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MTS Models FlexTest IIm/GT/SE Controller Hardware

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1. Front Panel Rear Panel with VMEbus Modules with Transition Modules 20 Introduction Models FlexTest IIm GT SE Controller Hardware 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 VMEbus modules The chassis has ten VMEbus slots that support a variety of MTS VMEbus plug in modules e The chassis requires at least one processor module The processor module provides the processing power to manage the other plug in modules that make up the controller e The chassis can have up to eight I O Carrier modules Each I O Carrier module supports up to four mezzanine cards e An optional Global Resource GRES module provides several connections to communicate with external devices such as a remote station control module temperature controller and other devices Transition bus Transition modules are panels plugged into the transition bus located in the rear of the chassis E
2. 144 FlexTest GT Controller Connections Models FlexTest IIm GT SE Controller Hardware 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 Note E 3 ol If your processor has more than one Ethernet 10 100 Base T connection use the connection labeled LAN 1 i Models FlexTest Ilm GT SE Controller Hardware FlexTest GT Controller Connections 145 Workstation Connection The symbol shown here indicates that you must not connect telecommunications equipment to the equipment showing this symbol amp 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 146 _ FlexTest GT Controller Connections Models FlexTest IIm GT SE Controller Hardware Remote Station Controller Connection Remote Station Controller Connection 188 718 Bi TIN CLOCK OUT O e7 EVENT OUT O N EVENT IN gt VU J3 IN J6 STATION 00000000
3. J17B SoGi J1 J8 J9 J15A J17D J25 J26 J28A J28D J41 and J42 J51 and J52 1 omole E Stop 497 01 Power D E Hydraulic Control Panel The 497 05 contains the power supply for a Model 497 01 Analog Chassis Connect your 497 01 Analog Chassis to J1 This connector communicates hydraulic status with the Model 498 22 Test Processor chassis This connector is not used in a standard FlexTest IIm system Each HSM channel has a set of three user defined interlock inputs Interlock 1 Interlock 2 and Shutdown These inputs can be configured to monitor contact closure or to accept logic level inputs This connector controls the hydraulic power supply HPS This connector accommodates a remote Emergency Stop switch These connectors control up to four hydraulic service manifolds HSMs These connectors create a serial communications loop between all of the chassis in your system These connectors create an interlock communications loop with the other chassis in your system Models FlexTest IIm GT SE Controller Hardware Installation 71 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 MODULE Processor Modules Test Processor Plug In Modules FUNCTION Standard FlexTest IIm Con
4. o_O System ground cable PN 037 766 102 connected to other gt O components Chassis ground is connected through the power cord connector Models FlexTest Ilm GT SE Controller Hardware Installation 53 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 gt 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 Proper grounding is required for safe operation It is also required to meet EMC emission and susceptibility requirements 54 Installation Models FlexTest IIm GT SE Controller Hardware Connecting Electrical Power Power All equipment related to the chassis should be connected on the same fused power circuit e The power supply can accept single phase voltages within 90 264 V AC at frequencies between 47 63 Hz e 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 t
5. s Models FlexTest Ilm GT SE Controller Hardware FlexTest GT Controller Connections 123 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 Also the ADDA II module address setting on the module must match the hwi file address For more information on the hwi file see the MTS 793 Utility Software manual The following A D or D A mezzanine cards can be installed Model 493 55 A D Model 493 56 D A Model 493 57 DSPAD Model 493 59 Universal Encoder 124 FlexTest GT Controller Connections Models FlexTest IIm GT SE Controller Hardware ADDA II Module I O connections Daughter Board 1 Daughter 3 Board 2 Daughter Board 3 Daughter Board 4 Models FlexTest IIm GT SE Controller Hardware 493 50 ADDA 1 ADDA II 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 I module assembly A connection from the front panel connector to a rear panel BNC transition
6. Analog Monitor T N ii fy Ch 1 2 o d Daughter Board 1 O x 2 x O O O 2 d O O 0O o Q ba Q Ch 5 C 9 Ch 6 9 o 2 a S Q F Daughter Board 3 k Ss _ ial Ss Ss R Daughter Board 4 IC T C z o 3 o Pl Pl ADDA II Module I O Connections Models FlexTest IIm GT SE Controller Hardware FlexTest Ilm Controller Connections 185 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 e 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 e Analog inputs can be connected at the BNC connectors of a Model 493 83 Filtered Analog Input transition module and the outputs from this module are connected to the Model 493 50 ADDA II module This configuration is typically used for A D mezzanine cards that requires filtering To From A D 493 81 Analog In Module lt 1 nput 1 lt M 2 3 nput 2 J11 J13 4 4 J J15 J17 q 5 F nput 3 atHH 6 4
7. 493 48 MODEL 493 55 Acceleration Conditioner Processes the signals from an accelerometer Each Acceleration Conditioner mezzanine card can support up to three accelerometers Before installing this board specific jumpers must be set on the I O Carrier module See I O Carrier jumper settings on page 119 for more information on jumper settings ADDA II Mezzanine Cards MODULE NAME A D FUNCTION 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 DIA 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 A DSP chip provides digital filtering This board requires the optional ADDA II module 493 59 46 Installation Universal Encoder Processes the signals from incremental absolute and Temposonics Ill encoders This board requires the optional ADDA II module Models FlexTest IIm GT SE Controller Hardware 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 Starti
8. Multiple Model 493 02 chassis and 407 Controllers 493 02 Chassis J25 HPS 493 02 Chassis J25 HPS 407 Controller F25 244 Hydraulic Configurations Note HPS OR 039 713 7XX HPU 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 039 710 7XX 24 V DC 039 710 8XX 115 V AC 493 07 Converter Box J1 J25 HPS HPS 039 713 8XX 24V DC 039 7 14 6XX 115 V AC 493 07 Ji Converter Box T25 HPS HPS 0 182 2XX 050 051 995 8XX CE low level Y cable 039 713 501 HPU 039 7 10 7xx 24V DC 039 710 8xx 115 V AC HPU Models FlexTest Ilm GT SE Controller Hardware Compatible Controllers 493 10 Chassis 039 710 7XX 24V DC High level Y cable 039 710 8XX 115 V AC _ 005 407 801 24V DC 005 401 801 115 V AC 039 713 8XX 24V DC 039 714 6XX 115 V AC J25 HPS 493 07 J1 Converter Box J25 HPU HPS HPS 458 or 039 708 7XX 24V DC 490 01 039 708 8XX 115 V AC 497 05 For standard Model 493 07 Converter Box jumper settin
9. b KOl 2 x N 2 o S N o amp J3IN d E ca Cam _ CH1 CH2 CH3 CH4 itik 11 12 3 4 11 12 amp C amp WO 5 A CH5 CH5 WON 6 p CH6 CH6 p ir ar 6 0 lh ir cir ON 5 6 13 14 5 6 13 14 Jout 665 s o a az l DRDD a x a AO m J11 We we CH 1 4 CH 1 4 a a KON E 7 8 15 16 7 8 15 16 iH 5 8 cli J O e ON A Ran E Ble BD l d od e e ee S Transition Modules Model 498 22 Chassis Rear Panel shown 74 Installation Models FlexTest Ilm GT SE Controller Hardware Test Processor Transition Modules TRANSITION MODULE 498 Analog Out This module includes eight BNC connectors that provide Test Processor Transition Modules FUNCTION 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 498 Input Filter This module includes eight BNC connectors that provide filtered analog inputs to the Model 498 65 ADDA module These inputs are associated with an A D mezzanine card Four channel systems use a standard ADDA module which provides four analog inputs For 8 channel syste
10. DD DD D J51 N N D 051 074 601 a AN s om BEE gp o oz J2 Paddle Board 049 792 301 lt to 498 backplane same slot as 498 71 to J2 rear to J2 rear 3 3l m S Al 0 ol ol 049 792 201 The System Digital I O and Digital I O transition modules along with the paddle board are located on the rear panel of the Series 498 XX Test Processor 192 FlexTest Ilm Controller Connections Models FlexTest IIm GT SE Controller Hardware 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 Any interlocks connected to the hydraulic control panel will generate a hydraulic Hydraulic Control interlock which shuts down the hydraulic power supply This type of interlock Panel shuts down all test stations Connector J52 requires a jumper plug to close the interlock chain If J26 is not connected it needs a jumper plug Connectors JI5A J17C Remote Interlock Inputs each require a jumper plug unless it is being used Jumper both pins of each connector Series 498 System Any interlock connected to the Series 498 System Digital I O transition module Digital I O can generate a station interlock to disable pressure the HSM to that station The Series 498 System Digital I
11. Encoders and Temposonics sensors are connected to the FlexTest Im 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 eo ADDA Encoder 9 Transition gees aa gee Module A di KON O T L ale O 758 O eae am rales J9 Os one z 3 OAE aoe s E m pa m tu 2 eC La 200 FlexTest IIm Controller Connections Temposonics III Transition Module The FlexTest Ilm controller supports both linear shown and rotational encoders A Temposonics sensor is usually mounted inside an actuator SG Models FlexTest IIm GT SE Controller Hardware Encoder Temposonics Connections Jumper configurations 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 The following is a list of the configuration drawings e 049 035 301 Absolute Encoder e 049 035 401 5 Volt Encoder e 049 035 501 12 Volt Encoder e 049 035 601 24 Volt Encoder e 049 035 701 Temposo
12. Or Run Stop ACT HI Interlock ACT LOW None ACT HI Models FlexTest IIm GT SE Controller Hardware FlexTest GT Controller Connections 163 Connecting Interlock Signals to 458 Controllers Connecting Interlock Signals to 458 Controllers To 493 74 HSM Transition Transition FlexTest GT Controllers monitor digital I O interlock signals through the Model 493 74 HSM transition module P434 D 9P N 24y ow 1 Jumper 2 HYD INTLK A INPUT 3 P44 45 Jumper D SS 4 24y OW 5 gt 2 To 5 Ez wa F RUN 458 XX mvv 6 o ral 7 EE Controller EVENT PROGRAM INTLK INPUT J We 7 OFF INTLK Jumper 8 vo LY Run Stop Program Interlock Cable PN 056 455 2xx Jumper 24V Sn INTLK o INPUT 20K 2n3904__C To i 458 XX M C Controller 1 4W 5 B E Hydraulic Enable Interlock Cable PN 056 455 1XX 1464 FlexTest GT Controller Connections Models FlexTest Ilm GT SE Controller Hardware 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 J50
13. 0000000 P 8 2 z J lil 3 io 049 876 501 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 JSOA Interlock 1 Connecting an RSC automatically assigns the RSC pod to the interlock The hwi file defines which connector is used for each station For more information see Hwi file additions on page 148 The RSC control panel is available in two configurations one provides an E Stop and HPS control for single station configurations and the other provides a Station Stop with no HPS control for multi station configurations Use Jumper Plug 055 634 101 in these connectors J 00000 00000 00000 ol J 00000 00000 00000 G 5 pay Stop J 00000 00000 00000 g MS 055 634 2xx E Stop or 055 634 3xx Station Stop Models FlexTest IIm GT SE Controller Hardware FlexTest GT Controller Connections 147 Remote Station Controller Connection Hwi file additions In order to use one or more RSCs with your Model 493 10 Chassis two sections must be added
14. Configuring the Debug To use a FlexTest SE Controller with a temperature controller configure the Serial Port Debug Serial Port as follows 1 Access the Model 498 96 Processor circuit card in the Controller s chassis 2 Locate switch S3 3 Set bit 8 to the off open position Models FlexTest IIm GT SE Controller Hardware FlexTest SE Controller Connections 239 Eurotherm Temperature Controller Connection Cabling the Two cables and an RS 232 RS 485 converter are required to connect the FlexTest temperature controller SE Controller to a temperature controller as shown ele ia amp ae J K J amp Je amp ee P fe BS amp CK A ey d a e Gap G p P al o o x Oz o Ve C9 Debug Serial Port 100 112 652 nezan 205 Euro Ce ene t 100 112 820 gt 056 7 19 6xx 651 Chamber I i OR i 056 719 7xx 409 83 ea acinar ls Temperature Controller 240 FlexTest SE Controller Connections Models FlexTest IIm GT SE Controller Hardware Debug serial port TO RS232 485 COMMUNICATION CONVERTER TO RS232 485 COMMUNICATION CONVERTER Adding a temperature controller resource to the hardware interface file Eurotherm Temperature Controller C
15. Note Itis good practice to use tapered wave shapes to apply the program command to the external controller slowly The Basic TestWare application allows you to create simple test programs that do not require complex signal management or mode switches for station configuration files To create more sophisticated test programs use the optional MultiPurpose TestWare application 5 On the 407 Controller select the External program source On the Function Generator menu select Waveform then scroll through the selections to select External Note The operational sequence in the following step may not be intuitive This sequence is necessary because of how the 793 and 407 Controllers are cabled together The following step assumes that at power up hydraulics are off the 793 Controller has a hydraulic and a program interlock active and the 407 Controller has a hydraulic interlock active 6 Apply the program To apply the program from the 793 Controller to 407 Controller A On the Station Manager application s Station Controls panel click Reset to clear the Hydraulic interlock B On the Station Manager application s Station Controls panel click HPU Power Low and then HPU Power High to turn on the HPU C On the Station Manager application s Station Controls panel click HSM Power Low and then HSM Power High to turn on the HSM 154 FlexTest GT Controller Connections Models FlexTest IIm GT SE Controller Hardware How to P
16. Lo gt 3 SERR ee 7 Motor 1 Relay R K 1 i High Hi Pressure E ae gt 4 SOL Solenoid P To J24 pin 13 5 O 24Vdc E stop 4 To J29 pin 8 gt 6 CRs Interlock XT Relay 2 HPS Defeat Voltage not connected in HPS Controller 24Vdce O 7 7 132 FlexTest GT Controller Connections 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 To From To From HPU J54 External Devices 24V0 1 lt 2 nput 1 x 3 zs 24V o 5 lt 6 nput 2 lt 7 lt a 8 24VG 9 lt 10 nput 3 i Gy 12 13 14 F Output 1 15 z Cable specification J54 Sys I O is a 15 contact type D female connector 15 contact type D male EMI connector e Backshell EMI metallized plastic e 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 Models FlexTest IIm GT SE Controller Hardware FlexTest GT Controller Connections 133 Station Connections Station Connection
17. 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 Handle Kit Parts ITEM DESCRIPTION QUANTITY 1 Support arm 2 2 Handle side leg 2 3 Clip 2 4 Washer 4 5 Screw 2 6 Spring 2 7 Button 2 8 Ratchet 2 9 Ratchet housing 2 10 Lock washer 2 11 Handle screw 2 12 Handle 1 13 Cover 2 58 Installation Models FlexTest IIm GT SE Controller Hardware Installing the Handle Kit _12 handle not shown 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 Insert a spring 6 and a button 7 into the handle side leg mounting hole over the screw 5 and washers 4 5 Press the button 7 into the handle side leg as far as you can and push a ratchet 8 over the button 7 leg detentes until it snaps into place over the first set of detentes Make certain
18. Processor g p PN 051 996 803 a 178 FlexTest Ilm Controller Connections Models FlexTest IIm GT SE Controller Hardware Sensor and Valve Connections Sensor and Valve Connections Cable specification The Model 497 01 Analog Chassis connectors J101 through J1601 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 Connectors J102 through J1602 provide a second connection for dual conditioners dual valve drivers or three stage valve drivers To From J101 J1601 AC DC Conditioner or Valve Driver 1 2 g 3 lt i 4 5 6 No Connection 7 8 9 lt 10 11 2 12 2m 13 lt 14 i 15 To From Transducer or Servovalve Excitation Excitation Guard Feedback Feedback Serial Ground future Shield Drain Serial Clock future Valve Command Excitation Sense Valve Command Feedback Return Valve 2 Feedback Return Valve 2 Serial Data future Excitation Sense Shield to Backshell Cable sensor Two twisted shielded pairs with an overall braided shield MTS material 003 724 401 Cable outer shield drain wire to pin 7 optional and cable outer braid folded back under the EMI backshell clamp Cable valve 18 AWG 4 conductor shielded Belden 9418 or
19. 92 FlexTest GT Controller Connections Models FlexTest Ilm GT SE Controller Hardware Model 493 21B DUC B Jumpers 4 or 8 wire Jumpers W2 and W3 establish the correct shunt calibration connections for 4 sensor cable 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 e Jumper W2 selects a 4 or 8 wire transducer for positive feedback e Jumper W3 selects a 4 or 8 wire transducer for negative feedback e The setting of jumper W8 single ended excitation enable may affect your choices for these jumpers W2 and W3 Note excitation excitation is standard Default cali ie EXto FB shuntin qm C EX to FB shunt EED 4 wire config B v2 in 4 wire config EE D u dE Bv EXto FBR shunt M E v2 EXto FBRshunt EHD v2 in 8 wire config EED in 8 wire config EED Bridge balance Jumper W4 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 KQ resistor to the input of the conditioner preamp Disable Disable Enabl B w SB v Models FlexTest IIm GT SE Controller Hardware FlexTest GT Controller Connections 93 Digital Universal Conditioner DUC BC Switches Excitation Jumpers W5 and W7 select the local on board or remote through a cable excitation sensor connect
