding the Console and Chassis Model 497.01 Analog Chassis About Analog Chassis Slots 61 62 63 63 Analog Chassis Plug-in Modules 64 Analog Chassis Transition Modules 66 Adding an Analog Chassis to Your Console Model 497.
How To Cable the Analog Chassis to the Hydraulic How To Cable the Analog Chassis to the Hydraulic Control Panel Connect J50 DC Pwr on the 497.01 Analog Chassis rear panel to J50 on the 497.05 Hydraulic Control Panel rear panel. 497.05 Hydraulic Control Panel PN 046-239-1xx J1 497.01 Analog Chassis J50 Grounding the Console and Chassis The system will not function correctly if it is not grounded properly. The power ground and chassis ground terminals are wired together when the chassis is manufactured.
Model 497.01 Analog Chassis Model 497.01 Analog Chassis About Analog Chassis Slots Slot pairing Slot assignments Chassis slot assignments are grouped in pairs. If you have a conditioner in a slot, then you cannot have a valve driver installed in the slot paired with it. Slots are paired as follows: Slots 1–2 Slots 9–10 Slots 3–4 Slots 11–12 Slots 5–6 Slots 13–14 Slots 7–8 Slots 15–16 The analog chassis contains 18 bus-board slots for plug-in modules.
Analog Chassis Plug-in Modules Analog Chassis Plug-in Modules Before you install any plug-in modules, be sure they are configured properly for your system. The following is a brief description of the plug-in modules available for the chassis. Plug-in Modules MODEL # PLUG-IN MODULE NAME FUNCTION 497.13* AC Conditioner Processes signals from AC-type sensors such as LVDTs or RVDTs. Note This module was designed to replace the Model 497.14 AC Conditioner. 497.
How to Install or Remove a Plug-in Module How to Install or Remove a Plug-in Module CAUTION Plug-in modules are static sensitive. Do not install or remove a module with electrical power on. Do not place modules that contain battery backup on a metal surface. Touch the console or other ground point before handling a module. Avoid making physical contact with any circuitry on the modules.
Analog Chassis Transition Modules Analog Chassis Transition Modules Transition modules located on the Model 497.01Rear Panel provide signal transfer between the Model 497 modules and external devices. One digital transition module and up to eight analog transition modules can be installed in this chassis. Each transition module plugs into the backplane connectors and connects to two chassis slot locations.
Transition Module Connectors Transition Module Connectors Cable connections to external devices are made from the 497.01 chassis rear panel connectors. J101–J1601 System connectors J101 through J1601 (JX01) are 15-pin D-type connectors located on the chassis rear panel. They connect either a valve driver to a servovalve or a conditioner to a transducer.
Transition Module Connectors Single chassis configuration Multichassis configuration If you have a single analog chassis: First install a cable from a Series 498 host computer serial port (debug) to J51 Intlk In on the Model 497.05 Hydraulic Control Panel, then from J52 Intlk Out to J51 Intlk In on the Model 497.01 Analog Chassis. Then install jumper plug assembly (PN 046-350-701) to J52 Intlk Out on the analog chassis. If you have a multiple analog chassis: 1.
Adding an Analog Chassis to Your Console Adding an Analog Chassis to Your Console To accommodate higher channel counts, it may be necessary to add one or more Model 497.01 Analog Chassis’ to your FlexTest IIm console. Depending on the number of analog chassis installed, you may have to modify switch settings and jumpers on the communication boards in your 497.05 Hydraulic Control Panel and in the 497.01 Analog Chassis. The analog chassis and the hydraulic control panel use identical communication boards.
Adding an Analog Chassis to Your Console Jumper and switch locations The following graphic illustrates the jumper locations on the Model 497.36 Communication Module.
Model 497.05 Hydraulic Control Panel Model 497.05 Hydraulic Control Panel The rear panel connectors of the hydraulic control panel are cabled to the hydraulic components of your system. The connectors also interface with the Model 497.01 Analog Chassis and Model 498.22 Test Processor chassis. J28D J15D J15C J15B J15A J16D J16C J16B J16A J17D J17C J17B J17A J28C J28B J9 Mstr/Slv J8 J41 J42 Hyd Enab Com In Com Out J51 Intlk In J52 Intlk Out I O J28A J26 Remote E-Stop J1 497.
Test Processor Plug-in Modules Test Processor Plug-in Modules The following table provides a brief description of the plug-in modules installed in your test processor chassis. Test Processor Plug-In Modules MODULE FUNCTION Processor Modules Standard FlexTest IIm Controllers have two processors installed in the Model 498.22 Chassis: • The first processor (in slot 1) communicates with the external computer. • The second processor (in slot 3) performs the digital control functions.
Test Processor Plug-in Modules ADDA II mezzanine cards MODULE NAME FUNCTION 493.55 A/D Converts up to eight external analog signals to digital signals for use by the controller. This board requires the optional ADDA II module. 493.56 D/A Converts up to eight internal digital signals to analog signals for use by external devices. This board requires the optional ADDA II module. 493.57 DSPAD Converts up to eight external analog signals to digital signals for use by the controller.
Test Processor Transition Modules Test Processor Transition Modules Transition modules are screwed into the back of the test processor chassis. Each rear-panel transition module corresponds to a plug-in module (or plug-in module mezzanine card) installed in the front of the chassis. Transition modules interface with the other test components via connectors for external digital, analog, and communication cables.
Test Processor Transition Modules Test Processor Transition Modules TRANSITION MODULE FUNCTION 498 Analog Out This module includes eight BNC connectors that provide analog outputs from the Model 498.65 ADDA module. These outputs are associated with a D/A mezzanine card. Four analog outputs are available with the standard ADDA module. Additional outputs require a second ADDA module (or an optional fourth mezzanine card).
UPS Systems UPS Systems 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 Systems for FlexTest 40 and FlexTest SE 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.
Specifications–UPS Systems Used with MTS 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 Connections for the Model 493.73 HPU 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.
UPS Connections for the Model 493.42 System UPS Connections for the Model 493.42 System board (FlexTest SE ) The following drawing shows UPS connections for the Model 493.42 System board. Once connected, you must use your controller software to configure the various UPS options. UPS 493.
Chapter 3 FlexTest GT Controller Connections This section describes the cable connections to the Model 493.10 Chassis. Note Contents For information on connecting power cables, see “Connecting Electrical Power” on page 38. CE EMC Compliant Cabling Typical Cabling 83 84 Cable Part Numbers 85 Model 493.
Digital I/O Connections 141 Workstation Connection 145 Remote Station Controller Connection Service Connections 147 149 Cabling and Programming Series 407 Controllers 151 How to Provide Program to a Series 407 Controller Connecting Interlock Signals to 407 Controllers 151 156 Sending and Receiving Signals to a Model 407 Controller Connecting Interlock Signals to 458 Controllers Eurotherm Temperature Controller Connection Miscellaneous Conditioner Output Connections Cabling for External Command I
CE EMC Compliant Cabling CE EMC Compliant Cabling CE EMC compliant cabling is required for all systems shipped to Europe. All cabling specifications in this chapter conform to the European CE EMC requirements. Cable fabrication All of the cables listed on the Cable Selector drawing are CE EMC compliant when used in an MTS system. Where possible, use standard cables listed on the System Cable Plug 493 Package Selection drawing (PN 700-000-656).
Typical Cabling Typical Cabling For additional cables, see “Cable Part Numbers” on page 85. r r Hydraulic Power Unit Control HPU 039-713-7xx Workstation 051-996-8xx Servovalve 039-708-3xx 056-126-5xx Load Unit Control 056-126-4xx l l MTS Sysrtems Corp 14000 Technologyu Dr.
Cable Part Numbers Cable Part Numbers System cables The following is a list of the most common cables, see the System Cable/Jumper Plug 493 Package Selection drawing (MTS PN 700-000-656) for the most current and additional cable part numbers. System Cables (part 1 of 2) CABLE DESCRIPTION PART NUMBER* MODULE CONNECTOR JUMPER PLUG† Servovalve 252.xx single 039-708-300 493.40 J4–J7 N/A Servovalve 252.xx dual 039-708-400 493.40 J4–J7 N/A 055-4396XX 039-7086XX 100-026-213 493.40 J4–J7 493.
Cable Part Numbers System Cables (part 2 of 2) CABLE DESCRIPTION PART NUMBER* MODULE CONNECTOR JUMPER PLUG† HPU 505 or 24V PLC Pump (for more information see “Hydraulic Configurations” on page 243) 039-7137XX 493.73 J25 039-713-301 HSM 298.11 on/off HSM Proportional 298.12 HSM 290.xx/293.xx/294.xx high/low 039-7015XX 056-1264XX 039-7014XX 493.74 J28 N/A Interlock—Test Enclosure 056-1263XX 493.74 J43 100-007-948 Interlock—Station per system 493.