20. Cable specification The cabling information shown assumes a single cable destination with an overall shield In other applications the cable may have more than one destination For these applications an overall shield is not practical and non EMI connectors and back shells are permissible e 37 contact type D male EMI connector e Back shell EMI metallized plastic e Cable shielded twisted pairs as required 24 AWG minimum with drain wire s connected to the metallized backshell at the chassis Models FlexTest IIm GT SE Controller Hardware FlexTest GT Controller Connections 143 Digital I O Connections Digital I O The digital inputs and outputs can be cabled to an optional digital I O access box access panel The box is a convenient way to wire digital sources and destination to the Model 493 72 Digital I O transition module 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 p for use in a console Hrn oo j EJE a L 7k oo oo pe 2 st La ur eae e lay eocccvcccvcccvccce f t
21. d A QU N intlk return out 4 lt G z ol Master dependent The master dependent input setting connector pin 8 determines whether a input controller box is master or dependent in the multibox chain If this pin is jumpered to ground the controller is dependent if not it is the master Upon a CPU or interlock reset software checks the state of this pin and configures the controller box accordingly Cable specification Use MTS cable PN 056 534 1xx 174 _ FlexTest GT Controller Connections Models FlexTest IIm GT SE Controller Hardware 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 clk in gt intlk out 1 gt intlk out 2 gt intlk out 3 gt intlk out 4 gt test gt oAN OO FP ON clk out gt intlk return in 1 lt 4 intlk return in 2 lt signal return lt wo N intlk return in 3 lt P intlk return in 4 oO signal return lt 4 Last controller jumper The last controller box in a chain must have a jumper plug MTS PN 100 079 126 on its J52 Box Out connector This jumper allows the return of the composite station interlock signal for all controllers
22. e Use pin 3 or 6 to prevent problems with floating grounds between devices e Analog inputs can be connected at the BNC connectors of a Model 493 75 Analog In transition module and the outputs from this module are connected to the Model 493 40 I O Carrier module e Analog inputs can be connected at the BNC connectors of a Model 493 77 Filtered Analog Input transition module and the outputs from this module are connected to the Model 493 40 I O Carrier module Models FlexTest IIm GT SE Controller Hardware FlexTest GT Controller Connections 115 Analog I O Connections Model 493 77 Filter The following filter modules are available for board mounting at the BNC Modules connectors of a Model 493 77 Filtered Analog Input transition module Filter Module Specifications ASSEMBLY NUMBER HZ TYPE 047 774 401 50 Bessel 047 774 402 100 Bessel 047 774 403 200 Bessel 047 774 404 500 Bessel 047 774 405 1000 Bessel 047 774 406 2000 Bessel 047 774 407 5000 Bessel 047 774 408 120 Bessel 047 774 409 300 Bessel 116 FlexTest GT Controller Connections Models FlexTest IIm GT SE Controller Hardware 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 To D A J4 J7 External Device s 1 2 Output 1 L _ 3 Vv gt 4 O 2 5 utpu 5
23. 2 On the Series 793 Controller create a station configuration file Use the Station Builder application to define controller resources to provide program to the Model 407 Controller When you create this type of station configuration you typically select an analog output for the channel output resource and Program Only or Program with Feedback for the channel type If you create a Program with Feedback channel you typically select analog inputs for the control mode input resources This allows you to receive 407 control mode feedback You also select unit type and dimension Note Because of wiring considerations between 793 and 407 Controllers you must assign an HSM in the station configuration file even if an HSM does not control power to the external controller 3 On the 793 Controller adjust the program signals Models FlexTest IIm GT SE Controller Hardware FlexTest GT Controller Connections 153 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 gt 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 Define a program with the Function Generator Basic Test Ware or MultiPurpose TestWare applications
24. 8 Contents Models FlexTest IIm GT SE Controller Hardware How to Get Technical Support Technical Support How to Get Technical Support Start with your manuals Technical support methods www mts com E mail Telephone Fax Outside the U S 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 MTS provides a full range of support services after your system is installed If you have any questions about a system or product contact Technical Support in one of the following ways The web site provides access to our technical support staff by means of an onlineform www mts com gt Contact MTS gt Service amp Technical Support button tech support mts com MTS Call Center 800 328 2255 Weekdays 7 00 A M to 5 00 P M Central Time 952 937 4515 Please include Technical Support in the subject line For technical support outside the United States contact your local sales and service office For a list of worldwide sales and service locations and contact information use the Global MTS link at the MTS web site www mts com gt Global MTS gt choose your region in the right hand colu
25. Ilm GT SE Controller Hardware Valve Connections Series 257 Valve The Series 257 Servovalve is a 3 stage servovalve that requires a power driver connections 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 To From J4 J7 To From I O Carrier Servovalve 1 Excitation 2 Excitation 3 q 4 Feedback q 5 Feedback oo Signal Ground 8 9 Valve Command 10 11 Valve Command 12 13 14 15 Controller Nave WOT Inner Loop FY Feedback Test Command 448 16 Command Control N a Driver Power po Mode Driver LVT stability i Loop Actuator VDT Feedback Outer Loop Models FlexTest IIlm GT SE Controller Hardware FlexTest GT Controller Connections 111 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 300
26. PN 005 402 3xx 62 Installation Models FlexTest IIm GT SE Controller Hardware Model 497 01 Analog Chassis Model 497 01 Analog Chassis About Analog Chassis Slots Slot pairing Slot assignments Slot A Slot B Slots 1 4 Slots 5 8 Slots 9 12 Slots 13 16 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 Each slot is reserved for a particular type of plug in module Reserved for the Model 497 34 Multistation Interlock Module Reserved for the Model 497 36 Communications Module These slots are reserved for up to four AC conditioners These slots are reserved for up to four DC conditioners These slots are reserved for options not used with standard systems These slots are reserved for up to four valve drivers Models FlexTest IIm GT SE Controller Hardware Installation 63 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 fro
27. 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 Single 407 Controller Connections 493 76 Analog Out 152 FlexTest GT Controller Connections PN 044 632 OXX 407 Controller n2 chs L al z o 493 77 Filtered Analog Input This module includes six BNC connectors that provide filtered analog inputs to a Model 493 45 A D mezzanine card Six analog inputs are available with each A D mezzanine card installed on the Model 493 40 I O Carrier module Models FlexTest IIm GT SE Controller Hardware How to Provide Program to a Series 407 Controller Multiple 407 Controller Connections 493 76 Analog Out i n tise 3l ol al Program In Program In Program In Conditioner Monitor Conditioner Monitor 493 76 Filtered Analog Input Fer n Conditioner Monitor Conditioner Conditioner Monitor Conditioner
28. backshells and connection shields as described in the cable specification for each connector See the appropriate rear panel connector for fabrication information It is possible that grounding both ends of the overall shield can produce a low frequency ground loop current If you experience an unacceptable low frequency noise level try the following in the order given e Connect the system chassis ground of the external device directly to the controller chassis Disconnect the overall shield from the metallized back shell at the external device and add a capacitor approximately 0 01 uf to one end of the cable between the shield and the metallized backshell Disconnect the overall shield from the metallized back shell at the external device Models FlexTest Ilm GT SE Controller Hardware FlexTest GT Controller Connections 83 Typical Cabling Typical Cabling For additional cables see Cable Part Numbers on page 85 iiss HPU Workstation 039 713 7xx 051 996 8xx 039 708 3xx Servovalve 056 126 5xx Load Unit Control 056 126 4xx Actuator Manifold HSM 055 634 2xx E stop or 055 634 3xx Station Stop Remote Rear Station Control Connectors with Transducer ID modules 052 544 2xx 052 543 1xx LVDT Boo e ooe Ol Force Sensor 052 544 2xx 052 542 5xx Typi
29. 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 493 10 Chassis Daughter Board 3 Daughter Board 4 J Front Rear Cable Conduit i T eee MTS ena 122 FlexTest GT Controller Connections Models FlexTest IIm GT SE Controller Hardware 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 For more information see Setting Up the Remote Setpoint Adjust in the MTS 793 Control Software manual Remote Setpoint Pod n rom Shunt Cal 100 051 058 J A o 38 88 So 3 88 83 g al z fh
30. 493 73 HPU Transition module has a connection to control a hydraulic power unit It includes connections for an emergency stop button and digital I O for system communications e Typically up to four Model 493 74 HSM Transition Modules can be used to support up to eight HSM stations Each HSM module includes connections to support two stations Each station supports an HSM a load unit run stop outputs auxiliary outputs and interlock controlled outputs Two types of interlocks are supported the system wide interlock and station interlocks The system wide interlock shuts down the hydraulic power unit and all stations and the station interlock shuts down a single station leaving other stations running The emergency stop function on the Model 493 74 HSM transition board contains two separate circuits the system wide interlock HPU and the station interlock HSM The emergency stop circuit consists of a loop that only runs through the rear panel transition boards of the chassis Any board that generates an interlock by breaking this system wide loop causes the hydraulic power unit to be shut down This will also cause all of the stations to shut down Note The emergency stop circuit meets the requirements of the Machinery Safety Directive EN 60204 1 1992 section 9 2 5 4 This means the emergency stop circuit is hard wired with electromechanical components Each station represents all of the components associated with an interlock cha
31. 6 7 Output 3 GF 8 9 Output 4 a 10 gt n outputs s 12 13 Output 6 T 14 15 e Each readout signal is from a 16 bit digital to analog converter e Each output is a 10 V analog output e The Model 493 46 D A Mezzanine Card provides analog signals to the Model 493 76 Analog Out transition module Analog outputs are available at the BNC connectors of a Model 493 76 Analog Out transition module for external devices DVM oscilloscope Models FlexTest IIm GT SE Controller Hardware FlexTest GT Controller Connections 117 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 e 15 contact type D male EMI connector e Backshell EMI metallized plastic e Cable type up to 6 shielded twisted pairs each with the drain wire connected to the signal source The cable to the Ch 1 Ch 6 connectors on the rear panel have the following specifications BNC connector UG88 U Cable RG 58 coaxial Use of a smaller coaxial cable and a RG 174 BNC connector with an appropriate cable end is permissible 14148 FlexTest GT Controller Connections Models FlexTest Ilm GT SE Controller Hardware Accelerometer Connections Accelerometer Connections An accelerometer requires the Model 493 48 Acceleration mezzanine card
32. A AC conditioners connections 180 AC power connections 55 accelerometer I O carrier connection 119 229 Models FlexTest IIm GT SE Controller Hardware ADDA cabling 183 connections 183 daughter boards 201 analog chassis 497 01 63 adding to console 69 chassis slots 63 modules 64 analog I O cable specifications 118 228 VO carrier connections 226 automated configuration 25 B back panel 26 Box In J51 234 Box Out J52 235 bridge completion T O carrier module 103 ID module 107 C cable specifications analog I O 118 228 digital I O 143 digital inputs 236 digital output 237 J24 E stop input 129 J25 HPS 497 05 190 J25 HPU 131 231 J28 HSM 497 05 191 J28 HSM solenoid 134 J29 E stop 232 J29 E stop input 232 J29 load unit 136 J43 interlock 137 233 J44 run stop 139 J49 auxiliary power 140 J54 system I O 131 231 servovalve 108 179 transducer 179 Index 257 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 frequency ground loops 8
33. F 7 nput 4 lt 8 4 1 t 2 NpUt S 4 3 F nput 6 J12 J14 4 J16 J18 4 5 nput 7 6 a nput 8 1 8 186 FlexTest Ilm Controller Connections Models FlexTest IIm GT SE Controller Hardware 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 e Fach readout signal is from a 16 bit digital to analog converter Each output is a 10 V analog output e 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 82 Analog Out transition module for external devices DVM oscilloscope From 19 External D A Device gt 1 Output 8 2 E gt 3 z Output 7 J11 di3 4 2 J15 J17 _p 5 7 Output 6 6 7 g Output 5 gt 8 9 Output 4 gt 10 11 Output 3 J12 J14 12 2 J16 J18 gt 13 7 14 Output 2 P 15 l gt 16 Output 1 ADDA II Universal Each encoder requires a Model 493 59 Universal Encoder mezzanine card Encoder connections installed on the Model 493 50 ADDA II module Models FlexTest IIm GT SE Controller Hardware FlexTest Ilm Controller Connections 187 ADDA II Connections Up to six
34. Interlock load frame 054 145 4XX Servovalve 252 xx single 046 440 1XX Servovalve 252 xx dual 046 440 4XX in phase 046 440 5XX out of phase Jumper plug 2nd servovalve eliminator 039 705 901 Servovalve 256 xx w valve 046 440 1XX Servovalve 256 xx w valve LVDT 046 440 8XX AP stability 047 927 6XX AP stability dual cells 048 049 6XX System ground console MTD FlexTest 005 402 3XX HSM on off HSM high low 292 xx 298 xx 039 705 3XX 24 V DC 039 719 1XX 115 V AC 039 705 5XX 24 V DC 039 719 2XX 115 V AC HSM on off 292 xx 298 xx 039 708 1XX 24 V DC 413 07 Hydraulic interface to 298 12 prop HSM 042 664 5XX 24 V DC 497 05 Control Panel to 413 07 042 075 701 24 V DC HPS HSM power not included 039 708 7XX 24 V DC 039 708 8XX 115 V AC Y adapter at HPS 005 407 801 24 V DC 005 401 801 115 V AC For CE configurations there are CE versions of these cables Refer to the System Cable Package Selection FlexTest drawing PN 047 922 501 for these cable numbers 216 FlexTest Iim Controller Connections Models FlexTest IIm GT SE Controller Hardware Chapter 5 FlexTest SE Controller Connections Contents This section describes the connections to the MTS 493 02 Chassis Note For information on connecting power cables see Connecting Electrical Power on page 53 Note For information about CE compliance see CE EMC Com
35. J7 Valve LVDT 039 708 6XX 493 40 J4 J7 Calibration Cable Package 100 026 213 493 40 J3 Y Adapter Servovalve Valve LVDT 039 710 501 493 40 J4 J7 N A required for 256 xx or 257 xx servovalves Workstation Link Ethernet cable 051 996 8XX 10 100 N A System ground table top 005 402 3XX N A System ground rack mount 039 709 2XX gnd lug Hydraulic Power Unit HPU see Hydraulic 039 713 7XX 493 42 J25 039 713 301 Configurations on page 243 for more information Hydraulic Service Manifold HSM 039 701 5XX 493 42 J28 N A Emergency Stop E STOP 493 42 J29 100 007 947 Interlock Intik Per System 493 42 J43 100 057 245 Auxiliary Power Aux Pwr Per System 493 42 J48 N A Box In 056 316 0xx 493 42 J51 N A Box Out 056 316 0xx 493 42 J52 100 057 246 Digital Input Dig In Per System 493 42 J54 N A Digital Output Dig Out Per System 493 42 J55 N A Analog In Anlg In Per System 493 42 N A Analog Out Anlg Out Per System 493 42 N A Models FlexTest IIm GT SE Controller Hardware FlexTest SE Controller Connections 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 223 Cable Part Numbers XX specifies cable length 01 through 09 represent 10 50 ft in 5 ft increments Higher numbers represent custom cable lengths t Jumper plugs are required if a cable is not installed The connector is the 10 100 BaseT connector on
36. See the System Cable Jumper Plug 493 Package Selection drawing PN 700 000 Module 656 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 120 052 543 5XX 056 125 8XX 493 40 J4 J7 300 052 443 6XX 056 125 9XX 493 40 J4 J7 Extensometer 633 capacitive 052 543 4XX 052 544 3XX 493 40 J4 J7 Force Transducer w PT connector 052 542 5XX 052 544 2XX 493 40 J4 J7 with PC connector 052 542 6XX 052 544 2XX 493 40 J4 J7 with MS connector 052 542 7XX 052 544 2XX 493 40 J4 J7 LVDT 052 543 1XX 052 544 2XX 493 40 J4 J7 AP control 052 543 2XX 052 544 2XX 493 40 J4 J7 Pressure Control Sensotec 052 543 3XX 052 544 2XX 493 40 J4 J7 Strain with Amphenol connector 052 542 9XX 052 544 2XX 493 40 J4 J7 with PT connector 052 543 0XX 052 544 2XX 493 40 J4 J7 Temposonics 052 543 7XX 056 126 0XX 493 40 J4 J7 Temposonics II low power conditioner 052 543 8XX 052 544 7XX 493 40 J4 J7 RVDT with MS connector 052 750 8XX 052 544 2XX 493 40 J4 J7 XX specifies cable length 01 through 09 represent 10 50 ft in 5 ft increments Higher numbers represent custom cable lengths 102 FlexTest GT Controller Connections Models FlexTest IIm GT SE Controller Hardware Shun
37. This chapter describes the hardware components and specifications of FlexTest GT FlexTest SE and FlexTest Im Controllers FlexTest GT Controllers 20 Model 493 10 Chassis 20 Hydraulic Control 22 Interlocks 22 Specifications 23 FlexTest SE Controllers 24 Model 493 02 Chassis 26 Hydraulic Control 26 Interlocks 26 Specifications 27 FlexTest Ilm Controllers 28 Model 497 01 Analog Chassis 30 Model 497 05 Hydraulic Control Panel 31 Model 498 22 Chassis with Test Processor FTIIm 32 Specifications 33 Models FlexTest IIm GT SE Controller Hardware Introduction 19 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 10 Chassis is a multi station multi channel VMEbus chassis which houses up to ten MTS VMEbus modules in its front panel and up to ten transition modules in its rear panel
38. at the load frame Jumper plug If connector J29 is not used you must install a jumper plug to maintain the integrity of the interlocks Use jumper plug 100 007 947 or jumper pins 3 and 4 5 and 7 8 and 13 Station stop The Emergency Stop connection can also be configured as a station stop When this is done be sure that you have other Emergency Stop boxes near by Pressing Station Stop will shut down the hydraulics to an individual station without shutting down power to the hydraulic power unit Note A Model 493 73 HPU Transition Board must be installed for the Emergency Stop connection to be enabled 136 FlexTest GT Controller Connections Models FlexTest IIm GT SE Controller Hardware J43 Interlock J43 Interlock Connector J43 Interlock accommodates two general purpose inputs to be connected to the interlock chain e Input is dedicated as a station interlock Input 2 is dedicated as a program interlock e Both inputs are optically isolated e Ifjust one contact is used the other must be jumped Both inputs can accept relay ee J43 p ai contacts or a logic signal 23919 ee RENICE Both configurations are 24V 0 WW 1 shown EERE P MW 2 Each input can be have MPUt1 I relay Station iy contacts either configuration Interlock lt 3 L a a Cable specification Power characteristics Jumper plug i logic Input 2 WW 6 Program va driver Inte
39. connectors The temperature controller can be connected to any of the four J50 connectors on the serial interface Temperature controller For more information on adding the Eurotherm hwi file resource see the MTS hardware resource 793 Utility Software manual Models FlexTest IIm GT SE Controller Hardware FlexTest GT Controller Connections 165 Eurotherm Temperature Controller Connection Program the Use the Station Builder application to configure a Eurotherm temperature temperature controller controller 498 718 493 71 GRES I Serial Interface Hav J50A ses Use Jumper Plug 055 634 101 Q in these connectors Y EVENT OUT A Y EVENTIN gt so O AR J5 DEBUG J6 STATION J Eurotherm Temperature Controller FTG 8G oy 049 876 501 To 056 172 0xx for Model 652 653 Temperature Chambers 056 128 Oxx for Model 651 Temperature Chambers 166 FlexTest GT Controller Connections Models FlexTest IIm GT SE Controller Hardware 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 Model 408 81 Testing Panel Model 408 82 DC Conditioner SENSOR OUTPUT Sensor output is available
40. controller automated configuration 25 back panel 26 front panel 24 handle kit install 58 interlocks 26 multiple connections 220 stand alone configuration 24 controller chassis DUC jumpers 92 94 97 controller connection CTM programmer 151 CTM programmer controller connections 151 D daughter boards 51 daughter boards ADDA module 201 DC conditioners connections 180 Models FlexTest IIm GT SE Controller Hardware 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 129 E stop out connector J29 232 HPU transition connectors 129 232 encoder T O carrier connections 121 encoders connections 200 daughter boards 201 jumper configurations 201 Eurotherm temperature controller cabling 165 209 239 how to configure 166 209 programming 165 209 239 external controllers 168 210 adjust command signal 168 212 allocating resources 168 211 cabling 168 204 211 conditioner outputs MTS products 167 programming 204 external programs rece
41. converter box is used with other configurations For more information see Hydraulic Configurations on page 243 Control voltages for hydraulic power units vary between models The HPU interface between the Model 493 73 HPU transition board and an HPU is 24 volt logic signals Connecting J25 to a non compliant HPU can damage the module DO NOT connect 24 V DC relay circuitry or 115 V AC circuitry to the HPU connector J25 The Service LED turns on when electrical power is applied and it turns off when the chassis makes contact with the personal computer and processor has successfully booted J25 HPS is a 15 pin type D male connector e 15 contact type D female EMI connector e Cable 24 AWG 10 conductor with overall foil shield Carol C0745 or equivalent with drain wire connected to metallized plastic backshell to the chassis If connector J25 HPS is not used you must install a jumper plug to maintain the integrity of the interlocks Use jumper plug PN 039 713 301 or jumper pins 1 7 2 3 5 6 9 8 10 11 12 Models FlexTest IIm GT SE Controller Hardware FlexTest GT Controller Connections 131 J25 Hydraulic Power Unit Connection J25 Diagram To From J25 To From Chassis HPU HPSOn Sense T 9 4 i d Y A gt 10 d aan paa P OverTemp t i i 1 ie o Low Level 12 e o HPS 24 Vdc E a iad CRM X Start SJ gt 2 OR
42. 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 Recommended standard module locations are described in the following sections For more information on the hwi file see the Hwi File Editor manual The plug in modules contain static sensitive components Improper handling of the module can cause component damage Be sure to follow these precautions when handling modules e Turn off electrical power before installing or removing a module e Use a static ground strap to ground yourself to the chassis ground before touching the chassis or a module e Keep unused modules in conductive bags Also be sure you are grounded when removing a module from a conductive bag e Handle modules with their front panel or circuit card edges Do not touch any circuit card components pins or circuit connection points Models FlexTest IIm GT SE Controller Hardware VMEbus Modules VMEbus Modules The VMEbus compatible modules should be installed in the front panel chassis slots according to the following guidelines e The processor module s must be located in the first and second slots e The GRESII module if used should be located in slot 10 It may also be located in slot 2 if a second processor is not used T O carrier modules and or ADDA II modules can be installed in slots 3 to 10 Install a module in slot 3
43. in a table top configuration a O L H tse lief CC D9 FlexTest SE Rear Panel Hydraulic Control The controller provides complete control of the test system hydraulics It can be used to control a hydraulic power unit and a hydraulic service manifold to apply low and high hydraulic pressure to the test system In multiple controller configurations the controller provides first on last off control of the hydraulic power unit in addition to control of a local hydraulic service manifold Interlocks The controller provides interlocks for adjustable upper lower limit underpeak error detection for each sensor conditioner installed and others These interlocks can be daisy chained for multiple controller configurations 26 Introduction Models FlexTest IIm GT SE Controller Hardware Specifications Specifications FlexTest SE Specifications PARAMETER SPECIFICATION Environmental For indoor use only Temperature 5 C 40 C 41 F 104 F Relative humidity 10 85 noncondensing Altitude For use at altitudes up to 2000 m 6500 ft Power input power factor corrected universal input Input voltage 100 240 V AC Input frequency 47 63 Hz Input surge lt 50 A Insulation over Category
44. in the chain to monitor Note _ If there is only one controller a jumper is still required on its Box Out connector Cable specification Use MTS cable PN 056 534 1xx Models FlexTest IIm GT SE Controller Hardware FlexTest GT Controller Connections 175 J52 Box Out 176 FlexTest GT Controller Connections Models FlexTest IIm GT SE Controller Hardware Chapter 4 FlexTest Ilm 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 178 Sensor and Valve Connections 179 ADDA Module Connections 183 Hydraulic Connections 189 HPU Connections 190 HSM Connections 191 Interlock Connections 192 Interlock Jumper Plugs 193 Serial Communications 195 Digital I O Connections 196 Encoder Temposonics Connections 200 Remote Station Controller RSC Connections 203 Cabling and Programming External Controllers 204 Programming Eurotherm Temperature Controllers 209 Cabling for External Command Inputs 210 Cabling for External Command Inputs 210 Cable Part Numbers 216 Models FlexTest IIm GT SE Controller Hardware FlexTest Ilm Controller Connections 177 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
45. interlock input 6 hyd low in Hydraulic low input 7 signal return Signal return for optically isolated inputs 8 master slave in Master Slave select input 9 clk in External clock input 10 hyd hi return out Hydraulic high return output 11 reset return out Interlock reset return output 12 ground Signal ground 13 intlk return out Hydraulic interlock return output 14 hyd low return out Hydraulic low return output 15 ground Signal ground 234 FlexTest SE Controller Connections Models FlexTest IIm GT SE Controller Hardware 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 J52 Connector Pin Assignments PIN NAME FUNCTION 1 clk in External clock output 2 hyd high out Hydraulic high output 3 reset out Interlock reset request output 4 ground Signal ground 5 intlk out Hydraulic interlock output 6 hyd low out Hydraulic low output 7 ground Signal ground 8 N C No connection 9 clk out External clock output 10 hyd hi return in Hydraulic high return input 11 reset return in Interlock reset return input 12 signal return Signal return for optically isolated inputs 13 intlk return in Hydraulic interlock return input 14 hyd low return in Hydraulic low return input 15 signal return Signal return for optically isolated inputs Jumper plug required Models FlexTest IIm G
46. option cards installed It is an 8 pin RJ 45 connector From To Daughter J3 External Boards Device gt 1 Slot 1 Monitor oF 2 Slot 1 Ground gt 3 Slot 2 Monitor 4 Slot 2 G d o roun 5 Slot 3 Monitor 6 Slot 3 Ground vV l 7 Slot 4 Monitor 8 Slot 4 Ground Important The signals at the J3 Service connector are provided for service and troubleshooting only These signals are defined by the I O option mezzanine cards that are installed on a respective Model 493 40 I O Carrier module Some of these signals may be uncalibrated Before use take appropriate steps to determine the characteristics of these signals 1450 FlexTest GT Controller Connections Models FlexTest Ilm GT SE Controller Hardware Cabling and Programming Series 407 Controllers Cabling and Programming Series 407 Controllers This section describes e Cabling and programming the FlexTest GT Controller to analog program and feedback signals from a Series 407 Controller e Connecting FlexTest GT Controllers to interlock signals from a Series 407 Controller e Setting up a Series 407 Controller to send and receive signals from FlexTest GT Controllers Important When used as a programmer FlexTest GT Controllers do not have automated mode switching capabilities Control mode selection on these controllers do not effect the control mode of the controller to which they are sending test commands How to Prov
47. single ended excitation excitation EX EX EX GND Default CED H FlexTest GT Controller Connections Models FlexTest Ilm GT SE Controller Hardware 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 R32 E BD Default No Resistor G BB Positive Offset ESD Negative Offset Models FlexTest IIm GT SE Controller Hardware FlexTest GT Controller Connections 99 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 700 000 656 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 Specifications 15 contact type D male EMI connector e Backshell EMI metallized plastic e Cable type For all applications including CE EMC Compliance use MTS cable material PN 050 530 101 two 22 AWG twisted pairs with inner and outer braided shield for the excitation and feedback signals plus a twisted quad for the ID signals and a single wire f
48. source can be a stand alone function generator another controller or a computer controlled analog output 226 FlexTest SE Controller Connections Models FlexTest IIm GT SE Controller Hardware Analog I O Connections A D connections The analog to digital mezzanine cards accommodate up to six analog input signals e Each A D input signal must be within 10 volts To From A D J4 J7 A D 1 F 2 nput 1 3 Analog lt __ Ground 4 nput 2 5 6 Analog Vv __ Ground lt lt 7 nput 3 at 8 9 nput 4 t 10 lt n E nput 5 a 12 tmMm 13 a ja a OPM 15 e Use pin 3 or 6 to prevent problems with floating grounds between devices Models FlexTest Ilm GT SE Controller Hardware FlexTest SE Controller Connections 227 Encoder Connections D A connections Digital to analog mezzanine cards support up to six program or readout signals to external devices e Each D A signal is an analog output within 10 volts From To D A J4 J7 External Device es ee O 1 2 a utpu 3 Vv gt 4 Output 2 5 SG 6 gt 7 F Output 3 S 8 9 Output 4 n outputs oor 12 13 Output 6 5 14 15 e Each readout signal is from a 16 bit digital to analog converter e Each output is a 10 V analog output Cable specification The cable specifications apply to both the analog inputs and analog output
49. specifications The specifications for the interlock status opto isolator outputs are as follows Output Format open collector open emitter transistor e Maximum Voltage 26 V DC e Minimum Guaranteed Output Current Drive 20 mA 30 mA typical 1 0 V max Jumper X5 Jumper setting X5 selects the source for interlock status output The following jumper settings select the indicated interlock source e X5 Jumpered HSM Board Interlocks Only X5 Not Jumpered Station and HPU Interlocks Jumpers W8 W9 Jumper settings W8 W9 determine the output polarity of the opto isolators Cable specification e 9 contact type D female EMI connector e Backshell EMI metallized plastic e Cable shielded twisted pairs 24 AWG minimum with drain wire s connected to the metallized backshell at the chassis Models FlexTest IIm GT SE Controller Hardware FlexTest GT Controller Connections 139 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 From J49 To Chassis External Devices F7 15 Vdc OS _ 1 Analog o 2 Ground W
50. the burred or sharper edges of the ratchet are pointing toward the handle side leg 6 Holda ratchet housing 9 in place over the ratchet 8 and press the posts on the back side of the ratchet housing 9 into the mounting holes on the side panel of the controller Models FlexTest IIm GT SE Controller Hardware Installation 59 Installing the Handle Kit 60 Installation 10 12 Insert a Phillips screwdriver through the hole in the button 7 and lightly tighten the screw 5 Assemble the remaining handle kit components to the other handle side leg 2 according to steps through 7 and mount the side leg to the mounting holes on the opposite side of the controller 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 Repeat this step for the other handle side leg then secure both screws 11 The mounting screw for the first handle side leg may have to be loosened slightly to allow the second handle side leg to be mounted Snap cover 13 in place over the handle screw 11 and lock washer 10 Secure mounting screws 5 on each side of the controller Press in both buttons 7 and rotate the handle assembly The assembly should rotate up and down easily When the buttons 7 are released the handle should lock into a detente position and remain there If the handle does not move easily or if it does not lock into a dete
51. you have more than one analog chassis you must plug each additional analog chassis into a remote power supply Models FlexTest IIm GT SE Controller Hardware Installation 61 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 8 EE PN 046 239 1xx J t 0 DD OG oO 497 01 Analog Chassis DO000000 DOODODODDDDDOODDO OD ag 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 Remove the jumper between the two grounds and connect each terminal as follows e Each chassis ground should be connected to the console with a short ground cable PN 037 766 102 e Each power ground should be connected at a common location on the power panel PN 037 766 1xx e The power panel ground should be connected to the console PN 037 766 101 The system ground cable connects the console to other system components
52. 0 3500 watt Flextest 40 494 04 1200 watt FlexTest 60 494 06 1800 watt FlexTest 100 494 10 2500 watt FlexTest 200 494 20 3500 watt Models FlexTest IIm GT SE Controller Hardware 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 Board J54 SYS DI O AC Fail Estoe Contacts 3 Open Logic 0 33 gt J54 SYS DIJO ad Low Battery Contacts Open Logic 0 493 73 HPU Board Cable specification To maintain EMC compliance J54 SYS DI O cables must comply with the following specifications Connector 15 contact type D male EMI connector Backshell metallized plastic or metal Cable 26 to 22 AWG 4 conductor with overall braided shield with the braided shield connected to the backshell at the chassis Models FlexTest IIm GT SE Controller Hardware Installation 79 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 conne
53. 00 00000 Front Rear LN OD 00 O GI 0000 o 0000 ii desa 493 10 Chassis AUNNaNNNANNNUNNNABNNANNNNNNNNNNENGENEN ase Front Rear Cable Conduit a ae on a 14142 FlexTest GT Controller Connections Models FlexTest Ilm GT SE Controller Hardware 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 J3 J8 lo Servovalve 1 2 Valve Command 3 Valve Command 4 Cable Loss 5 Cable Loss 6 7 8 9 10 Note Different customer actuator sign conventions might require alterations to the cable polarity Contact MTS for more information Improper operation can damage valve driver cards Damage can occur if you connect a high level signal to a valve driver card when the chassis power is off Do not apply a high level signal to a valve driver card when the chassis power is off Disconnect power from any externally powered devices before you swi
54. 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 connections 108 226 shunt calibration connector 103 installing handle kit 58 plug in modules 42 49 transition panels 47 VMEbus modules 43 50 interlock connections 192 HSM transition connections 137 138 jumper plugs 193 interlocks 22 26 J J29 E stop 232 J49 auxiliary power connector 234 J51 Box In connections 234 J52 Box Out connections 235 J54 Digital Input connections 236 J55 Dig Out connection 237 jumper settings adding analog chassis 69 communication module 497 36 70 260 Index jumpers shunt cal 98 4 8 wire sensor cable 93 95 97 498 System Digital I O 193 active guard 92 94 97 bridge balance 93 96 99 digital I O transition module 142 digital universal conditioner DUC 92 94 97 encoder configuration 201 excitation sense 94 96 98 HPU converter 251 interlock 193 J24 E stop input 130 J25 HPS 131 J25 HPS 497 05 190 J25 HPU 231 J29 E stop input 233 J29 load unit 136 J43 interlock 137 173 234 J52 Box Out 235 rear panel 235 single ended excitation 94 96 98 L load unit HSM transition connections 136 low frequency ground loops correcting noise problem 83 LVDT T O carrier connection 90 meters connecting external 210 modu