Model 493.40 I/O Carrier Connections Model 493.40 I/O Carrier Connections Each Model 493.40 I/O Carrier module can include up to four mezzanine cards. Each installed mezzanine card is assigned a specific I/O Carrier module front panel connector (J4–J7 I/O). A hardware interface file (hwi) defines each type of module (and their associated mezzanine cards) and maps each module location for the system software. The .
Sensor Connections Sensor Connections Sensor connections require a conditioner mezzanine card be installed in the I/O Carrier module. The following conditioners can be installed: Note Model 493.21B Digital Universal Conditioners are not compatible with stand-alone FlexTest SE Controllers. • Model 493.21B Digital Universal Conditioner • Model 493.21BC Digital Universal Conditioner • Model 493.25 Digital Universal Conditioner • Model 493.47 Encoder • Model 493.
Sensor Connections Excitation and feedback signals are passed through to the transducer, as shown. To/From Conditioner J4 - J7 1 + Excitation 2 - Excitation 3 Guard 4 + Feedback 5 - Feedback To/From Transducer If purchased as an option, a transducer ID module is located in the transducer cable. Excitation and feedback signals are passed through to the transducer.
Sensor Connections LVDT connections An LVDT requires an AC conditioning mezzanine card. E7 7 Inner Guard 3 3 -FB 5 5 E3 Backshell AC Sensor (LVDT) E5 Transducer ID Module +FB 4 4 -EX 2 2 +EX 1 1 Remote Cal 9 9 Clk 8 Data to ID 11 Data from ID 14 Sig Gnd 6 8 11 14 6 Temposonics II E4 E2 E1 Remote Cal ID Circuit The connection requires a DC conditioning mezzanine card.
Sensor Connections Temposonics III TO 493.74 AUX POWER The connection requires a DC conditioning mezzanine card. +24 V COM +24 V COM TO 493.
Model 493.21B (DUC B) Jumpers Force/strain sensor connections Force and strain sensors require a DC conditioning mezzanine card. GND Inner Guard 3 -FB 5 -FBR 13 7 E7 3 E3 Backshell E5 5 13 Future DC Sensor Transducer ID Module E4 +FB +FBR -EX -EXS +EX +EXS 4 12 2 15 1 10 4 12 Future 2 15 Future 1 10 Future Remote Cal Clk Data to ID Data from ID Sig Gnd 9 8 11 14 6 9 Remote Cal 8 11 ID Circuit 14 6 E2 E1 Model 493.21B (DUC B) Jumpers The following jumpers are for the Model 493.
Model 493.21B (DUC B) Jumpers 4- or 8-wire sensor cable Jumpers W2 and W3 establish the correct shunt calibration connections for 4wire and 8-wire sensor cables. The length of the sensor cable determines which type of cable is used. Short cables are typically 4-wire cables while long cables are typically 8-wire cables. • Jumper W2 selects a 4- or 8-wire transducer for positive feedback. • Jumper W3 selects a 4- or 8-wire transducer for negative feedback.
Digital Universal Conditioner (DUC BC) Switches Excitation Jumpers W5 and W7 select the local (on board) or remote (through a cable) excitation sensor connection. • The local selection is used with 4-wire transducer connections. • The remote selection is used with 8-wire transducer connections. • Jumper W7 configures the + excitation signal. • Jumper W5 configures the – excitation signal. • Both jumpers need to be set for the same configuration.
Digital Universal Conditioner (DUC BC) Switches 4- or 8-Wire sensor cable Switches S1-1, S1-2, S1-3, and S1-4 establish the correct shunt calibration connections for 4-wire and 8-wire sensor cables. The length of the sensor cable determines which type of cable is used. Short cables are typically 4-wire cables while long cables are typically 8-wire cables. • Switches S1-1 and S1-2 select a 4- or 8-wire transducer for positive feedback.
Digital Universal Conditioner (DUC BC) Switches Bridge balance Switch S1-5 changes the offset of the bridge balance circuit. If the zero offset is too large when the sensor bridge is balanced, you should enable this feature (it adds a 100 kΩ resistor to the input of the conditioner preamp). Disable Enabl S1-5 OFF S1-5 ON Default Excitation sense Switches S1-6 and S1-7 select the local (on board) or remote (through a cable) excitation sensor connection.
Full-Range Digital Universal Conditioner (FRDUC) Full-Range Digital Universal Conditioner (FRDUC) Jumpers The following jumpers are for the Model 493.25 Full-Range Digital Universal Conditioner. The jumpers are labeled W instead of X; the W jumpers are solder pads. The following jumper descriptions are from the 493.xx Module Setup configuration drawing (PN 049-336-301). Active guard Jumper W1 enables or disables an active guard for the sensor cable. A passive guard drive is the default.
Full-Range Digital Universal Conditioner (FRDUC) Excitation sense Jumpers W5 and W7 select the local (on board) or remote (through a cable) excitation sensor connection. • The local selection is used with 4-wire transducer connections. • The remote selection is used with 8-wire transducer connections. • Jumper W7 configures the + excitation signal. • Jumper W5 configures the – excitation signal. • Both jumpers should be set for the same configuration.
Full-Range Digital Universal Conditioner (FRDUC) Bridge balance R32 changes the offset of the bridge balance circuit. If the zero offset is too large when the sensor bridge is balanced, you should add an appropriately sized resistor.
Sensor Cables Sensor Cables A typical system is provided with a standard set of sensor cables as specified on the System Cable/Jumper Plug 493 Package Selection drawing (PN 700-000656). Refer to this drawing for the most current part numbers. Standard sensor cables do not have ID modules. Sensor cables with an ID module built into them are available as an option. Sensor cables with ID modules use a system cable to bridge the sensor cable to the appropriate connector on the rear panel of the chassis.
Sensor Cable Part Numbers Sensor Cable Part Numbers Sensor cables without ID Module See the System Cable/Jumper Plug 493 Package Selection drawing (PN 700-000656) for the most current sensor cable part numbers. Sensor Cables and Connectors CABLE DESCRIPTION CABLE CONNECTOR ADT 056-234-8XX 056-253-1XX 493.40 J4–J7 493.40 J4–J7 Extensometer 633 capacitive 051-649-5XX 493.40 J4–J7 Force Transducer w/PT connector with MS connector with PC 046-440-2XX 046-440-6XX 056-252-9XX 493.40 J4–J7 493.
Sensor Cable Part Numbers Sensor cables with ID Module See the System Cable/Jumper Plug 493 Package Selection drawing (PN 700-000656) for the most sensor cable current part numbers. Each sensor includes a cable with an ID module built into it. Use a system cable to bridge the sensor cable to the rear panel of the controller chassis. Sensor Cables and Connectors (ID Module) CABLE DESCRIPTION ID MODULE W/CABLE SYSTEM CABLE* MODULE CONNECTOR ADT 052-543-5XX 052-443-6XX 056-125-8XX 056-125-9XX 493.
Shunt Calibration/Bridge Completion Resistor Shunt Calibration/Bridge Completion Resistor Installation On a typical system, shunt calibration and bridge completion resistor installation is completed on the I/O Carrier module. If you have purchased optional sensor cables with transducer ID modules, shunt calibration and bridge resistors are installed on these modules.
I/O Carrier Module The following figures show three typical bridge configurations for a DC conditioner installed on an I/O Carrier module.
I/O Carrier Module Models FlexTest® IIm/GT/SE Controller Hardware FlexTest GT Controller Connections 105
Transducer Identification Modules Transducer Identification Modules Transducer ID modules (located at the end of the sensor cable) are optional components that can store sensor calibration information just like a sensor calibration file. Since the calibration information stays with the sensors, transducer ID modules make it easier to change sensors. Calibration information can be stored in the transducer ID EEPROM or in a sensor calibration file.
Transducer Identification Modules The following is the schematic diagram of the bridge balance and bridge completion circuit. Sensor ID Module -FB +EX Rcomp (R6) -FBR Rg Vin Pre-amp Rcomp (R7) -FB +FB +FB Rcomp (R8) Vout -EX Note For information about assigning sensors and saving data with Transducer ID Modules, see the MTS 793 Control Software manual.
Valve Connections Valve Connections The following types of valve connections are supported: • Single or dual Series 252 Servovalve(s) can be controlled with a Model 493.14 Valve Driver mezzanine card. • A Series 256 Servovalve can be controlled with a Model 493.15 3 Stage Valve Driver mezzanine card. • A Series 257 Servovalve can be controlled with a Model 493.15 3 Stage Valve Driver mezzanine card and a Model 448.16C Power Driver chassis.
Valve Connections Series 252 Servovalve connections From I/O Carrier J4 - J7 The Series 252 Servovalve is a 2-stage servovalve. The Model 493.14 Valve Driver supports single or dual valve configurations. The following figure shows the connections at the valve driver and the connections between the valve and the valve driver. To connect the valve to the I/O Carrier modulesee “Cable Part Numbers” on page 85.
Valve Connections Series 256 Servovalve connections To/From I/O Carrier J4 - J7 The Series 256 Servovalve is a 3-stage servovalve. The Model 493.15 Valve Driver supports the inner loop signals. The following figure shows the connections between the valve driver and the valve. To connect the valve to the I/ O Carrier module, see “Cable Part Numbers” on page 85.