55. 20 FlexTest SE Controller Connections Models FlexTest Ilm GT SE Controller Hardware Multiple Controller Connections Note The indicated cables on each controller must be connected before the controllers are turned on yt OS Sc al i Z 1 id if p 1d pid Gp efe liO sp Cp i e eE o Ef Master oi ime ey eas Tp EE Ps Gaz Pp SEE p EP lal a Qe gt ie i 3 z RP ACIE E 9 ts gt i El Dependent 1 gt P CA dca de p dez pcr Jb l IG it G3 peed lo lal Box Out Jumper Plug 100 057 246 056 316 0xx fol san p OE ge id Dependent 2 gt GIES Ore 3 z Tests C e ae g AAE lof 4 Ea 8 i Use the J51 Box In and J52 Box Out connectors on the 493 42 System I O module in the controller s rear panel to connect one controller t
56. 3 readout devices 171 214 rear panel J101 J1601 servovalve 179 J101 J1601 transducer 179 J102 J1602 dual servovalve 179 J23 E stop output 129 J24 E stop input 129 J25 HPU 131 230 J28 HSM solenoid 134 231 J29 E stop 232 J29 load unit 136 J3 In digital inputs 142 J4 Out digital outputs 143 J43 Interlock 233 J43 interlock 137 J44 run stop 138 J49 auxiliary power 140 234 J54 System I O 131 231 serial communications 195 typical system layout 84 valve 181 CE EMC compliance cabling 83 chassis grounding 53 62 installation options 51 power connections 53 61 power description 55 chassis modules installing 42 computers connections 178 258 Index conditioner jumpers DUC shunt cal 98 4 8 wire sensor cable 93 95 97 active guard 92 94 97 bridge balance 93 96 99 excitation sense 94 96 98 single ended excitation 94 96 98 conditioners cabling 180 configurations AC power 55 configurations FlexTest IIm Controller 28 connecting electrical power 53 external readout devices 210 connection workstation 229 connections AC power 55 AC sensors 180 ADDA analog to digital digital to analog 183 chassis ground 53 computer 178 console chassis power 61 DC sensors 180 digital I O 196 digital inputs 197 digital outputs 199 encoders 200 HPS 190 HSM 191 hydraulic control panel 71 multiple controllers 220 serial communications 195 System I O module 230 Temposonics sensors 200 console grounding 62
57. 7 Transition modules on the back 2 8 of the Series 498 test processor Ea ae chassis are used for analog inputs and outputs 498 Analog Out we This module includes 8 BNC 2 ee o ef ee 498 Input Filter Pa This module includes 8 BNC 2 e A E 6 connectors that provide analog cus connectors that provide ons outputs from the 498 65 ADDA filtered analog inputs to the module 498 65 ADDA module A amp Four analog outputs are Ge Four analog inputs are se available with the standard available with the standard ADDA module The other four ADDA module The other outputs require a second Shy four inputs require a second a ADDA module W ADDA module Do not interrupt FlexTest controller 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 power cannot be removed accidently while a test is in progress Optional ADDA II For the optional ADDA II configuration using the Model 493 50 ADDA II configuration module cable the analog inputs and outputs between the FlexTest controller and the external controller as follows Models FlexTest Ilm GT SE Controller Hardware FlexTest Ilm Controller Connections 205 How to Program an External Controller Note Analog I O connectors are located on th
58. 7 Jumper Plug 100 057 246 e va AN S o e LA LA A CL O L MME 2100 o O50 O 30 TOROLA 218 FlexTest SE Controller Connections Models FlexTest Ilm GT SE Controller Hardware Automated Cabling Overview Automated Cabling Overview Force Sensor ee Cable with Transducer D module Actuator 052 542 5xx A Manifold Cable from es HSM Transducer ID module o 056 126 4xx 052 544 2xx B Ls s Od imi E Servovalve 039 708 3xx e LVDT S gt Cable with Transducer E Stop ID module 556342 xx 052 543 1xx Workstation cea irom ject ransducer ID module 051 996 8xx 052 544 2xx 039 713 7xx Box Out Intik Jumper Plug Jumper Plug 100 057 246 00 057 245 z 3 F 26 9 P 5p lt a ea gt x A i 3 oil a SE oI F i lt lt a El fe Cle J P LNA ld as 9 JCO 100 240 VAC 50 60 Hz 12 68 Models Fl
59. 8 Hydraulic Service Manifold Connector 134 J29 Load Unit 136 J43 Interlock 137 J44 Run Stop 138 J49 Auxiliary Power 140 Models FlexTest IIm GT SE Controller Hardware FlexTest GT Controller Connections 81 Digital I O Connections 141 Workstation Connection 145 Remote Station Controller Connection 147 Service Connections 149 Cabling and Programming Series 407 Controllers 151 How to Provide Program to a Series 407 Controller 151 Connecting Interlock Signals to 407 Controllers 156 Sending and Receiving Signals to a Model 407 Controller 162 Connecting Interlock Signals to 458 Controllers 164 Eurotherm Temperature Controller Connection 165 Miscellaneous Conditioner Output Connections 167 Cabling for External Command Inputs 168 Cabling and Using External Readout Devices 169 82 FlexTest GT Controller Connections Models FlexTest IIm GT SE Controller Hardware CE EMC Compliant Cabling CE EMC Compliant Cabling Cable fabrication Low frequency ground loops 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 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 If it is not possible to use standard cables or you are constructing custom cables select cables
60. AC power failure condition from the facility s power grid This fault signal from the UPS can be used by the controller to start a safe shutdown sequence ramp command s to a safe state s and then shut off the power source Models FlexTest IIm GT SE Controller Hardware Installation 77 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 78 UPS power requirements Installation Any UPS used with an MTS system must comply with these specifications ITEM Operating temperature UPS Specifications REQUIREMENT 5 40 deg C Operating humidity 5 85 non condensing Supported UPS output voltage range 100 240 V AC nominal single phase sine wave output Input output frequency range 50 60 Hz Output load regulation 5 nominal operating voltage both in battery and normal operation modes Switch over time to battery 0s recommended lt 6 ms required on power loss The following UPS power requirements include power for the PC MTS Controller one chassis and 25 capability for other subsystems UPS Power Requirements CONTROLLER TYPE CONTROLLER CHASSIS UPS POWER REQUIRED FlexTest SE 493 02 1200 watt FlexTest GT 493 10 2500 watt Aero ST 493 2
61. 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 A DSP chip provides digital filtering This board requires the optional ADDA II module 493 59 Universal Encoder Processes the signals from incremental absolute and Temposonics III encoders Each type of encoder requires a specific encoder mezzanine card This board requires the optional ADDA II module Models FlexTest IIm GT SE Controller Hardware Installation 73 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 S OO Oe EO 498 498 498 498 DIGITAL I O ACCESS PANEL DIGITAL VO INPUT RS 48 SYSTEM DIGITAL IN1 16 x 12V 5V 5V 12V ed CH1 0o 0o00 Digital Input Digital Output asv x hannels Channels J3A innel inthe inthe oo
62. FlexTest IIm GT SE Controller Hardware specifications 493 10 chassis 23 27 33 sensor cables 100 UPS 78 stand alone configuration 24 standard configurations FlexTest IIm Controller 28 station connections 134 station signals available for monitoring 169 213 descriptions 169 external readout of 171 213 system cables analog I O 118 228 part number list 85 223 servovalve cables 108 system cables jumpers 223 System I O module connections 230 F temperature controllers connecting See transition modules Temposonics sensors connections 200 daughter boards 201 jumper configurations 201 test processor 498 22 about 32 transducer cables part numbers 101 specifications 100 transducer ID module assigning a sensor 107 transition bus 21 transition module connections analog chassis 67 transition modules analog chassis 497 01 66 transition panels description 48 installing 47 U UPS 493 73 connections 493 73 HPU Interface board UPS connections 79 FlexTest 40 FlexTest SE 77 FlexTest 60 100 200 GT 76 FlexTest SE 493 42 connections 80 specifications 78 Index 261 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 Ilm GT SE Controller Hardware MTS a MTS Systems Corporation 14000 Technology Drive Ede
63. I Module I O 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 Also the ADDA II module address setting on the module must match the hwi file address The following mezzanine cards can be installed Model 493 55 A D Model 493 56 D A Model 493 57 DSPAD Model 493 59 Universal Encoder The Model 493 55 A D Model 493 57 DSPAD and Model 493 56 D A mezzanine cards can be installed in the Model 493 50 ADD II module assembly as needed A connection from the front panel connector to a rear panel BNC transition module allows easy access to the analog channels 184 FlexTest Ilm Controller Connections Models FlexTest IIm GT SE Controller Hardware ADDA II Connections Note The external analog source can be a stand alone function generator another controller or a computer controlled analog output D D D0 DO pO 0 pO D DOUp0DODOPOP ODD PAD D D D O 0 0D OD D Of 00 D D D DOD J External Analog Source
64. Im GT SE Controller Hardware If You Contact MTS by Phone Know relevant For a computer problem have the following information available computer information 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 Know relevant For software application problems have the following information available software information The software application s name version number build number and if available software patch number This information can typically be found in the About selection in the Help menu The names of other applications on your computer such as Anti virus software Screen savers Keyboard enhancers Print spoolers Messaging applications If You Contact MTS by Phone A Call Center agent registers your call before connecting you with a technical support specialist The agent asks you for your Site number Name Company name Company address Phone number where you can be reached If your issue has a notification number please provide that number A new issue will be assigned a unique notification number Models FlexTest Ilm GT SE Controller Hardware Technical Support 11 Problem Submittal Form in MTS Manuals Identify system type Be prepared to troubleshoo
65. Incorporated e Cable 18 AWG 2 connector type SJOOW A for on off HSMs 18 AWG 3 connector type SJOOW A for high low HSMs e Cable assembly numbers 290 XX HSM on off 24 V DC PN 039 705 3XX 18 2 SJO 290 XX 294 XX HSM high low 24 V DC PN 039 705 5XX 18 3 SJO 298 11 HSM on off 24 V DC PN 039 708 1XX 18 2 SJO Models FlexTest Ilm GT SE Controller Hardware FlexTest Ilm Controller Connections 191 Interlock Connections Interlock Connections Remote Interlock Inputs 3 for each hydraulic channel 497 01 Analog Chassis 497 05 Hydraulic Control Panel J51 047 807 8xx O 2 bos 046 350 602 J52 Jumper Plug 046 350 701 E Stop 0ODDO00TT00DVOOND JODDDODDONDOOD 051 074 501 le za et ala m a Or a Oke a J6 E e e nl E
66. Inputs in the MTS 793 Control Software manual Task4 Start the External Command For more information see How to Enable and Run External Command Inputs in the MTS 793 Control Software manual 212 FlexTest Ilm Controller Connections Models FlexTest IIm GT SE Controller Hardware 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 To send station signals to an external readout device you must 1 Cable your controller to the readout device on page 214 2 Create a readout channel with Station Builder on page 215 3 Adjust the readout signal in Station Manager on page 215 Models FlexTest IIm GT SE Controller Hardware FlexTest Ilm Controller Connections 213 How to Send Signals to External Readout Devices Task1 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 e
67. J26 J35 J25 J34 J24 J33 J23 J32 J22 J31 J21 J41 J42 Aux 1 0 Aux VO Aux 1 0 Aux VO Aux VO Aux 1 0 Aux 1 0 Aux VO Com In Com Out gt gt S gt gt gt gt gt gt S gt gt gt eel EE el Oe lO ol AE O A nod 4 Analog Transition Modules _________ __ Digital Transition Modules Transition modules in the rear panel chassis 1 To install a transition module remove the appropriate panel cover from the analog chassis 2 Plug the transition modules into the backplane connectors Refer the following table for transition module slot assignments MODULE TYPE Analog Transition Slot Assignment SLOT ASSIGNMENT 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Digital Transition A B 3 Replace the panel cover and fasten the screw locks on all D connectors Installation Models FlexTest Ilm GT SE Controller Hardware Transition Module Connectors Transition Module Connectors J101 J1601 J102 J1602 J21 J28 J31 J38 J41 and J42 Single chassis configuration Multichassis configuration J43 and J44 J51 and J52 Models FlexTest IIm GT SE Controller Hardware Cable connections to external devices ar
68. M 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 gt Edit Hardware gt Power Options gt Power Type gt HPU HSM Select Slave HSM for Power Type on controllers connected to the master controller Power Type HSM Only Power Type Slave HSM aa Interlock Hydraulics 056 031 6xx 056 126 4xx HSM For this multiple controller configuration An HSM is connected to one controller only Select HSM Only for Power Type on the controller to which the HSM is connected Path Config gt Edit Hardware gt Power Options gt Power Type gt HSM Only Select Slave HSM for Power Type on controllers connected to the master controller Models FlexTest IIm GT SE Controller Hardware 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 Power Type HSM Only T J28 HSM Interlock Hydraulics E 056 316 0xx 056 126 4xx HSM 1 For this controller configuration 039 713 7xx e Two or more FlexTest SE Controllers are connected e An HSM is connected to each controller only e Select Auto HPU HSM for Power Type on the controller to which both a HSM and HPU is connected Path Config gt Edit Hardwar
69. MTS products you can use output connections with your FlexTest Im controller Conditioning Sensors with Other MTS Products MTS PRODUCT Model 408 81 Testing Panel Model 408 82 DC Conditioner SENSOR OUTPUT 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 Model 448 82 85 Test Controller with Model 448 21 22 AC and DC Conditioners Sensor output is available at rear panel connector J335 Ensure sensor conditioners are set as follows X1 2 amp 3 X2 2 amp 3 Model 458 10 20 MicroConsole with Model 458 11 12 13 14 AC and DC Controllers Sensor output is available at the MicroConsole rear panel connector Jx03 Connector Jx03 represents the module location J100 J600 MicroConsole jumper Jx00 should be set to 1 amp 2 standard setting Task1 Create your configuration file with Station Builder Using Station Builder define controller resources to provide programming to an external controller For more information see How to Create Your Station Configuration File and Creating Program Channels in the MTS 793 Control Software manual Task 2 Adjust the signals with Station Manager Adjust program signal Adjust the outgoing program signal for the required external controller channel For more information see How to Adjust Program Output Signa
70. O transition module supports Four stations of Hydraulics On digital inputs Four stations of Hydraulics Hi digital inputs Four stations of Hydraulics Enables Four stations of Remote Stop Run outputs Four stations of program interlocks Four stations of auxiliary interlocks Four stations of 497 interlock inputs Four stations of 497 interlock outputs Four stations of auxiliary interlock inputs Four stations of auxiliary interlock outputs Two spare digital inputs Two spare digital outputs Models FlexTest IIm GT SE Controller Hardware FlexTest IIm Controller Connections 193 Interlock Jumper Plugs The interlock connectors require jumpers under the following conditions e Ifyou do not use the external hydraulic program interlocks on any of the D 15S 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 e Ifyou 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 xx Chassis you must use an external jumper plug PN 050 774 701 on the J5 497 Intlk connector This shows how to connect an external switch or set of relay contacts to one of the station interlocks J3A J3D 12 VDC External Device Jo ofan ee eee x1 x4 Opto a Coupler e 1 O i om External Switch 1 Wy 1 i sa or 9 i Relay Contact pau eae ues 7 194 FlexTest Ilm Controller Connect
71. Stop i LY l e 9 contact type D female EMI connector e Cable 24 AWG 10 conductor with overall foil shield Carol C0745 or equivalent with drain wire connected to metallized plastic backshell to the chassis Models FlexTest Ilm GT SE Controller Hardware FlexTest GT Controller Connections 129 Emergency Stop Connections J24 E STOP In is a 15 pin type D female connector 15 contact type D male EMI connector e Backshell EMI metallized plastic e 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 Jumper plug required If connector J24 is not used you must install a jumper plug to maintain the integrity of the interlocks Use jumper plug PN 039 713 201 or jumper pins 5 and 7 8 and 13 130 FlexTest GT Controller Connections Models FlexTest IIm GT SE Controller Hardware J25 Hydraulic Power Unit Connection J25 Hydraulic Power Unit Connection Service LED Cable specification Jumper plug required Connector J25 HPS on the Model 493 73 HPU transition board controls the hydraulic power unit HPU e The module produces 24 V logic signals to control the HPU e 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
72. T SE Controller Hardware If connector J52 Box Out is not used you must install a jumper plug to maintain the integrity of the interlocks Use jumper plug PN 100 057 246 or jumper pins 2 10 3 11 4 12 5 13 6 14 7 15 FlexTest SE Controller Connections 235 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 e All of the inputs are optically isolated e Channel inputs can be 3 volts minimum and 26 volts maximum from an external voltage source Switch or dry contact gt Low side of Opto Inputs must be jumpered to ground Use 22 AWG To J54 From FTSE Controller External Device 24 V ott 1 Sa h 2 Input 1 iv zi A W4 M Input 2 d fv w L 5 I He Input 3 A ra a wu 7 8 V 9 V Jumper Wire Cable specification The cabling information shown assumes a single cable destination with an overall shield In other applications the cable may have more than one destination For these applications an overall shield is not practical and non EMI connectors and back shells are permissible 9 pin contact type D male EMI connector e Back shell EMI metallized plastic e Cable shielded twisted pairs as required 24 AWG minimum with drain wire s connected to the metallize
73. The following conditioners can be installed Note Model 493 21B Digital Universal Conditioners are not compatible with stand alone FlexTest SE Controllers e Model 493 21B Digital Universal Conditioner e Model 493 21BC Digital Universal Conditioner e Model 493 25 Digital Universal Conditioner e Model 493 47 Encoder e Model 493 48 Acceleration Conditioner Each 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 These connections can be used for any type of sensor provided the appropriate mezzanine card is installed 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 88 FlexTest GT Controller Connections Models FlexTest IIm GT SE Controller Hardware Sensor Connections Excitation and feedback signals are passed through to the transducer as shown To From Conditioner J4 J7 1 Excitation gt 2 Excitation To From 3 Guard v7 Transducer it 4 Feedback t 5 Feedback _ 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 To From Conditioner J4 J7 1 Exc
74. The indicated three jumpers must be set on the I O Carrier module X1010 Analog Bus 1 Analog Bus 2 Analog Bus 3 Analog Bus 4 Analog Bus 5 DUC X1039 DOOU DUC DUC X3030 ry X3040 o l X305 ot Ch 1 Accel Out X401 Accel Ch 2 Accel Out X402 Accel Daughter Ch3 Accel Out_x403 s N Transitio X404 Card X405 o Accelerometer Accelerometer _ Accelerometer Set these jumpers 120 FlexTest GT Controller Connections Models FlexTest IIm GT SE Controller Hardware Encoder Connections Encoder Connections I O Carrier module For an ADDA configuration using an I O Carrier module each encoder requires configuration 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 Models FlexTest IIm GT SE Controller Hardware FlexTest GT Controller Connections 121 Encoder Connections Optional ADDA II For the optional ADDA II configuration each encoder requires installation of a configuration Model 493 59 Universal Encoder mezzanine card on the Model 493 50 ADDA II
75. UNCTION 1 intlk in 24V 24 V through 6 6K resistor 2 intlk in high High side of opto isolator opto off intlk 3 intlk in low Low side of opto isolator 4 intlk in comm 24 V common 5 N C No connection 6 intlk out NO Normally open relay contact 7 intlk out COM Common relay contact 8 intlk out NC Normally closed relay contact 9 N C No connection Cable specification 9 contact type D male EMI connector e Backshell EMI metallized plastic e Cable shielded twisted pairs 24 AWG minimum with drain wire s connected to the metallized backshell at the chassis Power characteristics Channel inputs can be 3 volts minimum and 26 volts maximum from an external voltage source Models FlexTest IIm GT SE Controller Hardware FlexTest SE Controller Connections 233 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 J51 Connector Pin Assignments PIN NAME FUNCTION 1 clk in External clock input 2 hyd high in Hydraulic high input 3 reset in Interlock reset request input 4 signal return Signal return for optically isolated inputs 5 intlk in Hydraulic
76. W F4 15 V DC o S 9 _ 3 F9 24V DC O O o 9 24V 8 Common x7 E 5V DC o oco 5 5V Ground V7 Cable specification e 9 contact type D male EMI connector e Backshell EMI metallized plastic e Cable shielded twisted pairs 22 AWG minimum with drain wire s connected to the metallized backshell at the chassis 140 FlexTest GT Controller Connections Models FlexTest IIm GT SE Controller Hardware 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 From J3 To From J4 To External Device 493 72 Digital Input 493 72 Digital Output External Device Channel 1 Input 1 y i 1 Channel 1 Outpu BS I agu 5 20 j Channel 2 Input a 7 a Channel 2 Outpu 3 j 3 Channel 3 Input 22 22 Channel 3 Outpu Channel 4 Input ha i be Channel 4 Outpu Channel 5 Input i 7 Channel 5 Outpu Channel 6 Input z j 7 ka Channel 6 Outpu Channel 7 Input M _ A Channel 7 Outpu 8 F 8 h Ch 80 Channel 8 Input ne i _ pe anne utpu Channel 9 Input A _ _ EA Channel 9 Outpu Channel 10 Inpu Lis 10 Channel 10 Outpu 29 a 29 Channel 11 Inpu k n Channel 11 Outpu 30 7 7 30 Channel 12 Inpu 12 j i k Channel 12 Outp
77. ach transition module allows external devices to interface with the chassis Transition modules provide the following e Hydraulic control connections e Station control connections e Analog input and output connections e Digital input and output connections e Serial connections Cable conduit The chassis has a conduit that allows cables to be routed from the front VMEbus modules to the rear transition modules and out of the chassis Power supply Two power supplies are used One provides 5 V DC and 15 V DC for the plug in modules the other provides 12 V DC for plug in modules and 24 V DC for hydraulic power and the chassis fan The power supplies have universal inputs and will adapt to any line voltage between 90 and 264 V AC The power supply is protected with an external circuit breaker in the On Off switch that trips at a 10 amp overload An internal fuse in the power supply is not user accessible or repairable Models FlexTest IIm GT SE Controller Hardware Introduction 21 Hydraulic Control Cooling Hydraulic Control Interlocks System wide interlock 22 Station interlocks Introduction The chassis is cooled with a fan An overtemperature sensor is part of the standard power supply assembly If the internal chassis temperature exceeds 50 C this sensor will light an amber indicator located on the rear of the power supply module Hydraulic control is handled with two transition modules e The Model
78. ackup 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 Maintain the same potential between the module circuitry and the equipment or surfaces it contacts by touching the surfaces first or wearing a wrist strap connected to chassis ground To install a module in the chassis 1 Fully retract the two screws near the handles 2 Insert the module assembly and gently slide the module in until it connects with the backplane 3 Ensure that the circuit card is seated in the backplane connectors and tighten the two screws To remove a module from the chassis 1 Loosen the two screws near the module handles 2 Tug gently on the module to unseat it from the backplane connectors 3 Slide the module straight out of the chassis Models FlexTest IIm GT SE Controller Hardware Installation 65 Analog Chassis Transition Modules Analog Chassis Transition Modules How To Install a Transition Module 66 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 4 Chassis Slot Number p 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 A B J38 J28 J37 J27 J36
79. alog Chassis 4 Set to 4 Remove Install 3 and 4 optional 497 05 Hydraulic Control Set to 5t Install Install 1 and 2 Panel Jumper X5 is used for the RS 232 communications link between the first chassis and the test processor and the RS 422 communications link between the 497 communications modules in each chassis t The address switch on the hydraulic control panel should be set to the last number in the chassis chain For example if you have a single 497 01 Analog Chassis you should set the 497 05 Hydraulic Control Panel address to 2 If you have two analog chassis you should set it to 3 and so forth Models FlexTest IIm GT SE Controller Hardware Installation 69 Adding an Analog Chassis to Your Console Jumper and switch The following graphic illustrates the jumper locations on the Model 497 36 locations Communication Module X1 X3 00X2 S3 Communication Module Jumper and Switch Locations 70 Installation Models FlexTest Ilm GT SE Controller Hardware 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 J15B e jsa News ita Enab omin Com Out ikin inik Out
80. 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 407 Configuration Menu PARAMETER SETTING Eng Units EOC Act CYC Src PROGRAM SetPt R 150 s or highest Span R 300 s or highest Hyd Cnfg Intik Cnfg MASTER P V Sens Span Cnfg 1X CMD Sel EXT IN Prog Out Always designate one 407 in a station as a MASTER If there are other 407s in the same station daisy chain their interlocks and designate them as DEPENDENT 407 Function Generator Menu PARAMETER SETTING Wvform EXTERN Freq Setpnt Span Preset 1462 FlexTest GT Controller Connections Models FlexTest Ilm GT SE Controller Hardware Sending and Receiving Signals to a Model 407 407 Amplitude Control Menu PARAMETER SETTING Ampl Cntrl OFF Fdback Mean E 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
81. and any additional modules to the right of it Placement of 23 40 VMEbus modules in Ta Senice the front panel F i ry chassis im a shunt cat var G ver G gu O x rst O rst O O e O mo J a 80 aan 33 1 38 188 iar Cy E oO a oa oY B LOJ s510 jue PID ills PIO pay em Ht Jl o o ala alal L L fe a So So J eg eo Voy Toy Voy vay Voy Voy L L o ae PEO mg pene mg pae 88 ce ia O NOA KO LOA AOA KOA KOA 29 aal el ea 33 J l s 3 8 LIA L 83 o LY aT SERIAL Di A ks boa a A i O 5 o O o vV V 2 aryo ma ga ma ua a ma 29 7 rc WA MWA Ke WA KA WAL A 8 83 88 A H o2 Bo og 20 L 5 ies 88 br it Rait N ER olol olo v vle e j MIS Mts MTS Mrs Mrs MTS Mrs MTS MTS MIS Ii oO 2 Z 1 2 3 4 5 6 7 8 9 10 Models FlexTest IIm GT SE Controller Hardware Installation 43 VMEbus Modules Setting I O Carrier Use the dipswitch S1 and rotary d
82. ardware FlexTest GT Controller Connections 157 Connecting Interlock Signals to 407 Controllers Multiple 407 Controller The following figure shows how to cable interlocks for multiple Model 407 interlock connections 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 P28 Digital CPC 4P I O Connector mio N a 24yo t M H 3 ENA DIGITAL Hydraul g H2 7 4 NI J ActiveLow T 2 7 1 oicrra Run Stop Controller J el OUT 1 f ActiveHigh Station 1 ar P43 To D 9P 493 74 HSM 24V OW 1 J Transition A umper a DAE Jumper 4 24V OW 5 6 Mae og S OFF INTLK Jumper v Interlock Cable PN 056 455 0XX P28 Digital CPC 4P O Connector N aa e fel a m 3 Hydraulic a MENA NT f Interlock in 2 T 4 ActiveLow 407 3 I 5 l oicitaL Run Stop Controller L_ l 6 TT f ActiveHigh Station 2 P43 To D 9P 493 74 HSM 24V OW 1 J Transition gt umper wher ee F Jumper 24V OW 5 t 6 PROT lO OFF INTLK i Jumper v Interlock Cable PN 056 455 0XX 158 FlexTest GT Controller Connections Models FlexTest IIm GT SE Controller Hardware Connecting Interlock Signals to 407 Controllers How to connect The following figure sho
83. aren MTS be certain MTS Models FlexTest IIm GT SE Controller Hardware Service Information for Controllers Using Series 793 Software Hardware Descriptions Specifications Installation Cabling 100 147 133 G Copyright information Trademark information Publication 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 All other trademarks or service marks are property of their respective owners MANUAL PART NUMBER PUBLICATION DATE MTS 793 SOFTWARE RELEASE 100 147 133 A June 2006 Version 4 0A or later 100 147 133 B October 2006 Version 4 0B or later 100 147 133 C December 2006 Version 4 0B or later 100 147 133 D November 2007 Version 5 0B or later 100 147 133 E January 2008 Version 5 0B or later 100 147 133 F September 2008 Version 5 1A or later 100 147 133 G August 2009 Version 5 2A or later Models FlexTest IIm GT SE Controller Hardware Contents Technical Support 9 How to Get Technical Support 9 Before You Contact MTS 10 If You Contact MTS by Phone 11 Problem Submittal Form in MTS Manuals 12 Preface 15 Before Y
84. as e Hydraulic and mechanical component manuals e Assembly drawings e Parts lists e Operation manual e Preventive maintenance manual Controller and application software manuals are typically included on the software CD distribution disc s Models FlexTest IIm GT SE Controller Hardware Preface 15 Documentation Conventions Conventions Documentation Conventions 16 Hazard conventions Notes Special terms Preface The following paragraphs describe some of the conventions that are used in your MTS manuals 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 Three different levels of hazard notices may appear in your manuals Following are examples of all three levels Note For general safety information see the safety information provided with your system Danger notices indicate the presence of a hazard with a high level of risk which if ignored wi result in death severe personal injury or substantial property damage Warning notices indicate the presence of a hazard with a medium level of risk which if ignored can result in death severe personal injury or substantial property damage Caution notices indicate the presence of a hazard with a
85. 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 Model 448 82 85 Test Controller with Model 448 21 22 AC and DC Conditioners Sensor output is available at rear panel connector J335 Ensure sensor conditioners are set as follows X1 2 amp 3 X2 2 amp 3 Model 458 10 20 MicroConsole with Model 458 11 12 13 14 AC and DC Controllers Sensor output is available at the MicroConsole rear panel connector Jx03 Connector Jx03 represents the module location J100 J600 MicroConsole jumper Jx00 should be set to 1 amp 2 standard setting Models FlexTest IIm GT SE Controller Hardware FlexTest GT Controller Connections 167 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 External Analog Source 403 81 ANALOG INPUT E 9 S OQO e F O S o Gd O Gd 2 O S 2 ia S O O From I O Carrier Module 2 Allocate external command resources in Station Builder Using Station Builder allocate controller resources to receive pro
86. cal Cabling of a FlexTest System 84 FlexTest GT Controller Connections Models FlexTest IIm GT SE Controller Hardware 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 MODULE JUMPER PLuct NUMBER CONNECTOR 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 Servovalve 256 xx 3 stage N A Valve 055 439 493 40 J4 J7 Valve LVDT 6XX 493 40 J4 J7 Calibration Cable Package 039 708 493 40 J3 6XX Y Adapter Servovalve Valve LVDT 100 026 493 40 J4 J7 N A required for 256 xx or 257 xx servovalves 213 039 710 501 Servovalve 257 xx 3 stage N A Valve 039 701 448 16 to 257 XX 9XX 493 40 J4 J7 Valve Velocity 039700 2XX 493 40 J4 J7 Valve LVDT 039700 9XX 493 40 J3 Calibration Cable Package 039708 6XX N A 100 026 493 40 J4 J7 Y Adapter Servovalve Valve LVDT 213 required for 256 xx or 257 xx servovalves 039 710 501 System ground console 005 402 N A System ground floor standing 3XX gnd lug 039 709 2XX E stop 318 Load Unit with crosshead locks 056 126 493 74 J29 100 007 947 E stop 318 Load Unit without crosshead locks 5XX 493 74 J29 100 007 947 056 126 6XX 493 73 J24 039 713 201 Emergency Stop Mo
87. can use the Event Action Editor window to define an action that occurs in response to a digital input event The defined action can then be selected in the Station Setup window s Digital Input panel e Sixteen jumpers located on the Series 498 Digital I O transition module allow each input to be configured for a relay contact or logic signal e Each digital input connector on the built in Digital I O Access panel FlexTest IIm supports two channels e Each digital input supports a differential TTL to 30 V DC signal or a switch or relay contact switching the on board 12 V supply Models FlexTest IIm GT SE Controller Hardware FlexTest Ilm Controller Connections 197 Digital I O Connections So See se ERE N T E cee uae aay Fis shows now i Digital I O 498 Digital O connect an external Access Panel Transition Module switch or a set of relay iG contacts to channel 1 of J1 2 ee see the digital inputs Opto External Device es CH1 a i Coupler l 1 2 vy 1 Ko 2 CH1 S External Switch or 1 o 12 VDC Relay Contact This shows how to connect an external logic signal to channel 4 of the External Device digital inputs 7 12 volt common a y Digital O 498 Digital I O Access Panel Transition Module 12 VD J3 4 i ERO X4 Opto H4 Coupler 7 fet mm Courier 1 2 i 4 CH4 i RL 4 198 FlexTest Ilm Controller Connections 5 o 12 VDC 8 i 12 volt comm
88. ck e The setting of jumper W8 single ended excitation enable may affect your choices for these jumpers W2 and W3 Note excitation excitation is standard J Z Default EXto FBshunt M E 2 Exto FB shunt Ge B v2 in 4 wire config EED in 4 wire config EED EX to FBR shunt M E 2 EXto FBRshunt E B v2 BTI i R i in 8 wire con 1g q ES W3 in wire contig a E E W3 Models FlexTest Ilm GT SE Controller Hardware FlexTest GT Controller Connections 97 Full Range Digital Universal Conditioner FRDUC 98 Excitation sense Jumpers W5 and W7 select the local on board or remote through a cable excitation sensor connection e The local selection is used with 4 wire transducer connections e The remote selection is used with 8 wire transducer connections e Jumper W7 configures the excitation signal e Jumper W5 configures the excitation signal Both jumpers should be set for the same configuration ws ws E w7 w7 Local Remote Shunt cal The shunt calibration resistor can be installed on the Full Range Digital Universal Conditioner module or in the transducer ID module R33 assigns a positive or negative excitation to the shunt calibration resistor if installed on the Full Range Digital Universal Conditioner module not the transducer ID module R33 BBD Default No Resistor EHE B EX Shunt EB EX Shunt Single ended Jumper W8 connects EX to ground for situations requiring
89. cted you must use your controller software to configure the various UPS options 493 42 System Board J54 AC Fail Contacts Open Logic 0 Low Battery Contacts Open Logic 0 Cable specification To maintain EMC compliance the J54 Digital Input cable must comply with the following specifications Connector type 9 pin contact type D male EMI connector Back shell EMI metallized plastic or metal Cable 26 to 22 AWG 4 conductor with overall braided shield with the braided shield connected to the backshell at the chassis 80 Installation Models FlexTest IIm GT SE Controller Hardware Chapter 3 FlexTest GT Controller Connections Contents This section describes the cable connections to the Model 493 10 Chassis Note For information on connecting power cables see Connecting Electrical Power on page 38 CE EMC Compliant Cabling 83 Typical Cabling 84 Cable Part Numbers 85 Model 493 40 I O Carrier Connections 87 Sensor Connections 88 Sensor Cables 100 Shunt Calibration Bridge Completion Resistor Installation 103 Transducer Identification Modules 106 Valve Connections 108 Multiple Universal Driver Connections 112 Analog I O Connections 114 Accelerometer Connections 119 Encoder Connections 121 Remote Setpoint Adjust Connections 123 ADDA II Connections 124 Emergency Stop Connections 129 J25 Hydraulic Power Unit Connection 131 Station Connections 134 J2