Valve Connections Series 257 Valve connections The Series 257 Servovalve is a 3-stage servovalve that requires a power driver. The Model 493.15 Valve Driver supports the inner loop signals. The following figure shows the connections between the valve driver and the valve. To connect the valve to the I/O Carrier module, see “Cable Part Numbers” on page 85.
Multiple Universal Driver Connections Multiple Universal Driver Connections For special applications, the Model 493.79 Multiple Universal Driver (MUD) board provides up to six drivers that can be used to drive standard 252 servovalves. Inputs to this board originate from a Model 493.46 D/A board on a Model 493.40 I/O Carrier Module. A Y-cable (PN 100-006-173) connects the I/O Carrier module (15 pin, D-Type) to J9/J10 on a MUD board (RJ45). 493.40 I/O Carrier Front Rear 493.
Multiple Universal Driver Connections Output connections Each valve driver output is an RJ50 connection that contains two valve drive output lines and a cable loss detection loop. Cable loss detection The cable loss detection wire loops out to the servovalve and back to the driver output allowing MUD board logic to detect a cable break or a cable disconnect at the MUD board output. A cable loss will not be detected if the cable is disconnected at the servovalve.
Analog I/O Connections Analog I/O Connections The Model 493.45 A/D and Model 493.46 D/A mezzanine cards are installed in the Model 493.40 I/O Carrier front panel module. A connection from the front panel mezzanine card to a rear panel BNC transition module allows easy access to the analog channels. Note The external analog source can be a stand-alone function generator, another controller, or a computer controlled analog output. External Analog Source 493.40 I/O Carrier Select Waveform 410.
Analog I/O Connections Analog inputs The analog-to-digital mezzanine cards accommodate up to six analog input signals. Each A/D input signal must be within ±10 volts. To A/D From A/D J4 - J7 1 + 2 - 3 4 + 5 - 6 7 + 8 + 9 10 + 11 12 + 13 + 14 - Input 1 Analog Ground Input 2 Analog Ground Input 3 Input 4 Input 5 Input 6 15 • Use pin 3 or 6 to prevent problems with floating grounds between devices. • Analog inputs can be connected at the BNC connectors of a Model 493.
Analog I/O Connections Model 493.77 Filter Modules The following filter modules are available for board mounting at the BNC connectors of a Model 493.
Analog I/O Connections D/A Connections Digital-to-analog mezzanine cards support up to six program or readout signals to external devices. Each D/A signal is an analog output within ±10 volts. From D/A To External Device J4 - J7 1 + 2 - Output 1 3 4 + 5 - Output 2 6 7 + 8 Output 3 9 + 10 - 11 12 + Output 5 - 13 + 14 - Output 4 Output 6 15 • Each readout signal is from a 16 bit digital to analog converter. • Each output is a ±10 V analog output. • The Model 493.
Analog I/O Connections Cable specification The cable specifications apply to both the analog inputs and analog outputs. The cable from the front panel of the I/O Carrier module has the following specification: • 15-contact type D male EMI connector. • Backshell–EMI metallized plastic. • Cable type–up to 6 shielded twisted pairs, each with the drain wire connected to the signal source.
Accelerometer Connections Accelerometer Connections An accelerometer requires the Model 493.48 Acceleration mezzanine card (installed in a Model 493.40 I/O Carrier module) and the Model 493.78 Accelerometer Transition Board. • Each Model 493.48 Acceleration mezzanine card supports up to three accelerometers. • The transition board accommodates two types of accelerometers: Low impedance Voltage Mode (LIVM) type accelerometers and High Level Signal Conditioned type accelerometers. 493.
Accelerometer Connections In the example shown below, the Acceleration Conditioner supports three accelerometers. The indicated three jumpers must be set on the I/O Carrier module.
Encoder Connections Encoder Connections I/O Carrier module configuration For an ADDA configuration using an I/O Carrier module, each encoder requires installation of a Model 493.47 Encoder Interface mezzanine card on the Model 493.40 I/O Carrier board. The I/O Carrier connector is based on the location of the mezzanine card installed on the board of the I/O Carrier module. 493.
Encoder Connections Optional ADDA II configuration For the optional ADDA II configuration, each encoder requires installation of a Model 493.59 Universal Encoder mezzanine card on the Model 493.50 ADDA II module. The Model 493.80 Encoder Transition module provides up to four channels of encoder interface between the Model 493.50 ADDA II module and various incremental, Temposonics, or other digital or serial transducers. Daughter Board 1 Daughter Board 2 Front Rear 493.
Remote Setpoint Adjust Connections Remote Setpoint Adjust Connections A Remote Setpoint Adjust (RSA) control is an optional, stand-alone hardware device that uses an incremental or absolute encoder to control actuator setpoints. Each RSA control pod requires installation of a Model 493.47 Encoder Interface mezzanine card on the Model 493.40 I/O Carrier board. The I/O Carrier connector is based on the location of the mezzanine card installed on the board of the I/O Carrier module.
ADDA II Connections ADDA II Connections Each optional Model 493.50 ADDA II module supports up to four mezzanine cards. Each installed mezzanine card is assigned a specific ADDA II module front panel connector (J11–J18). A hardware interface file (.hwi) defines each type of module (and their associated mezzanine cards) and maps each module location for the system software. The hwi file and the physical locations for each type of module and associated mezzanine cards must match.
ADDA II Connections ADDA II Module I/O connections The Model 493.55 A/D, Model 493.57 DSPAD, and Model 493.56 D/A mezzanine cards are installed in the Model 493.50 ADD II module assembly. A connection from the front panel connector to a rear panel BNC transition module allows easy access to the analog channels. Note The external analog source can be a stand-alone function generator, another controller, or a computer controlled analog output.
ADDA II Connections Analog inputs The analog-to-digital mezzanine cards accommodate up to eight analog input signals. Each A/D input signal must be within ±10 volts. • Analog inputs can be connected at the BNC connectors of a Model 493.81 Analog In transition module and the outputs from this module are connected to the Model 493.50 ADDA II module. • Analog inputs can be connected at the BNC connectors of a Model 493.
ADDA II Connections D/A connections Digital-to-analog mezzanine cards support up to eight program or readout signals to external devices. Each D/A signal is an analog output within ±10 volts. • Each readout signal is from a 16 bit digital to analog converter. • Each output is a ±10 V analog output. • The Model 493.56 D/A Mezzanine Card provides analog signals to the Model 493.82 Analog Out transition module. Analog outputs are available at the BNC connectors of a Model 493.
ADDA II Connections ADDA II Universal Encoder connections Each encoder requires a Model 493.59 Universal Encoder mezzanine card installed on the Model 493.50 ADDA II module. Up to four encoders can be connected to the Model 493.80 ADDA II Encoder Transition module when the Model 493.50 ADDA II module is fully populated with Universal Encoder cards.
Emergency Stop Connections Emergency Stop Connections Connectors J23 E-STOP Out and J24 E-STOP In are located on the Model 493.73 HPU transition board. The Emergency Stop switch and signal are part of a controller-wide interlock system. Emergency stop output Connector J23 E-STOP Out provides an output to external devices when an emergency stop signal is generated. The inactive status is shown in the figure.
Emergency Stop Connections J24 E-STOP In is a 15 pin type D female connector. Jumper plug required 130 • 15-contact type D male EMI connector. • Backshell–EMI metallized plastic. • Cable–24 AWG 4 connector with overall foil shield, (Belden 9534 or equivalent) with drain wire connected to metallized plastic backshell at the chassis and to ground at the emergency stop station. If connector J24 is not used, you must install a jumper plug to maintain the integrity of the interlocks.
J25 Hydraulic Power Unit Connection J25 Hydraulic Power Unit Connection Connector J25 HPS on the Model 493.73 HPU transition board controls the hydraulic power unit (HPU). • The module produces 24 V logic signals to control the HPU. • The Model 493.07 HPU Converter Box allows any MTS HPU to be connected to the chassis with the following exceptions: – 506.52-.92 HPUs (24 volt, PLC compatible) – All Series 505 HPUs The converter box is used with other configurations.
J25 Hydraulic Power Unit Connection J25 Diagram To/From Chassis J25 HPS On Sense To/From HPU 9 10 Over Temp Low Level HPS 24 Vdc 11 12 +24 vdc 1 CRM Start Lo 2 1CR Start Relay 3 Motor Relay High E-stop 4 To J24 pin 13 5 To J29 pin 8 6 Controller 24 Vdc 7 8 132 FlexTest GT Controller Connections SOL Hi Pressure Solenoid +24 Vdc CRM HPS Interlock Relay HPS Defeat Voltage (not connected in HPS) Models FlexTest® IIm/GT/SE Controller Hardware
J25 Hydraulic Power Unit Connection System I/O Connector J54 Sys I/O provides three digital inputs and one digital output. The inputs are connected to the high and low inputs of an opto-isolator. The output is from the collector (+) and emitter (-). For circuit drawings, see the “Digital I/O Connections” on page 141.
Station Connections Station Connections Each Model 493.74 HSM transition board controls up to two stations. A standard chassis configuration supports up to four stations. Each station has the following connections • J28 Hydraulic service manifold (HSM) • J29 Load unit • J43 Interlock • J44 Remote run/stop • J49 Auxiliary power As a system option, the Model 493.10 Chassis can be configured to support six or eight stations. See “Optional Station Configurations” on page 255.
J28 Hydraulic Service Manifold Connector Proportional output .hwi file settings The proportional output is configured with the controller software. • The output signal can be ramped from 20 mA (minimum) to 700 mA (maximum) which corresponds with 50 psi (0.4 MPa) and 3000 psi (21 MPa). By default, low pressure is factory set at 500 psi and high pressure is set at 3000 psi. • The ramp rate from zero to high pressure can be set to two or four seconds.
J29 Load Unit J29 Load Unit Connector J29 Load Unit connects to the load unit lift/lock panel. Pins 1, 2, 3, and 4 can be configured for contacts (with jumpers X* and X†) or a logic signal (without jumpers X* and X†).
J43 Interlock J43 Interlock Connector J43 Interlock accommodates two general purpose inputs to be connected to the interlock chain. • Input 1 is dedicated as a station interlock. • Input 2 is dedicated as a program interlock. • Both inputs are optically isolated. • If just one contact is used, the other must be jumped. To Chassis Both inputs can accept relay contacts or a logic signal. Both configurations are shown.
J44 Run/Stop J44 Run/Stop Run/Stop status 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). From Chassis J44 To External Devices 1 Run/Stop 0 2 3 4 + 5 - Interlock Status Output 6 7 Run/Stop 1 8 Interlock status 138 Connector J44 Run/Stop also provides opto-isolator outputs that indicate the interlock status of each station to an external device.
J44 Run/Stop Output specifications Jumper X5 Jumpers W8/W9 Cable specification The specifications for the interlock status opto-isolator outputs are as follows: • Output Format: open collector, open emitter transistor • Maximum Voltage: 26 V DC • Minimum Guaranteed Output Current Drive: 20 mA (30 mA typical) @ 1.0 V max Jumper setting X5 selects the source for interlock status output.
J49 Auxiliary Power J49 Auxiliary Power Connector J49 Aux Pwr provides +5 V DC, ±15 V DC, and 24 V DC from the chassis internal power supply to drive external high level conditioners, proximity switches, solenoids, and so forth. • The outputs are fused at 0.75 A to protect the power supply from an external short. • The fuses can be reset by shutting off power and waiting a few minutes (the fuses automatically reset when cooled) then reapplying power.
Digital I/O Connections Digital I/O Connections The Model 493.72 Digital I/O transition module has two connectors; one provides connections for sixteen digital inputs and the other provides connections for sixteen digital outputs.
Digital I/O Connections Digital inputs The J3 In connector accommodates up to sixteen digital signals from external devices. You can use digital input signals to trigger test events with your controller applications. • All of the inputs are optically isolated and support relay contacts or logic inputs (see the following figure). • Channel inputs can be 3 volts (minimum) and 26 volts (maximum) from an external voltage source. • Jumpers select the debounce time for each group of four inputs.
Digital I/O Connections Digital outputs Connector J4 Out provides sixteen general purpose digital outputs that can send digital logic signals to external switches or logic devices. • Minimum output current drive is 6 mA. Maximum output current drive is 20 mA. Note The maximum output current can vary from unit to unit. The minimum guaranteed output current is 6 mA and the maximum output current is 20 mA. You can connect the digital outputs in parallel to increase the current drive.
Digital I/O Connections Digital I/O access panel The digital inputs and outputs can be cabled to an optional digital I/O access box. The box is a convenient way to wire digital sources and destination to the Model 493.72 Digital I/O transition module. 493.72 Digital I/O +12V J3 IN Connectors J10 and J20 on the side of the module and on top of the module are the same. The top connectors are used when the module is configured for use in a console.
Workstation Connection Workstation Connection The workstation computer is connected to the Model 498.96 Processor module installed in the VMEbus of the chassis. It is an Ethernet 10/100 Base-T connection. The workstation computer must have a dedicated Ethernet compatible connector. 498.98-2 Power PC ABT BFL CPU RST PMC m Note m Models FlexTest® IIm/GT/SE Controller Hardware If your processor has more than one Ethernet 10/100 Base T connection, use the connection labeled LAN 1.
Workstation Connection CAUTION The symbol shown here indicates that you must not connect telecommunications equipment to the equipment showing this symbol. Several modules have connectors that look similar to a phone connector. Special cables are required. Installing telecommunications equipment cables can cause equipment damage to the electrical components of the chassis or to your telecommunications system.
Remote Station Controller Connection Remote Station Controller Connection The optional Remote Station Controller (RSC) module requires a Model 498.71B GRES III VMEbus module and a Model 493.71 Serial Interface transition module to be installed in the chassis. The RSC can be connected to any of the four J50 connectors of the serial interface. An interlock is permanently assigned to each J50 connector (e.g., J50A= Interlock 1). Connecting an RSC automatically assigns the RSC pod to the interlock. The .
Remote Station Controller Connection Hwi file additions 148 In order to use one or more RSCs with your Model 493.10 Chassis, two sections must be added to your .hwi file—an RSC section and a GRES III section. Note Remote Station Controllers are not available with the optional 6 or 8station system configurations Note If you specified RSC support when you ordered your test system, these sections will be added to your .hwi file at the factory. For information on editing your .
Service Connections Service Connections The Model 493.10 Chassis can have several service connectors. There are two types of connectors: Chassis service • The chassis connection monitors the power supply. • The connection on the I/O Carrier module monitors the output of each mezzanine card. The J39 Power Monitor connector is located on the rear panel of the chassis. It functions as test points for a service technician.
Service Connections I/O Carrier service The J3 Service connector on the Model 493.40 I/O Carrier module provides the monitor output from each of the four I/O option cards installed. It is an 8-pin RJ45 connector.
Cabling and Programming Series 407 Controllers Cabling and Programming Series 407 Controllers This section describes: • Cabling and programming the FlexTest GT Controller to analog program and feedback signals from a Series 407 Controller. • Connecting FlexTest GT Controllers to interlock signals from a Series 407 Controller. • Setting up a Series 407 Controller to send and receive signals from FlexTest GT Controllers.
How to Provide Program to a Series 407 Controller WARNING Do not interrupt Model 493.10 Chassis power when you are programming another controller. A power interrupt may cause the external controller to react to a zero command and move the actuator unexpectedly. Ensure that power cannot be removed accidently while a test is in progress. For more detailed information about analog I/O connections, see “Analog I/ O Connections” on page 114.
How to Provide Program to a Series 407 Controller Multiple 407 Controller Connections Conditioner Monitor 493.76 Analog Out Program In Conditioner Monitor 407 493.76 Analog Out Ch 1 493.76 Filtered Analog Input 493.77 Filtered In Ch 1 Ch 2 Ch 2 Ch 3 Conditioner Monitor Ch 4 Ch 5 Program In 407 Conditioner Monitor J12 (Ch 5-6) Program In Ch 3 Ch 4 Ch 5 Ch 6 J11 (Ch 1-4) Conditioner Monitor Conditioner Monitor 407 m Ch 6 J11 (Ch 1-4) J12 (Ch 5-6) m 2.
How to Provide Program to a Series 407 Controller Use the Station Manager application to adjust the full scale, polarity, gain, and offset for the external controller channel (Display menu > Station Setup). If your station configuration includes sensor feedback, you can also adjust the full scale, gain, polarity, and offset of the incoming sensor signals, as well as limits. 4. On the 793 Controller, set up the program.
How to Provide Program to a Series 407 Controller D. On the 407 Controller, clear the hydraulic Interlock: – Press the Alt Function button. –Press the Reset button (“9” on the key pad). The Interlock indicator on the front panel should extinguish. E. On the 407 Controller, apply hydraulic pressure with the Hydraulic Pressure buttons. F. On the 407 Controller, press Run. This step readies the 407 Controller to receive program from the 793 Controller. G.
Connecting Interlock Signals to 407 Controllers Connecting Interlock Signals to 407 Controllers The Model 793 Controller monitors digital I/O interlock signals through the Model 493.74 HSM transition module’s J43A and J43B connectors. Use these connectors when connecting to Model 407 Controllers. Model 493.74 HSM transition module connectors are as shown in the figure that follows. Interlock cabling to Model 407 Controllers depends on your system’s configuration.
Connecting Interlock Signals to 407 Controllers How to jumper the hydraulic terminal on a single station Model 407 Controller The following figure shows how to cable the hydraulic terminal on a single station Model 407 Controller.