90. ctions HPU Connections Cable specification Jumper plug Connector J25 controls the hydraulic power unit To From J25 To From 497 05 HPU i 2 Interlock 1 lt 3 Interlock 2 m 4 HPS Ground ie 5 Hyd Interlock Reset HPU 7 Interlock Common lt 9 HPU Power 10 Es 12 11 HPU Start q 14 Interlock 3 y 15 HPU High y 16 Defeat 17 HPU Common 18 Voltage Common Bg 19 HPU Defeat 24 V O P25 is a 24 contact CPC female connector AMP Incorporated Cable 18 AWG 14 conductor rated for 300 V Compatible with MTS 24 V DC or 115 V AC control cables Cable assembly numbers PN 039 708 7XX 24 V DC 039 708 8XX 115 V AC Uses special MTS cable material PN 044 297 301 If an HPU is not connected to the digital controller a jumper plug is required to maintain the integrity of the interlocks Use jumper plug 039 719 901 or jumper pins 2 and 3 3 and 7 9 and 19 10 and 12 11 and 16 17 and 18 1490 FlexTest Ilm Controller Connections Models FlexTest Ilm GT SE Controller Hardware HSM Connections HSM Connections The outputs provide 24 V DC to turn on the HSM solenoids From J28 To HSM Connector J28 controls the Hydraulic I O Solenoids low pressure and high pressure solenoids of a 1 Low Pressure hydraulic service manifold 2 DC Common 4 High Pressure Cable specification e P28 is a 4 contact CPC male connector AMP
91. d Index Ser Clk Input 4 B Interrogate Jit rs A Serial Data J15 J17 Return Gnd Index Ser Clk Input 3 B Interrogate A Serial Data on owrk WRN 10 Index Ser Clk Input 2 11 B Interrogate 12 A Serial Data 13 Return Gnd 14 Index Ser Clkt input 1 15 B Interrogate lt _ gt lt _ gt lt gt lt gt lt _ gt lt gt lt gt lt gt lt lt 9 Return Gnd lt gt lt gt lt gt lt gt lt gt lt gt lt 4 16 A Serial Data 128 FlexTest GT Controller Connections Models FlexTest IIm GT SE Controller Hardware 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 Connector J23 E STOP Out provides an output to external devices when an stop output emergency stop signal is generated The inactive status is shown in the figure From J23 To Chassis External Devices 1 SS 2 Emergency ae Stop 3 Emergency Connector J24 E STOP In accommodates an external emergency stop switch stopinput As shown several connectors maintain the continuity of the emergency stop interlock External J24 E Stop 1 palo 13 O 24V V7 Relay OO 7 E Stop Signal l lw Cable specifications J23 E STOP Out is a 9 pin type D male connector T a R 8 E
92. d LIVM accelerometers and three signal conditioned type accelerometers 493 79 Multiple Universal Driver Provides up to six drivers that can be used to drive standard Board 252 servovalves Inputs to this board can originate from either a ADDA II board 6 outputs or a Model 493 46 D A board 6 outputs 493 80 Encoder Transition Interfaces with up to four encoders 493 81 Analog In BNC Provides up to eight channels of analog input to each Model 493 55 A D module The input signals must be within 10 V DC 493 82 Analog Out BNC Provides eight channels of analog output from the Model 493 56 D A modules The output signals are within 10 V DC 493 83 Filtered Analog Input Provides up to eight channels of filtered analog input to each 48 Installation Model 493 55 A D module Models FlexTest IIm GT SE Controller Hardware 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 42 VMEbus Modules 50 Chassis Installation Options 51 Connecting Electrical Power 53 Installing the Handle Kit 58 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 bottom of the faceplate The plug in modules contain stat
93. d backshell at the chassis 236 FlexTest SE Controller Connections Models FlexTest IIm GT SE Controller Hardware 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 e The digital output relays are rated for a maximum of 1 Amp max 30 V DC AC max The outputs are optically isolated From J55 To FT SE Controller External Device 1 Relay Contact TA Channel 1 Output 2 3 Relay Contact A Channel 2 Output 4 5 6 Relay Contact Channel 3 Output L___ 7 24Vor gt 8 9 Beg Cable specification The cabling information shown assumes a single cable destination with an overall shield In other applications the cable may have more than one destination For these applications an overall shield is not practical and non EMI connectors and back shells are permissible 9 pin contact type D male EMI connector e Back shell EMI metallized plastic e Cable shielded twisted pairs as required 24 AWG minimum with drain wire s connected to the metallized backshell at the chassis Run Stop setup _If required digital output 1 pins 1 and 2 can be set up as a Run Stop connector Use the following procedures to set up this Run Stop connector Models FlexTest IIm GT SE Controller Hardware FlexTest SE Controller Connections 237 J55 Digital Outputs S
94. del 498 65 ADDA module Model 498 71B GRES II module Model 498 96 X Processor module Models FlexTest IIm GT SE Controller Hardware Specifications FT Iim standard 4 6 8 12 or 16 channels of control configurations 16 inputs and 16 outputs of user DIO e Per channel resources One valve driver output One D A output One A D input One AC Conditioned input Two DC conditioned inputs Console The FlexTest IIm Controller is available in a full bay vertical console a table top console or a roll around console Note The larger full bay consoles can also accommodate rack mount scopes x y recorders and so forth Customization A standard FlexTest IIm system can be customized for specific test requirements In these cases the standard hardware and software can be changed to accommodate a specific customer requirement Models FlexTest IIm GT SE Controller Hardware Introduction 29 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 e 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 e Processor Analog Chassis communications A communications module provides data conversion between the test processor and the 497 analog plug in modules e Transducer conditioning AC and DC c
95. dels FlexTest IIm GT SE Controller Hardware FlexTest GT Controller Connections 85 Cable Part Numbers System Cables part 2 of 2 CABLE DESCRIPTION PART MODULE JUMPER PLuct NUMBER CONNECTOR HPU 505 or 24V PLC Pump for more information see 039 713 493 73 J25 039 713 301 Hydraulic Configurations on page 243 7XX HSM 298 11 on off 039 701 493 74 J28 N A HSM Proportional 298 12 5XX HSM 290 xx 293 xx 294 xx high low 056 126 4XX 039 701 4XX Interlock Test Enclosure 056 126 493 74 J43 100 007 948 3XX Interlock Station per system 493 74 J43 100 007 948 Remote Station Control with E Stop 055 634 493 71 J50 055 634 101 2XX Remote Station Control with Station Stop 055 634 493 71 J50 055 634 101 3XX Workstation Link Ethernet cable 051 996 10 100 N A 8XX Remote Setpoint Adjust Control 100 051 058 493 40 J4 J7 N A represent custom cable lengths t Jumper plugs are required if a cable is not installed The connector is the 10 100 BaseT connector on the power PC module 86 FlexTest GT Controller Connections Models FlexTest Ilm GT SE Controller Hardware XX specifies cable length 01 through 09 represent 10 50 ft in 5 ft increments Higher numbers 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 Ca
96. dware Cabling for External Command Inputs 210 How to Enable and Run External Command Inputs 210 Cabling and Using External Readout Devices 213 How to Send Signals to External Readout Devices 213 Cable Part Numbers 216 Chapter 5 FlexTest SE Controller Connections 217 Stand alone Cabling Overview 218 Automated Cabling Overview 219 Multiple Controller Connections 220 Cable Part Numbers 223 Model 493 40 I O Carrier Connections 225 Sensor Connections 226 Valve Connections 226 Analog I O Connections 226 Encoder Connections 228 Workstation Connection 229 Service Connection 229 Model 493 42 System I O Connections 230 J25 Hydraulic Power Unit Connection 230 J28 Hydraulic Service Manifold Connector 231 J29 Emergency Stop Connections 232 J43 Interlock 233 J49 Auxiliary Power 234 CJ51 Box In 234 J52 Box Out 235 J54 Digital Inputs 236 J55 Digital Outputs 237 Eurotherm Temperature Controller Connection 239 Models FlexTest Ilm GT SE Controller Hardware Contents 7 Appendix A Hydraulic Configurations 243 Model 493 02 Chassis Multiple Controller Interconnections 246 Independent HSM no HPU 246 Independent HSM shared HPU 247 Shared HSM with HPU 247 Shared HSM no HPU 248 Independent HSM with HPU First On Last Off 249 Appendix B Model 493 07 Converter Box 251 Appendix C Chassis Maintenance 253 Appendix D Optional Station Configurations 255 6 Station Configuration 255 8 Station Configuration 256 Index 257
97. e gt Power Options gt Power Type gt Auto HPU HSM e Select HSM Only for Power Type on controllers with an independent HSM but no HPU Note The HPU can be connected to any controller in the interconnected group of controllers Models FlexTest Ilm GT SE Controller Hardware Hydraulic Configurations 249 Independent HSM with HPU First On Last Off 250 Hydraulic Configurations Models FlexTest Ilm GT SE Controller Hardware Appendix B Model 493 07 Converter Box Jumper configurations 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 You must have the Model 493 07 Converter Box designed for the correct voltage before installation Connecting a 24 V Converter Box to a 115 V AC HPU causes improper operation Be sure that the voltage marked on the cover of the Converter Box matches the required voltage for the HPU The following figure shows the main components of the 493 07 Converter Box including connectors and jumpers If the converter box remains connected to a 120 volt HPU voltage will be present Failure to disconnect cables could expose the operator
98. e cards in the I O Carrier module 2 Install a second Model 493 40 I O Carrier module in slot 3 of the controller chassis e 5 i C JEO U al i 6 5 RelO pid gt lt m gt EP gt gt z efi EA errre E Ip ron 8 Z Hi 3 Change your hwi file to reflect the added I O Carrier module and its mezzanine cards 4 Use the Station Builder application to allocate resources for the additional hardware Models FlexTest IIm GT SE Controller Hardware FlexTest SE Controller Connections 225 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 46 D A mezzanine cards are installed in the Model 493 40 I O Carrier front panel module Note The external analog
99. e emergency stop button For details about configuring the hydraulic control panel for your system see the Series 497 Electronics Product Information manual PN 100 036 577 Hydraulic Control Panel Models FlexTest IIm GT SE Controller Hardware Introduction 31 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 For more information see the Series 498 Electronic Product Information manual PN 100 036 578 7 i A AAA cama Model 498 22 Test Processor Chassis Front Panel 32 Introduction Models FlexTest IIm GT SE Controller Hardware Specifications Specifications Model 497 01 Specifications PARAMETER Environmental SPECIFICATION For indoor use only Temperature Relative humidity 5 C 40 C 41 F 104 F 10 85 relative noncondensing Power requ
100. e made from the 497 01 chassis rear panel connectors 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 The cable that is plugged into these connectors depends on whether a valve driver or a conditioner is installed in the corresponding chassis slot location Connectors J102 through J1602 JX02 provide a second connection for dual conditioners dual valve drivers or three stage valve drivers Each module has four rear panel connectors associated with it Jx01 Jx02 J2x and J3x Rear panel I O connectors J21 through J28 J2X are 15 pin D type connectors located on the chassis rear panel They are used to connect either a valve driver to D A converters command or a conditioner to A D converters feedback Rear panel Aux connectors J31 through J38 provide the same signals as J21 through J28 and are used to connect external readout devices Rear panel communication connectors J41 Com In and J42 Com Out are associated with the communication module installed in slot B This connector allows serial communication with a host computer If you have a single analog chassis install a cable PN 056 027 101 from a Series 498 host computer serial port debug to J41 Com In on the Model 407 05 Hydraulic Control Panel then from J42 Com Out to J41 Com In on the Model 497 01 Analog Chassis If you have a mu
101. e 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 Ifyou will monitor sensor feedback for data acquisition or control feedback connect the external conditioner output to a 493 83 Filtered Analog Input BNC connector For conditioner output locations on various MTS devices see Sample conditioner output connections on page 207 Transition modules on the rear panel of the Series 498 test processor chassis are used for analog inputs and outputs 2 Ed 493 82 Analog Out This module includes 8 BNC connectors that provide analog outputs from a Model 493 56 D A mezzanine card 493 83 Filtered Analog Input This module includes 8 BNC connectors that provide filtered analog inputs to the Model 493 55 A D mezzanine cards Eight analog inputs are available with the each A D mezzanine card installed on the Model 493 50 ADDA II module 2 gt o gt o O o gt Eight analog outputs are available with each D A mezzanine card installed on the Model 493 50 ADDA II module 2 gt o a x o x oo 4 O bn 4 l Transition Module Connections 206 FlexTest IIm Controller Connections Models FlexTest IIm GT SE Controller Hardware How to Program an External Controller Sample conditioner This table shows connector assignments for various
102. el 493 15 3 Stage Valve Driver mezzanine card e 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 e For single and dual valve configuration wiring information see the servovalve product manual included with the System Documentation CD Improper operation can damage valve driver cards Damage can occur if you connect a high level signal to a valve driver card when the chassis power is off Do not apply a high level signal to a valve driver card when the chassis power is off Disconnect power from any externally powered devices before you switch the chassis power off Cable specification 15 contact type D male EMI connector e Backshell EMI metallized plastic e Cable type 4 conductor w foil shield and drain PN 010 093 580 or equivalent with the drain wire connected to metallized plastic backshell at the chassis e For Series 256 and 257 Servovalves the valve LVDT uses the same type of connectors as the actuator LVDT e Servovalve valve LVDT Y cable required for Series 256 or 257 servovalves PN 039 710 5XX 108 FlexTest GT Controller Connections Models FlexTest IIm GT SE Controller Hardware Valve Connections Series 252 Servovalve The Series 252 Servovalve is a 2 stage servovalve The Model 493 14 Valve connections Driver supports single or dual valve configurations The following figure shows the connections at the val
103. equivalent Cable outer shield drain wire to pin 7 optional and to the EMI backshell Models FlexTest IIm GT SE Controller Hardware FlexTest Ilm Controller Connections 179 Sensor and Valve Connections AC sensor connection AC Sensor LVDT ae s FB 1 l 2o gt 3 Z 3 FB 2 i l C lat tf Inner gt i i A SEN Guard E Siak 1 TEE BLU EX 4 T k a H B coe Itt za EX 5 r Goe OUTER BRAID DC sensor connection 4 wire connections are the f jodeessdeesdseetenedz most common An 8 wire Se Dal a l connection is typically used i for long cables cisa The additional wires for an FB 8 wire connection are FBR shown with dashed lines FB FBR EX EXS EX 1 EXS 1480 FlexTest Ilm Controller Connections Models FlexTest Ilm GT SE Controller Hardware Sensor and Valve Connections Single valve connection Valve 9 i hl Command 1 i ni B E c Valve 11 2 Command 1 E D L C Dual valve connection Shown for valves phased the same hydraulically For valves phased opposite hydraulically reverse A and D on P2 Valve Command 1 Valve Command 1 Models FlexTest IIm GT SE Controller Hardware FlexTest Ilm Controller Connections 181 Sensor and Valve Connections Sample control The following figure illustrates sample connections
104. er e 1 i External Switch A wy i CH1 f or 20 i Relay Contact 3m ee V I Digital I O 493 72 Digital I O Access Panel J3 Transition Module External Device o 18 S _9 04 12 C Opto CH1 Coupler o 1 7 i 7 A AS i i E 20 CH1 p o 36 o e V gt 142 FlexTest GT Controller Connections Models FlexTest IIm GT SE Controller Hardware 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 e 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 When connected in parallel the station must be configured so that all paralleled outputs are driven from the same event The output is rated for a maximum of 30 V DC e Fused 12 V DC is available at pins 18 and 19 Install a current limiting resistor that is appropriate for the external device e Ifan output is not used a jumper is not needed to complete a circuit e The outputs are optically isolated The outputs are triggered by the system controller 493 72 Digital I O Digital I O Transition Board J4 Access Panel External Device a Voltage oy
105. eter this signal is only available for the Timed meter Error Displays the error signal in engineering units The error is the difference between the command signal and the sensor feedback signal Abs Error Displays the absolute value of the error signal in engineering units 1470 FlexTest GT Controller Connections Models FlexTest IIm GT SE Controller Hardware 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 Im 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 HS Analog Monitor 28 S n e g gt Ch 5 ch 6 3 m C s R From O Carrier Module Io a MTS 2 Create a readout channel with Station Builder 3 Adjust the readout signal in Station Manager Use Station Manager to adjust the readout signal Models FlexTest IIm GT SE Controller Hardware FlexTest GT Controller Connections 171 Multi Box I O Module Multi Box I O Module Module features J8 Interlock IN Electrical specifications The optional Model 493 43 Multi Box I O module allows multiple controllers to share a master hardware
106. exTest IIm GT SE Controller Hardware FlexTest SE Controller Connections 219 Multiple Controller Connections Multiple Controller Connections About multiple Some characteristics of a multiple controller network are as follows controller networks e Each controller in the network provides control for one station with up to two channels e A hub connects each controller in the network to the supervising PC e A single network may have a maximum of four stations regardless of the number of controllers cabled to the hub When used in a network controllers must be registered for automation and operate in the automation mode e Each controller in the network must have a unique ID and name For more information about setting up multiple controller networks for FlexTest SE Controllers see Appendix D Using Multiple Automated Controllers in the FlexTest SE User s Manual 011 437 8xx 011 437 8xx 011 437 8xx GA lt H I i ff oy i i izl P o Hr e oloto o eTe Typical multiple controller cabling Master dependent Connect two or more FlexTest SE Controllers in a master dependent FlexTest SE configuration as shown below Controllers 2