Connecting Interlock Signals to 407 Controllers Multiple 407 Controller interlock connections The following figure shows how to cable interlocks for multiple Model 407 Controllers to the Model 493.10 Chassis (via its Model 493.74 HSM transition module). Use the specified interlock cable (PN 056-455-0xx) to make these connections for each Model 407 Controller station. Digital I/O Connector Hydraulic Interlock, ActiveLow Run/Stop, ActiveHigh To 493.
Connecting Interlock Signals to 407 Controllers How to connect hydraulic terminals on multiple station 407 Controllers The following figure shows how to cable hydraulic terminals on multiple station Model 407 Controllers, where each Model 407 Controller can run an independent test program. Repeat this scheme for each additional Model 407 Controller.
Connecting Interlock Signals to 407 Controllers Interlock connections for master/dependent 407 Controllers The following figure shows how to cable interlocks when a master Model 407 Controller is daisy-chained with three other dependent Model 407 Controllers to run a single test program on a FlexTest GT Controller (via its Model 493.74 HSM transition module). Use the specified four-channel master/dependent interlock cable (PN 056-448-9XX) to make these connections for each Model 407 Controller station.
Connecting Interlock Signals to 407 Controllers How to connect hydraulic terminals on master-dependent 407 Controllers The following figure shows how to cable hydraulic terminals on three Model 407 Controllers in a master-dependent daisy-chain. Note that the last dependent controller in any daisy-chain must have jumper plugs installed in its Hyd Out and Intlk In terminals.
Sending and Receiving Signals to a Model 407 Sending and Receiving Signals to a Model 407 Controller After cabling the Model 407 Controller, you must configure it to receive and send signals from the FlexTest GT Controller. The tables below list typical menu settings. Refer to the Model 407 Controller Product Information Manual for more information.
Sending and Receiving Signals to a Model 407 407 Amplitude Control Menu PARAMETER SETTING Ampl Cntrl OFF Fdback — Mean — Ampl — AMC Gain — 407 Digital I/O Menu PARAMETER SETTING Din1 Definition Program in RUN Din1 RUN/STOP Din1Pol ACT HI Din2 Definition Hydraulic Interlock Din2 Interlock Din2Pol ACT LOW Dout1 Definition Hydraulics ON* Dout1 HYD OFF Dout1Pol ACT LOW Din2 Definition — Dout2 — Dout2Pol — * Or Run/Stop (ACT HI), Interlock (ACT LOW), None (ACT HI).
Connecting Interlock Signals to 458 Controllers Connecting Interlock Signals to 458 Controllers FlexTest GT Controllers monitor digital I/O interlock signals through the Model 493.74 HSM transition module. Jumper Jumper To 493.74 HSM Transition To 458.XX Controller Jumper Run/Stop Program Interlock Cable (PN 056-455-2xx) Jumper To 458.XX Controller To 493.
Eurotherm Temperature Controller Connection Eurotherm Temperature Controller Connection When equipped with a Model 498.71B GRES III plug-in module, your controller can program and control one or more Series 2200/2400 Eurotherm Temperature Controllers via the J50 serial connectors on a Model 493.71 Serial Interface transition module. In order to use this configuration, a special temperature controller resource must be added to your .hwi file.
Eurotherm Temperature Controller Connection Program the temperature controller Use the Station Builder application to configure a Eurotherm temperature controller. . 493.71 Serial Interface 498.71B GRES III +12V J50A Use Jumper Plug 055-634-101 in these connectors.
Miscellaneous Conditioner Output Connections Miscellaneous Conditioner Output Connections The following table shows connector assignments for various MTS products you can use with your the Model 493.10 Chassis. Conditioning Sensors with Other MTS Products MTS PRODUCT SENSOR OUTPUT Model 408.81 Testing Panel/ Model 408.82 DC Conditioner Sensor output is available at the rear-panel connector J201 or J202. Model 409.
Cabling for External Command Inputs Cabling for External Command Inputs Cabled properly, Model 793 Controllers can receive programming from an external controller. How to Enable and Run External Command Inputs 1. Cable the controllers. Cable the external programmer analog out connector to a Model 493.75 Analog In module BNC connector.
Cabling and Using External Readout Devices Cabling and Using External Readout Devices Cabled appropriately, your controller can send station signals to external readout devices such as oscilloscopes and digital-volt-meters. You define which signal is sent to the readout device using the Station Setup window’s Readout panel. For more information, see “Working with Readout Devices” in the MTS 793 Control Software manual.
Cabling and Using External Readout Devices The following table provides a description of the various station signals. Station Signals SIGNAL DESCRIPTION Time Displays the time reference signal derived from the internal clock that increments continually. This signal exists to support data acquisition by test program applications, such as Basic TestWare and MultiPurpose TestWare. It is not practical to monitor the time signal with an external readout device.
How to Send Signals to External Readout Devices How to Send Signals to External Readout Devices 1. Cable your controller to the readout device. Cable your FlexTest IIm analog output connector to the readout device. Analog I/O connectors are located on the rear of the test processor chassis. Connect an external readout device analog input to a BNC connector on a Model 493.76 Analog Out module. 493.76 Analog Out Analog Monitor From I/O Carrier Module 2. Create a readout channel with Station Builder. 3.
Multi-Box I/O Module Multi-Box I/O Module The optional Model 493.43 Multi-Box I/O module 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.
J9 Interlock OUT Cable specifications Jumper plug • Connector: 25-contact, type D, male, EMI • Backshell: EMI, metalized plastic • Twisted pairs with overall braided shield. Braided shield is terminated to conductive backshell at the chassis. Use MTS jumper plug PN 100-079-233. J9 Interlock OUT Connector J9 Interlock OUT provides four station interlock outputs that can be connected to a multiple MTS controller box interlock chain.
J51 Box In J51 Box In 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.
J52 Box Out J52 Box Out The J52 Box Out connector provides an interface for connecting multiple MTS controller boxes together to allow sharing of station interlock status and a master synchronization clock.
J52 Box Out 176 FlexTest GT Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware
Chapter 4 FlexTest IIm Controller Connections Contents Note For information on connecting power cables, see “Connecting the Console and Chassis Power” on page 61. Note For information about CE compliance, see “CE EMC Compliant Cabling” on page 83.
Workstation Connection Workstation Connection Connect the computer’s network interface card to the 10/100 BaseT connector on the front panel of the processor installed in slot 1.
Sensor and Valve Connections Sensor and Valve Connections The Model 497.01 Analog Chassis connectors J101 through J1601 are 15-pin Dtype connectors located on the chassis rear panel. They connect either a valve driver to a servovalve or a conditioner to a transducer. Connectors J102 through J1602 provide a second connection for dual conditioners, dual valve drivers, or three-stage valve drivers.
Sensor and Valve Connections AC sensor connection AC Sensor (LVDT) +FB -FB Inner Guard +EX -EX DC sensor connection 4-wire connections are the most common. An 8-wire connection is typically used for long cables. Outer Shield 7 Inner Guard 3 The additional wires for an 8-wire connection are shown with dashed lines.
Sensor and Valve Connections Single-valve connection + Valve Command 1 9 A B C – Valve Command 1 11 D Dual-valve connection P2 A B C Shown for valves phased the same hydraulically. For valves phased opposite hydraulically, reverse A and D on P2.
Sensor and Valve Connections Sample control channel The following figure illustrates sample connections to a sensor and a servovalve. Valve Driver Signals J1401 J1301 DC Conditioner Signals J601 AC Conditioner Signals J501 J201 J101 Force Force (load sensor) Valve Valve LVDT LVDT (displacement sensor) Model 497.
ADDA Module Connections ADDA Module Connections In order to process A/D and D/A signal conversion, you must connect your Model 497.01 Analog Chassis to your Model 498.65 ADDA plug-in module. The following graphic illustrates the connections for a Model 497.01 Analog Chassis containing four AC conditioners, dual DC conditioners, and valve drivers. Valve Drive Signals DC Conditioner Signals AC Conditioner Signals J28 J24 J22 J27 J23 J21 497.
ADDA II Connections ADDA II Connections Each optional Model 493.50 ADDA II module supports up to four mezzanine cards. Each installed mezzanine card is assigned a specific ADDA II module front panel connector (J11–J18). A hardware interface file (.hwi) defines each type of module (and their associated mezzanine cards) and maps each module location for the system software. The hwi file and the physical locations for each type of module and associated mezzanine cards must match.
ADDA II Connections Note The external analog source can be a stand-alone function generator, another controller, or a computer controlled analog output. External Analog Source Select Waveform 0 Invert Sync Remote Local Local Single Cycle Breakpt 5 - 05% Full Scale +100% FS Output Mode Control Mode Output Main +100% FS Normal 410.
ADDA II Connections Analog inputs The analog-to-digital mezzanine cards accommodate up to eight analog input signals. Each A/D input signal must be within ±10 volts. • Analog inputs can be connected at the BNC connectors of a Model 493.81 Analog In transition module and the outputs from this module are connected to the Model 493.50 ADDA II module. This configuration is typically used for DSPAD mezzanine cards that provide on-board digital filtering.
ADDA II Connections D/A connections Digital-to-analog mezzanine cards support up to eight program or readout signals to external devices. Each D/A signal is an analog output within ±10 volts. • Each readout signal is from a 16 bit digital to analog converter. • Each output is a ±10 V analog output. • The Model 493.56 D/A mezzanine card provides analog signals to the Model 493.82 Analog Out transition module. Analog outputs are available at the BNC connectors of a Model 493.
ADDA II Connections Up to sixteen encoders can be connected to the Model 493.80 ADDA II Encoder Transition module when the Model 493.50 ADDA II module is fully populated with Universal Encoder cards.
Hydraulic Connections Hydraulic Connections You must connect your external hydraulic equipment to the Model 497.05 Hydraulic Control Panel. The FlexTest IIm hardware supports control of up to four hydraulic stations simultaneously. J25 Hydraulic Power Unit J28C J28B POTS J28D J28A GNINRAW .egat yrujni erelov suodrazaH ves esuac naC .htaed ro dna rew secruos re op niam ffo nruT wop e .
HPU Connections HPU Connections Connector J25 controls the hydraulic power unit. To/From 497.
HSM Connections HSM Connections The outputs provide 24 V DC to turn on the HSM solenoids. From Hydraulic I/O Cable specification J28 To HSM Solenoids 1 Low Pressure 2 DC Common 4 High Pressure Connector J28 controls the low-pressure and highpressure solenoids of a hydraulic service manifold. • P28 is a 4-contact CPC male connector (AMP Incorporated). • Cable—18 AWG/2 connector type SJOOW-A for on/off HSMs 18 AWG/3 connector type SJOOW-A for high/low HSMs • Cable assembly numbers: – 290.
Interlock Connections Interlock Connections Remote Interlock Inputs (3 for each hydraulic channel) 497.05 Hydraulic Control Panel J8 J52 (Jumper Plug, (046-350-701) J51 J52 J26 E-Stop 047-807-8xx 046-350-602 497.01 Analog Chassis J51 051-074-601 J52 051-074-501 24X1 Processor 498.71B 24X1 GLOBAL RESOURCES III Processor 498 498 System Digital I/O 498.
Interlock Jumper Plugs Interlock Jumper Plugs Several jumper plugs must be installed to maintain the integrity of the interlock chain. Each jumper plug represents a place where you can add a custom connection to the interlock chain. Model 497.05 Hydraulic Control Panel Series 498 System Digital I/O Any interlocks connected to the hydraulic control panel will generate a hydraulic interlock which shuts down the hydraulic power supply. This type of interlock shuts down all test stations.
Interlock Jumper Plugs The interlock connectors require jumpers under the following conditions: • If you do not use the external hydraulic/program interlocks on any of the D15S connectors (J3A Sta 1, J3B Sta 2, J3C Sta 3, and J3D Sta 4). Use an external jumper plug (PN 052-750-501) on each connector not used. • If you use the system digital I/O as a stand-alone unit. That is, if you do not connect the System Digital I/O Module to a 497.
Serial Communications Serial Communications Each chassis communicates with each other through a serial communications cable. Model 497.05 Hydraulic Control Panel J41 J42 046-350-902 Model 497.01 Analog Chassis J41 J42 Debug 24X1 Processor BEI ABT RST 498.65 ADDA BEI CPU ABT PMC RST CPU PMC MOTOROLA Models FlexTest® IIm/GT/SE Controller Hardware GLOBAL RESOURCES III 10/100 BASET 10/100 BASET Model 498.22 Test Processor 498.
Digital I/O Connections Digital I/O Connections Digital I/O hardware enables two-way communication between your test and external logic devices. This transition module provides user digital I/O the built-in digital I/O access panel (FTIIm) 498 This transition module reserves system DIO.
Digital I/O Connections Digital inputs • Digital inputs can be wired to allow the input from a switch contact, a relay contact, or a logic signal. • All digital inputs are optically isolated at the Series 498 Digital I/O transition module. • For example, an action defined in the can be selected, in the Station Setup window’s Digital Input panel, as an Action. • The digital inputs are used by the Digital Input process in the MultiPurpose TestWare application.
Digital I/O Connections This shows how to connect an external switch or a set of relay contacts to channel 1 of the digital inputs. Digital I/O Access Panel 498 Digital I/O Transition Module +12 VDC J1 - 2 External Device +CH1 6 -CH1 2 External Switch or Relay Contact 1 1 2 +12 VDC 7 This shows how to connect an external logic signal to channel 4 of the digital inputs.
Digital I/O Connections Digital outputs • Digital outputs provide an optically isolated open collector/open emitter output. • The digital outputs are controlled by the Digital Output process in the MultiPurpose TestWare application. They can also be controlled manually in the Station Manager application. • Each digital output connector located on the Digital I/O Access Panel supports two channels. • Each digital output is an open collector/open emitter rated at 30 V DC max at 50 mA max.
Encoder/Temposonics Connections Encoder/Temposonics Connections Encoders and Temposonics sensors are connected to the FlexTest IIm controller in a similar way. Each type of sensor requires a different jumper configuration on the Model 498.65 Transition Module and a different mezzanine card for the 498.65 ADDA Module. Model 498.65 ADDA Module ADDA Encoder 498.
Encoder/Temposonics Connections Jumper configurations ADDA mezzanine cards The Series 498 transition module can be configured for a Temposonics sensor, a 5 V DC encoder, a 12 V DC encoder, a 24 V DC encoder.
Encoder/Temposonics Connections The Model 493.80 Encoder Transition module provides up to four channels of encoder interface between the Model 493.50 ADDA II module and various incremental, Temposonics, or other digital and serial data transducers.
Remote Station Controller (RSC) Connections Remote Station Controller (RSC) Connections When equipped with a GRES III plug-in module and a corresponding Series 498 RS-485 transition module, your FlexTest IIm controller can accommodate up to four remote station controllers (one RSC for each station). Each RSC connects to a J50 serial connector on the Series 498 RS-485 transition module. The hwi file defines which connector is used for each station.
Cabling and Programming External Controllers Cabling and Programming External Controllers Cabled properly, you can use your FlexTest controller to send test commands to another controller. For detailed setup information, see “How to Program an External Controller” on page 204. When programming Series 2200 and 2400 Eurotherm temperature controllers, the FlexTest IIm controller supports a special serial connection and software setup.
How to Program an External Controller 2. If you will monitor sensor feedback for data acquisition or control feedback, connect the external conditioner output to a Series 498 Input Filter connector. For conditioner output locations on various MTS devices, see “Sample conditioner output connections” on page 207. Transition modules on the back of the Series 498 test processor chassis are used for analog inputs and outputs.
How to Program an External Controller Note Analog I/O connectors are located on the rear panel of the Series 498 test processor chassis. 1. Connect a 493.82 Analog Out BNC connector to the external controller program (analog) input. 2. If you will monitor sensor feedback for data acquisition or control feedback, connect the external conditioner output to a 493.83 Filtered Analog Input BNC connector.
How to Program an External Controller Sample conditioner output connections This table shows connector assignments for various MTS products you can use with your FlexTest IIm controller. Conditioning Sensors with Other MTS Products MTS PRODUCT SENSOR OUTPUT Model 408.81 Testing Panel/ Model 408.82 DC Conditioner Sensor output is available at the rear-panel connector J201 or J202. Model 409.81C Temperature Controller Temperature output (via an analog signal) is available at rear-panel connector J1.
How to Program an External Controller For mroe information, see “How to Configure an Externally Conditioned Feedback Signal” in the MTS 793 Control Software manual. Task 3 Set up your program. Define a program with the Function Generator, Basic TestWare, or Multipurpose TestWare applications. Using Function Generator Refer to “How to Program with the Function Generator” in the MTS 793 Control Software manual.
Programming Eurotherm Temperature Controllers Programming Eurotherm Temperature Controllers When equipped with a GRES III plug-in module, your FlexTest IIm controller can program and control one or more Series 2200/2400 Eurotherm Temperature Controllers via the J50 serial connectors on the Series 498 RS-485 transition module.
Cabling for External Command Inputs Cabling for External Command Inputs Cabled properly, your FlexTest controller can receive programming from an external controller. How to Enable and Run External Command Inputs To enable an external command source, perform the following: 1. “Cable the controllers.” on page 211. 2. “Allocate external command resources in Station Builder.” on page 211. 3. “Adjust the command signal with Station Manager.” on page 212. 4. “Start the External Command.” on page 212.
How to Enable and Run External Command Inputs Task 1 Cable the controllers. Cable the external programmer analog out connector to a Series 498 Input Filter connector. Analog I/O connectors are located on the rear of the test processor chassis. Note If you cable the hardware before you create a station configuration file, note the connector you use on the FlexTest IIm rear console.