107. g only Alternate settings are required for Model 436 11 and 413 05 controllers See Appendix B Model 493 07 Converter Box You can mix Models 493 07 458 490 and 497 05 Controllers directly on the same HPU without the use of an HPU isolation box You cannot mix Models 493 07 458 490 and or 497 05 Controllers with 436 413 05 or 413 8X Controllers unless you use an isolation box You can jumper the Model 493 07 Converter box so you can use it directly with 436 and 413 05 Controllers However if you do this you must use an isolation box if you attempt to use the Converter Box with Models 458 490 and 497 05 Controllers See Appendix B Model 493 07 Converter Box on page 251 Models FlexTest Ilm GT SE Controller Hardware Hydraulic Configurations 245 Model 493 02 Chassis Multiple Controller Model 493 02 Chassis Multiple Controller Interconnections 246 Hydraulic Configurations FlexTest SE Controllers support the following hydraulic interconnections for multiple controller configurations Independent HSM control with no HPU Independent HSM control with a shared HPU Shared HSM with an HPU Shared HSM without HPU Independent HSM controlled with a shared HPU using first on last off For more detailed information about multiple controller configurations see Multiple Controller Connections on page 220 and the FlexTest SE User Manual Independent HSM no HPU Power Type HSM Only lA sort K f P
108. g signals for use by external devices 493 47 Encoder Processes the signals from an encoder or a Temposonics III transducer with an SSI interface Chassis Installation Options Models FlexTest Ilm GT SE Controller Hardware The chassis can be fitted with the optional handle kit for table top use in the stand alone configuration shown below and for the automated configuration it can be installed without the handle kit in a standard MTS equipment rack Note For information about installing the optional handle kit see page 58 om FlexTest SE a A Sx l Daaa FB o Recall gt saa Program Controller D aa with optional o Ommon handle kit ms amp Se an awe ns are cs seat SS a Installation 51 Chassis Installation Options Rack mounting When installing the chassis in an equipment rack allow a minimum of 2 in 5 1 requirements 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 The chassis can be installed in any Model 490 8x console Install the console with the Model 493 02 Chassis Rack Mounting Kit PN 100 063 209 The rack mounting kit provides the hard
109. gramming from an external controller 3 Adjust the command signal with Station Manager 4 Start the External Command 1468 FlexTest GT Controller Connections Models FlexTest Ilm GT SE Controller Hardware 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 Station signal diagram The block diagram identifies the station signals you can monitor Compensated Command Command Output Valve Driver Signals from Other Modes of this Channel PIDF Controller Output Valve Driver Scalar Signal convert control Test Command Command Compensator Mode signal to counts Su Switch a Ry lt 1 Closed Absolute Error Loop Generator Sw Dela P Load Cell Feedback Stabilization A ai Feedback Input Signal Conditioning Signal Inner Outer Error Detector LVDT Feedback pane Input Signal Conditioning Signal Absolute Error Error Sensor Signal Stabilization Station signal Except for time and auxiliary data signals station signals listed in your software descriptions windows
110. he computer e The power supply automatically selects the proper voltage range and line frequency e The power supply is protected with an external circuit breaker in the On Off switch that trips at a 5 amp overload An internal fuse in the power supply is not user accessible or repairable AC power disconnect Turn off the AC power switch Remove the AC power cord from the unit This will remove all AC power from the Model 493 02 Chassis Models FlexTest IIm GT SE Controller Hardware Installation 55 Connecting Electrical Power Note Be sure to locate the chassis so you have adequate access to disconnect the power cord from the chassis Stand Alone Configuration i Bete et lt Line Voltage Outlet Strip w circuit breaker Automated Configuration Outlet Strip Outlet Strip printer etc w circuit breaker 56 Installation Models FlexTest IIm GT SE Controller Hardware Connecting Electrical Power Rack Mounted Configuration Outlet Strip vertical outlet strip Power Panel ig
111. ic sensitive components Improper handling of the module can cause component damage Be sure to follow these precautions when handling modules e Turn off electrical power before installing or removing a module e Use a static ground strap to ground yourself to the chassis ground before touching the chassis or a module e Keep unused modules in conductive bags Also be sure you are grounded when removing a module from a conductive bag e Handle modules with their front panel or circuit card edges Do not touch any circuit card components pins or circuit connection points Models FlexTest IIm GT SE Controller Hardware Installation 49 VMEbus Modules VMEbus Modules The VMEbus compatible modules should be installed in chassis slots according to the following guidelines e The processor module is installed in slot 1 The I O carrier module is installed in slot 2 e The System I O module is installed in slots 4 and 5 Placement of 5 le VMEbus modules in the chassis 4 4 3 E 3 e P of lolz fe 2 E 2 E QQQ 3 de my lief VMEbus Modules SLOT MODULE NAME FUNCTION Slot 1 Processor Provides PIDF processing for the Controller and management of the other plug in modules in the standalone configuration Provides an interface between the Controller and an external co
112. ide Program to a Series 407 Controller 1 Cable the Series Series 793 and Model 407 Controllers together Cable the analog inputs and outputs between the Model 493 10 chassis and a Model 407 Controller as follows Note Analog I O connectors are located on the rear panel of the chassis A Connect a Model 493 76 Analog Out BNC connector to the program analog input on the 407 Controller Connections for single or multiple Model 407 Controllers are shown B Ifyou intend to monitor sensor feedback for data acquisition or control feedback connect the external controller s conditioner output to a Model 493 77 Filtered Analog Input BNC connector For conditioner output locations on various MTS devices see Miscellaneous Conditioner Output Connections on page 167 C Make interlock connections as appropriate See Connecting Interlock Signals to 407 Controllers on page 156 Models FlexTest IIm GT SE Controller Hardware FlexTest GT Controller Connections 151 How to Provide Program to a Series 407 Controller Transition modules on the rear panel of the Model 493 10 chassis are used for analog inputs and outputs 493 76 Analog Out This module includes six BNC connectors that provide analog outputs from a Model 493 46 D A mezzanine card Six analog outputs are available with each D A mezzanine card installed on the Model 493 40 I O Carrier module Do not interrupt Model 493 10 Chassis power when you are programming
113. in All of the modules plugged into the chassis can be assigned to stations If one of the stations generates an interlock all of the components assigned to the station are shut down Standard configurations support up to four independent stations Models FlexTest IIm GT SE Controller Hardware Specifications Specifications FlexTest GT Specifications PARAMETER Environmental Temperature Relative humidity Altitude SPECIFICATION For indoor use only 5 C 40 C 41 F 104 F 10 85 noncondensing For use at altitudes up to 2000 m 6500 ft Power input Input voltage Input frequency Input surge Power Insulation over voltage Pollution degree power factor corrected universal input 100 240 V AC 47 63 Hz lt 100A lt 1000 W Category Il 2 Power supply 1 5 V DC 15 V DC maximum draw is 400 W total 40A 7 5A Power supply 2 12 V DC 24 V DC maximum draw is 400 W total 4A 10A Weight approximately 45 kg 100 Ib in stand alone configuration The specification shown conforms to CE Low Voltage Directive requirements The specification allows for 10 of the values stated The actual voltage the 493 10 chassis can operate is 90 264 V AC Models FlexTest IIm GT SE Controller Hardware Introduction 23 Specifications FlexTest SE Controllers FlexTest SE Controller FlexTest SE front panel controls 24 Introduction The MTS Model 493 02 FlexTest SE Contr
114. include the name of their associated control channel For example if your channel is labeled Ch 1 the available station signals would be Ch 1 Output Ch 1 Command and so forth Models FlexTest Ilm GT SE Controller Hardware FlexTest GT Controller Connections 169 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 Rollover Time Displays the time reference signal derived from the internal clock that resets every hour Like the time signal this signal exists to support data acquisition by test program applications It is not practical to monitor the hourly rollover time with external readout devices Output Displays the test control signal sent to the valve driver in volts Command Displays the program command signal in engineering units Comp Cmd Displays the value of the compensated command signal in engineering units This signal is only valid when using PVP PVC AIC APC or ALC compensators Count Displays the number of segments played out so far in the selected control channel When using a Station Manager m
115. 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 O E A 493 21B Universal Ea Conditioner Bg Gl Accelerometer 4 Accelerometer LIVM 493 21B Universal 38 pe Conditioner or Accelerometer T a 493 21B Universal pa Lo pom 493 48 Acceleration Conditioner Accelerometer High revel Signal Conditioned ji id Accelerometer Kel 493 21B Universal Conditioner 493 21B Universal Conditioner 493 21B Universal Conditioner 493 48 Acceleration Conditioner I O Carrier jumper Before installing a Model 493 48 Acceleration Conditioner mezzanine card in a settings Model 493 40 I O Carrier module specific jumpers must be set Jumper settings depend on the number and configuration of your system accelerometers Models FlexTest IIm GT SE Controller Hardware FlexTest GT Controller Connections 119 Accelerometer Connections In the example shown below the Acceleration Conditioner supports three accelerometers
116. ion e The local selection is used with 4 wire transducer connections e The remote selection is used with 8 wire transducer connections e Jumper W7 configures the excitation signal e Jumper W5 configures the excitation signal Both jumpers need to be set for the same configuration Remote Local L zi Default Bv aD Ww B vws GBD v Single ended Jumper W8 connects EX to ground for situations requiring single ended excitation excitation EX EX EX GND Default CE B vs d HB Ws Digital Universal Conditioner DUC BC Switches The following switch settings are for the Model 493 21BC Digital Universal Conditioner The switches are labeled S1 1 8 and replace the former solder pads The following descriptions are from the 493 XX Module Setup configuration drawing PN 049 336 301 Active guard Switch S1 8 enables or disables the guard connection to ground GND for the sensor cable Enable Disable C Short to Ground Cap to Ground 1 8 ON 1 8 OFF Default 94 FlexTest GT Controller Connections Models FlexTest IIm GT SE Controller Hardware Digital Universal Conditioner DUC BC Switches 4 or 8 Wire Switches S1 1 S1 2 S1 3 and S1 4 establish the correct shunt calibration sensor cable 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 typica
117. ion HYD INTLK 2 a t A Hydraulic INPUT e 4 3 Jumper 3 M DIGITAL Interlock To 4 4 N1 J Active Low 407 Controller 24v ow 5 5 L orcrrat Run Stop Dependent 6 6 our f Active High raD e me OFF INTLK Jumper 3 8 2 s i r Hydraulic Interlock z m oN f Active Low To 407 Controller 7 oicitaL Run Stop Dependent 6 J out f Active High fo J l 10 FT L_ all i Hydraulic 3 as orcitat Interlock 4 N1 J Active Low To alles Pinisi 407 Controller 1 DIGITAL un Stop e T oT f Active High Dependent 160 FlexTest GT Controller Connections Master Dependent Interlock Cable PN 056 448 9XX Models FlexTest IIm GT SE Controller Hardware Connecting Interlock Signals to 407 Controllers How to connect The following figure shows how to cable hydraulic terminals on three Model 407 hydraulic terminals on elvan Ai ina ee Fane a me that he oe a f _ controller in any daisy chain must have jumper plugs installed in its Hyd Ou master ao and Intlk In terminals ontrollers Master 407 Controller No Connection H gt 4 Dependant 407 Controller l Last Dependant 407 Controller No Connection Out Jumper Plug PN 049 635 901 Out Jumper Plug PN x 049 635 901 Models FlexTest IIm GT SE Controller Hardware FlexTest GT Controller Connections 161 Sending
118. ions Models FlexTest IIm GT SE Controller Hardware Serial Communications Serial Communications Model 497 05 Hydraulic Control Panel Model 497 01 Analog Chassis Each chassis communicates with each other through a serial communications cable oo oo 00 00 J41 J42 Models FlexTest IIm GT SE Controller Hardware 046 350 902 41 a eall eala al l la p2 WI Ww B U U U e U eee ve U U U U U Diao Debug 056 027 101 Pra i ale 5p 3 oje s os E Model 498 22 jal g ET Test Processor E Ole d e E a al a FlexTest Ilm Controller Connections 195 Digital I O Connections Digital I O Connections Digital I O hardware enables two way communication between your test and exte
119. ipswitch S2 on each I O Carrier module to addresses set its address in accord with its installed chassis slot as follows SLOT 1 2 3 4 5 6 7 8 9 10 ADDRESS PPC C20 C22 C24 C26 C28 C2A c2c C2E Setting I O Carrier The dipswitch settings for address C20 is shown below Increment the rotary module addresses dipswitch as required to complete I O Carrier module addressing Setting GRES Ill The dipswitch settings for address C08 is shown below Increment the rotary module addresses dipswitch as required to complete GRES III module addressing Setting ADDA II Use the onboard rotary dipswitches S3 S2 and front panel rotary dipswitch on addresses each ADDA II module to set its address in accord with its installed chassis slot as follows SLOT 1 2 3 4 5 6 7 8 9 10 ADDRESS PPC PPC C40 C41 C42 C43 C44 C4A Cc4c 44 Installation Models FlexTest IIm GT SE Controller Hardware 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 Fo 4 Fo 4 Fo 4 E 2 E 2 E 2 olie EO A 4 A 4 A 4 9 5 9 5 9 5 87 6 87 6 87 6 3 2 On ADDA II Front Panel Front Panel VMEbus Modules MODEL MopuLE NAME FUNCTION 493 40 1 0 Carrier Supports up to four mezzanine cards 493 43 Multi Box I O The optional module allows multiple controllers to share a master hardware synchronization clock and pass station interlock
120. irements 15 V at 6 A 15 V at6 A 5 Vat6A 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 05 Specifications part 1 of 2 PARAMETER SPECIFICATION 2 A max Individual solenoid current Total HSM solenoid current 6 A max Solenoid operating voltage 24 V DC or 115 V AC switch selectable 497 05 power supply output 24Vat7 5A 497 01 power supply output 5Vat6A 15Vat6A 15Vat6A Power requirements 90 132 V AC 180 264 V AC 47 63 Hz 500 W Models FlexTest IIm GT SE Controller Hardware Introduction 33 Specifications Model 497 05 Specifications part 2 of 2 PARAMETER SPECIFICATION Interlock logic level inputs 0 0VDC 1 3 2 to 24 V DC Dimensions Height 8 9 cm 3 5 in Width 48 3 cm 19 in Depth 54 6 cm 21 5 in 34 Introduction Models FlexTest IIm GT SE Controller Hardware 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 Ib plus 0 5 kg 1 Ib per module Rack mounting requirements Clearance each side Clearance back Clearance top bottom 5 7 cm 2 25 in for air flow 15 3 cm 6 0 in for cabling No restrictions Number of slots 12 VMEbus slots Power requirements 100 120 V AC at 12 A bet
121. itation o 2 Excitation To From 3 Guard Transducer z 4 Feedback lt 5 Feedback S 6 Signal Common o 8 Clock gt 11 Data to Sensor ID lt _ 14 Data from Sensor ID at 10 Excitation Sense To From oo Transducer 9 Remote Calibration ID Module lt a 12 Feedback Return at 13 Feedback Return 14 lt a 15 Excitation Sense Models FlexTest IIm GT SE Controller Hardware FlexTest GT Controller Connections 89 Sensor Connections LVDT connections An LVDT requires an AC conditioning mezzanine card 0 E7 Backshell J pescani O Inner E3 AC Sensor LVDT Guard 3 BU oe a ee O FB 5 i A AE EE we Transducer ID Module FB 4 OT lect eects eye eas PI sx 2 e g EX 1 Pa OEE E y Remote Cal 9 _ 9 Remote Cal Clk 8 8 Data to ID 11 BEEN Data from ID 14 ID Circuit Sig Gnd 6 Temposonics Il The connection requires a DC conditioning mezzanine card EX 1 f EXC r EX 2 M DC FROM TEMPOSONICS II RETURN SENSOR FDBK 4 A FDBK FDBK 5 S mono REMOTE caL 9 SIG GND 6 gt CLK 8 DATATO ID 11 DATA FROM ID 14 y il 6 ID Circuit 90 FlexTest GT Controller Connections Models FlexTest Ilm GT SE Controller Hardware Sensor Connections Temposonics Ill The connecti
122. iving 210 external readout devices 169 210 213 adjust readout signals 171 215 cabling 171 214 create readout channel 171 215 sending station signals to 171 213 station signals available 169 213 Models FlexTest IIm GT SE Controller Hardware F force strain sensor T O carrier connection 92 front panel 24 function generation 25 G grounding chassis AC power 39 console chassis 62 low frequency ground loops 83 grounding chassis 53 H HPU 230 HPU transition board connection 131 system I O connector 133 HPU connector J25 230 HPU transition board E stop cable specifications 129 232 E STOP connectors 129 232 E STOP Out J23 129 HPU cable specifications 131 231 HPU connector J25 131 system I O connector J54 133 HSM proportional output 135 HSM transition board J28 HSM connector 134 J29 load unit connection 136 J43 interlock connection 137 J43 interlock connector 137 J44 run stop connection 138 J49 auxiliary power connector 140 hydraulic control panel 497 05 about 31 71 rear panel connectors 71 hydraulic pressure control 26 hydraulics cabling 189 VO carrier daughter boards connecting 87 description 45 46 73 Index 259 VO 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