How to Enable and Run External Command Inputs Task 3 Adjust the command signal with Station Manager. For more information, see “How to Enable and Run External Command Inputs” in the MTS 793 Control Software manual. Task 4 Start the External Command. For more information, see “How to Enable and Run External Command Inputs” in the MTS 793 Control Software manual.
Cabling and Using External Readout Devices Cabling and Using External Readout Devices Cabled appropriately, your FlexTest controller can send station signals to external readout devices such as oscilloscopes and digital-volt-meters. You define which signal is sent to the readout device with the Adjust Readouts window. For a diagram and description of signals available to the station, refer to “Station signal descriptions” on page 169.
How to Send Signals to External Readout Devices Task 1 Cable your controller to the readout device. Cable your FlexTest IIm analog output connector to the readout device. Analog I/ O connectors are located on the rear of the test processor chassis. Connect a Series 498 Analog Out connector to the external readout device analog input. 498 Analog Out This module includes 8 BNC connectors that provide analog outputs from the 498.65 ADDA module.
How to Send Signals to External Readout Devices Task 2 Create a readout channel with Station Builder. For more information, see “How to Create a Readout” in the MTS 793 Control Software manual. Task 3 Adjust the readout signal in Station Manager. Use the Station Manager application to adjust the readout signal. For a detailed description of readout signal configuration and adjustment, see “How to Configure a Signal for External Readout” in the MTS 793 Control Software manual.
Cable Part Numbers Cable Part Numbers Refer to the following table for cable part numbers used to connect test hardware to the Model 497.01 Analog Chassis rear-panel connectors. DESCRIPTION CABLE PART NUMBER Load cell, 661.xx w/MS connector 046-440-6XX Load cell, 661.xx w/PT connector 046-440-2XX Strain w/PT connector 050-120-0XX LVDT 046-440-3XX ADT–120º 048-341-1XX Remote E-stop/X-head Interlock-load frame 054-145-4XX Servovalve, 252.xx single 046-440-1XX Servovalve, 252.
Chapter 5 FlexTest SE Controller Connections This section describes the connections to the MTS 493.02 Chassis. Contents Note For information on connecting power cables, see “Connecting Electrical Power” on page 53. Note For information about CE compliance, see “CE EMC Compliant Cabling” on page 83. Stand-alone Cabling Overview 218 Automated Cabling Overview 219 Multiple Controller Connections Cable Part Numbers 220 223 Model 493.
Stand-alone Cabling Overview Stand-alone Cabling Overview 218 FlexTest SE Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware
Automated Cabling Overview Automated Cabling Overview Models FlexTest® IIm/GT/SE Controller Hardware FlexTest SE Controller Connections 219
Multiple Controller Connections Multiple Controller Connections About multiple controller networks Some characteristics of a multiple controller network are as follows: • Each controller in the network provides control for one station with up to two channels. • A hub connects each controller in the network to the supervising PC. • A single network may have a maximum of four stations (regardless of the number of controllers cabled to the hub).
Multiple Controller Connections E-stop J29 J7 I/O J25 Hpu mm Power J28 HSM Intlk J43 J49 Aux Pwr J6 I/O J54 Dig In J4 I/O 1 2SHUNT CAL 3 4 J5 I/O Analog out Box Out J52 Analog In S E R V I C E 493.40 I/O CARRIER J51 Box In 493.42 SYSTEM I/O AIR FLOW Master Dig Out J55 The indicated cables on each controller must be connected before the controllers are turned on.
Multiple Controller Connections Interlock function Power must be applied to all controllers in the chain for proper interlock operation. If power is not applied to any one of the controllers, you will not be able to clear an interlock condition in any of the controllers.
Cable Part Numbers Cable Part Numbers System cables The following is a list of the most common cables, see the System Cable/Jumper Plug 493 Package Selection drawing (MTS PN 700-000-656) for the most current and additional cable part numbers. Model 493.02 Chassis Cables CABLE DESCRIPTION PART NUMBER* MODULE CONNECTOR JUMPER PLUG† Servovalve 252.xx single 039-708-3XX 493.40 J4–J7 N/A Servovalve 252.xx dual 039-708-4XX 493.40 J4–J7 N/A Servovalve 256.
Cable Part Numbers * -XX specifies cable length. –01 through –09 represent 10–50 ft. in 5 ft. increments. Higher numbers represent custom cable lengths. † Jumper plugs are required if a cable is not installed. ‡ The connector is the 10/100 BaseT connector on the power PC module. Sensor cables See “Sensor Cables” on page 100 for a detailed list of sensor cables and part numbers. For the most current part numbers, see the System Cable/Jumper Plug 493 Package Selection drawing (PN 700-000-656).
Model 493.40 I/O Carrier Connections Model 493.40 I/O Carrier Connections For more information, see “Model 493.40 I/O Carrier Connections” on page 87. Automated option Automated FlexTest SE Controllers are designed to be used with a PC, MTS 793 software, and various types of support files, including a hardware interface file (.hwi) file. The .hwi file defines each type of electronic module in the chassis (and associated mezzanine cards), and maps each module location for the MTS 793 software. The .
Sensor Connections Sensor Connections See “Sensor Connections” on page 88. See “Sensor Cables” on page 100. See “Shunt Calibration/Bridge Completion Resistor Installation” on page 103. See “Transducer Identification Modules” on page 106. Valve Connections See “Valve Connections” on page 108. See “Series 252 Servovalve connections” on page 109. See “Series 256 Servovalve connections” on page 110. See “Series 257 Valve connections” on page 111. Analog I/O Connections The Model 493.45 A/D and Model 493.
Analog I/O Connections A/D connections The analog-to-digital mezzanine cards accommodate up to six analog input signals. • Each A/D input signal must be within ±10 volts. To A/D From A/D J4 - J7 1 + 2 - 3 4 + 5 - 6 7 + 8 + 9 10 + 11 12 + 13 + 14 - Input 1 Analog Ground Input 2 Analog Ground Input 3 Input 4 Input 5 Input 6 15 • Use pin 3 or 6 to prevent problems with floating grounds between devices.
Encoder Connections D/A connections Digital-to-analog mezzanine cards support up to six program or readout signals to external devices. • Each D/A signal is an analog output within ±10 volts. From D/A To External Device J4 - J7 1 + 2 - Output 1 3 4 + 5 - Output 2 6 7 + 8 9 + 10 - 11 12 13 14 Output 3 Output 4 + Output 5 + Output 6 - 15 Cable specification • Each readout signal is from a 16 bit digital to analog converter. • Each output is a ±10 V analog output.
Workstation Connection Workstation Connection The workstation computer is connected to the processor module installed in the VMEbus of the chassis. It is an Ethernet 10/100 Base-T connection. The workstation computer must have an Ethernet compatible connector. RUN 6TS BFL ABT TYPE E PC-MIP TYPE E PC-MIP RST DEBUG PCI MEZZANNE CARD CAUTION The symbol shown here indicates that you must not connect telecommunications equipment to the equipment showing this symbol.
Model 493.42 System I/O Connections Model 493.42 System I/O Connections The Model 493.42 System I/O module is a dual-wide VME-based slave board used in the Model 493.02 Chassis. • Provides box-in and box-out, analog and digital I/O, E-Stop, and HSM and HPU control. • Contains three general purpose digital input channels and three general purpose digital output channels. • Interfaces the controller with a hydraulic power unit.
J28 Hydraulic Service Manifold Connector Cable specification Jumper plug required The J25 HPU and J51 Box In connectors are 15 pin type D male connectors. • 15 contact type D female EMI connector. • Cable—24 AWG, 10 conductor with braided shield with drain wire connected to metallized plastic backshell to the chassis. If connector J25 HPU is not used, you must install a jumper plug to maintain the integrity of the interlocks.
J29 Emergency Stop Connections J29 Emergency Stop Connections Connector J29 E-STOP provides an output to external devices when an emergency stop signal is generated. This connector may also be used with an external E-stop.
J43 Interlock 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 PN 100-007-947B or jumper pins: 34, 5-7, 8-13. J43 Interlock Connector J43 Interlock contains one optically isolated interlock input and one relay contact interlock output. Note The intlk out relay (Pin 6) is normally energized when no interlocks are active.
J49 Auxiliary Power 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 PN 100-057-245, or jumper pins: 1-2, 3-4. J49 Auxiliary Power See “J49 Auxiliary Power” on page 140. CJ51 Box In Connector J51 Box In allows the Model 493.02 chassis to receive clock, hydraulic, and interlock signals from another Model 493.02 chassis.
J52 Box Out J52 Box Out Connector J52 Box Out allows the Model 493.02 Chassis to send clock, hydraulic, and interlock signals to another Model 493.02 Chassis.
J54 Digital Inputs J54 Digital Inputs Connector J54 Dig In accommodates up to three digital signals from external devices. You can use digital input signals to trigger test events with your controller applications. • All of the inputs are optically isolated. • Channel inputs can be 3 volts (minimum) and 26 volts (maximum) from an external voltage source. To FTSE Controller +24 V Input 1 Input 2 Input 3 J54 From External Device 1 3 4 5 6 7 8 9 Cable specification 236 Switch or dry contact.
J55 Digital Outputs J55 Digital Outputs Connector J55 Dig Out provides three general purpose digital outputs that can send digital logic signals to external switches or logic devices. • The digital output relays are rated for a maximum of 1 Amp max, 30 V DC/ AC max. • The outputs are optically isolated.
J55 Digital Outputs Stand-alone mode 1. Press Setup on the console front panel menu. 2. Scroll down the Setup menu to Digital Output 1. 3. Press the button next to Digital Output 1. 4. Press the button next to Assignment until the state Run/Stop is shown. 5. Press Polarity to select Normal or Inverted. Automation mode 1. Ensure that digital outputs have been added using Station Builder. 2. In the Station Manager window’s Display menu, select Station Setup. 3.
Eurotherm Temperature Controller Connection Eurotherm Temperature Controller Connection Automated FlexTest SE Controllers can program and control a single Eurotherm temperature controller. Note Stand-alone FlexTest SE Controllers are not equipped for use with temperature controllers. To use a temperature controller with a FlexTest SE Controller: 1. Configure the FlexTest SE Controller’s Debug Serial Port. 2. Cable the temperature controller to the FlexTest SE Controller. 3.
Eurotherm Temperature Controller Connection E-stop J29 mm J28 HSM J7 I/O J25 Hpu J6 I/O J5 I/O J4 I/O J54 Dig In J49 Aux Pwr Intlk J43 Dig Out J55 Box Out J52 Power 1 2 3 4 Analog In J51 Box In SHUNT CAL S E R V I C E 493.40 I/O CARRIER 493.42 SYSTEM I/O AIR FLOW Analog out Two cables and an RS 232/RS 485 converter are required to connect the FlexTest SE Controller to a temperature controller, as shown.
Eurotherm Temperature Controller Connection Debug serial port Two different cables can be used to connect the converter to the temperature controller: • For Eurotherm Temperature Controllers used with Series 651 chambers, use cable assembly PN 056-719-6xx. • For MTS Model 409.83 Temperature Controllers (equipped with Eurotherm control modules), use cable assembly PN 056-719-7xx.
Eurotherm Temperature Controller Connection To add the resource, select the Miscellaneous tab and select 1 for temperature controllers, then save the file. The application automatically adds the required information in the proper syntax to the text in the hardware interface file. Adding a temperature control channel to the station configuration file After updating the hardware interface file, you must add a temperature control channel to the Controller’s station configuration file.
Appendix A Hydraulic Configurations This section describes how to connect the Model 493.10 Chassis (FlexTest GT Controllers) and the Model 493.02 Chassis (FlexTest SE) to a variety of MTS hydraulic configurations. Use the following connectors and cables to connect the Model 493.10/02 Chassis to your HPU with a Model 493.07 Converter Box: Note Models 493 Chassis to 493.07 Converter Box Model 493.07 Converter Box to HPU Hydraulic pump configurations For jumpering information, see Appendix B: Model 493.
Single Model 493.02 chassis with a 24 V PLC pump (506.52-.92) or 505 pump 493.02 Chassis 039-713-7XX HPU J25 HPS Note 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 Model 493.02 chassis with a non-PLC pump 493.02 Chassis 039-713-8XX (24 V DC) 039-714-6XX (115 V AC) J25 HPS 493.
Compatible Controllers 039-710-7XX (24 V DC) 039-710-8XX (115 V AC) 039-713-8XX (24 V DC) 039-714-6XX (115 V AC) 493.10 Chassis J25 HPS J1 HPS 493.07 Converter Box 458* or 490.01* 497.05* * High-level Y cable 005-407-801 (24 V DC) 005-401-801 (115 V AC) HPU J25 HPS 039-708-7XX (24 V DC) 039-708-8XX (115 V AC) For standard Model 493.07 Converter Box jumper setting only. Alternate settings are required for Model 436.11 and 413.05 controllers. See Appendix B: Model 493.07 Converter Box.
Model 493.02 Chassis Multiple Controller Model 493.
Independent HSM (shared HPU) Independent HSM (shared HPU) Power Type = HPU/HSM FlexTest SE A FG B Setup Recall 8 9 4 5 6 1 2 3 Hydraulic Interlock +/- 0 .
Shared HSM (no HPU) For this multiple controller configuration: • The HSM and HPU are connected to one controller only. • Select HPU/HSM for Power Type on the controller to which the HSM and HPU is connected. Path: Config > Edit Hardware > Power Options > Power Type > HPU/ HSM • Select Slave HSM for Power Type on controllers connected to the master controller.
Independent HSM with HPU (First On-Last Off) Independent HSM with HPU (First On-Last Off) Note This interconnect option is only available for controllers on the same interlock. Power Type = Auto. HPU/HSM FlexTest SE A FG B Setup Recall Status Scope Enabled Meters Tuning Emergency Stop Config Limits Log Monitor 1 Navigate Monitor 2 ? J28 HSM Menu 7 8 9 4 5 6 1 2 3 +/- 0 .
Independent HSM with HPU (First On-Last Off) 250 Hydraulic Configurations Models FlexTest® IIm/GT/SE Controller Hardware
Appendix B Model 493.07 Converter Box This section describes how to jumper the Model 493.07 Converter Box to connect the Model 493.10 chassis and other controller types to a hydraulic power unit (HPU). The Converter Box converts logic-level signals to and from the Model 493.10 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. CAUTION You must have the Model 493.
Note 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 407.05 Jumper change required: Note 252 If the Model 493.10 Chassis is the only device connected to the HPU, the jumper settings do not matter. Model 493.
Appendix C Chassis Maintenance This section describes how to maintain your MTS controller chassis. Cleaning the chassis Remove any dust from the chassis with Endust for Electronics or equivalent. Cleaning 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 Models FlexTest® IIm/GT/SE Controller Hardware
6-Station Configuration Appendix D Optional Station Configurations This section describes how to configure your Model 493.10 Chassis (FlexTest GT Controllers) to support an optional six or eight stations. When configuring your system for a six or eight stations you must consider the following: • Ensure that the .hwi file is correctly set for the desired multi-station configuration, especially the interlock and HSM board settings. • Power to each HSM is limited.
8-Station Configuration 8-Station Configuration The 8-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 1.5 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.
Index Numerics 252 servovalve,I/O carrier connection 109, 226, 228 256 servovalve,I/O carrier connection 110 257 servovalve,I/O carrier module connection 111 407 controller,programming to receive, send signals 162 493.07 HPU Converter 251 493.10 chassis 39 AC grounding 39 digital universal conditioner (DUC) jumpers 92, 94, 97 functional description 21 grounding 39 power connections 40 specifications 23, 27, 33 493.
cables CE ECM compliant 83 E-stop 129 fabrication 83 HPU connector 131, 231 part number list 85, 223 sensor 100 system 223 cabling AC sensor connections 180 ADDA 183 cable numbers 179 console/chassis power 61 DC sensor connections 180 digital I/O 196 E-stop 232 Eurotherm temperature controller 165, 209, 239 external controllers 168, 204, 211 front panel 227 J4-J7 A/D inputs 115 J4-J7 D/A outputs 117, 127, 187 J4-J7 transducer 108 J4-J7 valve 108 HPS 190 HSM 191 hydraulic connections 189 interlock 192 low-fr
digital I/O connections 196 digital I/O access panel 144 digital I/O connections 141 digital I/O transition module J3 In connector 142 J4 out connector 143 digital inputs cable specification 236 J3 In connector 142 J54 Dig In connector 236 digital inputs, connections 197 digital outputs cable specification 143, 237 J4 out connector 143 J55 Dig Out connector 237 digital outputs, connections 199 E electrical power connecting 38 grounding 39 emergency stop cable specifications 129, 232 E-STOP Out connector 12
I/O carrier module 252 servovalve connection 109, 226, 228 256 servovalve connection 110 257 servovalve connection 111 accelerometer connection 119, 229 analog I/O cable specifications 118, 228 analog I/O connection 114, 226 analog I/O connections 226 analog inputs 115, 227 bridge completion circuits 103 connecting force/strain sensor 92 connecting LVDT 90 D/A connection 117, 127, 187, 228 daughter boards 51, 87 encoder connections 121 J3 Service connector 150 servovalve cable specifications 108 servovalve
power UPS requirements 78 power cabling 53, 61 power connections 493.10 chassis 40 pressure control 26 programming Eurotherm temperature controller 209 receiving from external controllers 210 sending to external controllers 204 R readout channel, creating 171, 215 readout devices, using external 210 readout signal, adjust 171, 215 rear-panel connectors 497.01 analog chassis 67 497.05 hydraulic control panel 71 remote station controller .
V valve dual-valve connection 181 single-valve connection 181 VME bus 21 VMEbus installing modules 43 VMEbus modules description 45 descriptions 50 installing 43, 50 W workstation connection 145, 229 262 Index Models FlexTest® IIm/GT/SE Controller Hardware
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.