123. les analog chassis 497 01 64 Multiple Controller networks 220 multiple controllers connecting 220 P pinouts digital input output connectors 199 plug in modules installing 42 49 plug in modules analog chassis configuration information 64 install remove 65 Models FlexTest Ilm GT SE Controller Hardware 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 hwi file 148 203 serial interface connection J50 147 serial interface connection J50 203 S scope connecting external 210 sensor analog chassis connection 179 assigning with transducer ID 107 cables 100 sensor cables 4 8 wire jumpers 93 95 97 active guard jumper 92 94 97 part numbers 101 specifications 100 with ID module 102 without ID module 101 serial communications cabling 195 service connections J3 Service I O carrier 150 J39 power monitor 149 servovalve analog chassis connection 179 VO carrier cable specifications 108 T O carrier connection 108 226 shunt calibration T O carrier connector 103 shunt resistor connector 103 Models
124. ller 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 For more information see Programming Eurotherm Temperature Controllers on page 209 How to Program an External Controller To send programming to an external controller you must 1 Cable the controllers on page 204 2 Create your configuration file with Station Builder on page 207 3 Adjust the signals with Station Manager on page 207 4 Set up your program on page 208 Cable the controllers Standard Configuration For a standard configuration using the Model 498 65 ADDA module cable the analog inputs and outputs between your FlexTest controller and the external controller Analog I O connectors are located on the rear of the test processor chassis 1 Connect a Series 498 Analog Out connector to the external controller program analog input 204 FlexTest Iim Controller Connections Models FlexTest IIm GT SE Controller Hardware How to Program an External Controller 2 Ifyou 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 20
125. llers 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 498 RS 485 Transition Module Cable the Eurotherm temperature controller to the proper J50 serial connector using cable PN 055 634 3XX Eurotherm Temperature Controller J50 connector The J50 connectors provide two way communication between the FlexTest controller and the Eurotherm temperature controller Temperature controller For more information on adding the Eurotherm hwi file resource see the Hwi hardware resource File Editor manual Program Eurotherm Use the Station Builder application to configure a Eurotherm temperature Temperature controller Controller For more information see How to Program a Eurotherm Temperature Controller in the MTS 793 Control Software manual Models FlexTest IIm GT SE Controller Hardware FlexTest Ilm Controller Connections 209 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
126. lly 8 wire cables e Switches S1 1 and S1 2 select a 4 or 8 wire transducer for positive feedback e Switches S1 3 and S1 4 select a 4 or 8 wire transducer for negative feedback e The setting of jumper W8 single ended excitation enable may affect your choices for these switches Note excitation excitation is standard Sensor Cable Settings 4 8 Wire REQUIRED CONNECTION SWITCH SETTINGS EX to FB shunt in 4 wire 1 1 OFF configuration 1 2 OFF DEFAULT 1 3 ON 1 4 OFF EX to FB shunt in 4 wire 1 1 ON configuration 1 2 OFF 1 3 OFF 1 4 OFF EX to FBR shunt in 8 wire 1 1 OFF configuration 1 2 OFF 1 3 OFF 1 4 ON EX to FBR shunt in 8 wire 1 1 OFF configuration 1 2 OFF 1 3 ON S1 4 OFF Models FlexTest IIm GT SE Controller Hardware FlexTest GT Controller Connections 95 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 kQ resistor to the input of the conditioner preamp Disable Enabl S1 5 OFF 1 5 ON Default Excitation sense Switches S1 6 and S1 7 select the local on board or remote through a cable excitation sensor connection e The local selection is used with 4 wire transducer connections e The remote selection is used with 8 wire transducer connections e Switch S1 7 configu
127. low level of risk which if ignored cou d cause moderate or minor personal injury or equipment damage or could endanger test integrity Notes provide additional information about operating your system or highlight easily overlooked items For example Note Resources that are put back on the hardware lists show up at the end of the list The first occurrence of special terms is shown in italics Models FlexTest IIm GT SE Controller Hardware Documentation Conventions Illustrations 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 Electronic manual This manual is available as an electronic document in the Portable Document conventions File PDF format It can be viewed on any computer that has Adobe Acrobat Reader installed Hypertext links The electronic document has many hypertext links displayed in a blue font All blue words in the body text along with all contents entries and index page numbers are hypertext links When you click a hypertext link the application jumps to the corresponding topic Models FlexTest IIm GT SE Controller Hardware Preface 17 Documentation Conventions 18 Preface Models FlexTest IIm GT SE Controller Hardware Chapter 1 Introduction Contents This manual contains installation cabling jumpering and hardware interfacing information for MTS 793 Controllers
128. ls in the MTS 793 Control Software manual Adjust feedback Ifyou will monitor sensor feedback for data acquisition or control feedback signals adjust the incoming feedback signals Models FlexTest IIm GT SE Controller Hardware FlexTest Ilm Controller Connections 207 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 Task3 Setup your program Define a program with the Function Generator Basic TestWare or Multipurpose TestWare applications Using Function Refer to How to Program with the Function Generator in the MTS 793 Control Generator Software manual Using Basic TestWare The Basic TestWare application allows you to create simple test programs that do not require complex signal management or mode switches for station configuration files Refer to Defining the Test Command in the MTS 793 Control Software manual Note Itis good practice to use tapered wave shapes to apply the program command to the external controller slowly Using MultiPurpose To create more sophisticated test programs use the optional MultiPurpose TestWare TestWare application For more information see the MTS 793 Application Software manual 208 FlexTest Iim Controller Connections Models FlexTest IIm GT SE Controller Hardware Programming Eurotherm Temperature Controllers Programming Eurotherm Temperature Contro
129. ltiple analog chassis 1 Install a cable from a Series 498 host computer serial port debug to J41 Com In on the Model 497 05 Hydraulic Control Panel then from J42 Com Out to J41 Com In on the first Model 497 01 Analog Chassis 2 Install a chassis interconnect cable PN 046 350 902 from J42 Com Out of the first Model 497 01 Analog Chassis to J41 Com In of the next analog chassis Install as many cables as needed to connect all the chassis These connectors are not used Rear panel interlock connectors J51 Intlk In and J52 Intlk Out are associated with the interlock controller module installed in slot A Each connector handles up to four test stations Installation 67 Transition Module Connectors Single chassis If you have a single analog chassis configuration o 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 Multichassis If you have a multiple analog chassis configuration 1 Install the cable from the chassis to J51 Intlk In on the Model 497 05 Hydraulic Control Panel then from J52 Intlk Out to J51 Intlk In on the first Model 497 01 Analog Chassis see Interlock Connections on page 192 2 Install a chassis interconnect cable from J52 Intlk Out of the first a
130. lug in modules cee mz 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 The Rack Mounting kit provides the hardware L shaped brackets to support the chassis and mounting screws to secure the chassis to the console rack 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 38 Installation Models FlexTest IIm GT SE Controller Hardware Grounding System ground cable PN 039 709 2xx connected to other components Configuration Configuration Chassis ground is connected through the power cord connector AC grounding Connecting Electrical Power Note 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 Signal Ground Chassis Ground e For the console configura
131. m AC type sensors such as LVDTs or RVDTs Note This module was designed to replace the Model 497 14 AC Conditioner 497 15 Three Stage Valve Driver Produces the control signal and inner control loop for a Series 256 Servovalve or Series 257 Servovalve 497 22 Dual DC Conditioner Processes the signals from two DC type sensors such as a force transducer or extensometer 497 26 Two Stage Valve Driver Produces the control signal for one Series 252 Servovalve The second valve driver is not used in standard systems 497 34 Multistation Interlock Monitors the plug in modules for interlocks This is a part of Controller the interlock chain between Model 497 05 Chassis and any other 497 01 chassis 497 36 Communication Module Provides communications between the Model 497 01 Analog Chassis and the Model 498 22 Test Processor This conditioner is normalized and can be swapped with a conditioner of the same model number without recalibrating the sensor conditioner pair Normalized conditioners contain an EEPROM in which normalization values are stored during manufacturing These values compensate for variations in conditioner components 64 Installation Models FlexTest IIm GT SE Controller Hardware How to Install or Remove a Plug in Module How to Install or Remove a Plug in Module Plug in modules are static sensitive Do not install or remove a module with electrical power on Do not place modules that contain battery b
132. mn gt choose the location closest to you Models FlexTest Ilm GT SE Controller Hardware Technical Support 9 Before You Contact MTS Before You Contact MTS Know your site number and system number Know information from prior technical assistance Identify the problem 10 Technical Support MTS can help you more efficiently if you have the following information available when you contact us for support 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 Example site number 571167 When you have more than one MTS system the system job number identifies your system You can find your job number in your order paperwork Example system number US1 42460 If you have contacted MTS about this problem before we can recall your file based on the e MTS notification number e Name of the person who helped you Describe the problem and know the answers to the following questions e How long and how often has the problem occurred e Can you reproduce the problem e Were any hardware or software changes made to the system before the problem started e What are the equipment model numbers e What is the controller model if applicable e What is the system configuration Models FlexTest I
133. 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 81 ANALOG INPUT Analog Monito ANALOG Front Rear e e 493 10 Chassis J CPTTITITeTeti iret Front Rear Cable Conduit FlexTest GT Controller Connections 125 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 e 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 e Analog inputs can be connected at the BNC connectors of a Model 493 83 Filtered Analog Input transition module and the outputs from this module are connected to the Model 493 50 ADDA II module To From A D 493 81 Analog In odule lt 1 nput 1 tM 2 gt lt 3 Fi nput 2 J11 J13 4 4 a J15 J17 4 5 7 nput 3 lt 6 7 j nput 4 t 8 lt 1 2 z ae it _ 3 Input 6 J12 JILA 4 J16 J18 q 5 J Input 7 a 6 jz lt 7 Input 8 8 126 FlexTest GT Controller Connections Models FlexTe
134. module is a dual wide VME based slave board used in the Model 493 02 Chassis e Provides box in and box out analog and digital I O E Stop and HSM and HPU control e Contains three general purpose digital input channels and three general purpose digital output channels e Interfaces the controller with a hydraulic power unit e Interfaces the controller with a hydraulic service manifold and other devices e Provides one BNC channel for analog output signals The output signals are within 10 V DC e Provides one BNC channel of analog input The input signals must be within 10 V DC J25 Hydraulic Power Unit Connection Connector J25 HPU controls the hydraulic power unit HPU e The connector provides 24 V logic signals to control the HPU e The connector may be connected directly to MTS Series 505 HPUs other MTS HPUs via the Model 493 07 HPU Converter Box and 24 V PLC compliant HPUs Note For more information see Hydraulic Configurations on page 243 Control voltages for hydraulic power units vary between models The HPU interface between the Model 493 42 System I O board and an HPU is 24 volt logic signals Connecting J25 to a non compliant HPU can damage the module DO NOT connect 24 V DC relay circuitry or 115 V AC circuitry to connector J25 on the Model 493 42 System I O board 230 FlexTest SE Controller Connections Models FlexTest IIm GT SE Controller Hardware J28 Hydraulic Service Manifold Connecto
135. mputer in the automated configuration Slot 2 Model 493 40 I O Carrier Supports up to four mezzanine cards that can be used for sensor conditioning driving a servovalve and in the automated configuration providing A D and or D A channels Slot 3 Blank in standard configurations May be used for additional Model 493 40 I O Carrier factory installed option for automated systems Additional carrier chassis that can house up to four mezzanine cards for expanded sensor conditioning and A D and D A channels Note This is not a standard option It is available only for automated systems and must be configured at the factory For more information contact MTS Slots 4 5 Model 493 42 System I O 50 Installation Provides box in and box out connections for daisy chaining multiple Controllers analog and digital I O E Stop and HSM and HPU control Models FlexTest IIm GT SE Controller Hardware Chassis Installation Options Model 493 40 I O Carrier Mezzanine Cards MODEL MopuLE 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 46 D A Converts up to six internal digital signals to analo
136. ms a second ADDA module or an optional fourth mezzanine card is required to provide the other four inputs 498 RS 485 Transition Module This module provides serial connections for use with remote station controllers RSCs or Eurotherm temperature controllers 498 System Digital I O Transition Module The System Digital I O Transition module is double width module that provides connection to the system digital I O and the station interlocks on the Model 498 71B GRES III module 498 Digital I O Transition Module This transition module provides 16 channels of user defined digital inputs and outputs In order to use these digital inputs and outputs this module must be connected to a Model 498 Digital I O Access Panel Note On some custom FlexTest Ilm Controllers this module must be connected to a Model 498 Remote Digital I O Access Panel 493 80 Encoder Transition Interfaces with up to four encoders 493 81 Analog In BNC Provides up to eight channels of analog input to each Model 493 55 A D module The input signals must be within 10 V DC 493 82 Analog Out BNC Provides eight channels of analog output from the Model 493 56 D A modules The output signals are within 10 V DC 493 83 Filtered Analog Input Models FlexTest IIm GT SE Controller Hardware Provides up to eight channels of filtered analog input to each Model 493 55 A D module Installation 75 UPS Systems UPS Sys
137. n 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 com ISO 9001 Certified QMS
138. n 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 Immerse the filter in a large pan filled with warm water and a mild detergent and allow it to soak a few minutes 3 Gently agitate the filter to loosen debris 4 Rinse the filter thoroughly with clean water Note Do not use compressed air to help dry the filter Compressed air may damage the filter element 5 Allow to drip until completely dry Note The air filter has a distinct top and bottom Ensure that you orient the filter properly 6 Replace the filter in the chassis Models FlexTest IIm GT SE Controller Hardware Chassis Maintenance 253 254 Chassis Maintenance Models FlexTest IIm GT SE Controller Hardware Appendix D 6 Station Configuration 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 e Ensure that the hwi file is correctly set for the desired multi station configuration especially the interlock and HSM board settings e Power to each HSM is limited e Cross head interlocks with solenoid power are not supported e Remote Station Control RSC is not supported e AC input power mus
139. nalog chassis to J51 Intlk In of the next chassis Install as many cables as needed to connect all the chassis 3 On the last chassis install jumper plug assembly PN 046 350 701 to J52 Intlk Out 68 Installation Models FlexTest IIm GT SE Controller Hardware 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 For jumper and switch locations see Jumper and switch locations on page 70 Configure the jumpers and switches for each chassis according to the following table Communication Modules Switch and Jumper Settings CHASSIS X1 Switcu S3 JUMPERS X1 X2 X3 JUMPER X5 For a single analog chassis 497 01 Analog Chassis 1 Set to 1 Remove Install 3 and 4 497 05 Hydraulic Control Set to 2 Install Install 1 and 2 Panel For multiple analog chassis 497 01 Analog Chassis 1 Set to 1 Remove Install 3 and 4 497 01 Analog Chassis 2 Set to 2 Remove Install 3 and 4 optional 497 01 Analog Chassis 3 Set to 3 Remove Install 3 and 4 optional 497 01 An
140. ng 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 Install multiple modules of the same model number next to each other Placement of 9 8 7 6 5 4 3 2 1 B A transition panels 10 en ee ee mare eae in the rear panel ieee HSM HSM Digital VO chassis service ua mk aB soa tnt yaa 78 883 Boeour A rea rea re ogol jpj o2 o2 o2 of Ch 2A In Ch2 Ch2 O 02 WY nt is 88 SJ ssa Runstop saas sasa RuniStop saas KO A QO Q 909 a 8 Fo lt 3 388 3 3 3 3 299 Estorn 88 8 8 88 8 8 g g 2 Ol co Lo Lo lt a S ik goc 29 J49A AuxPwr J49B J49A AuxPwr J49B SIA KO God 98 za AA gesl L2 98 98 98 98 000 go So So 8 gg sej Jee seJ Jles is Sat SS Gy ses O 98 3500 J29A Load Unit J298 J29A Load Unit J298 98 a 5 gt 3 Q oA A L ed oe 188i cay 50 seal lles 88 e chen 880 2 3 22 gt ses esli 1138 38 fo 88 88 08 oO Koy mee hey go sen eJ 7 Ps O biisin J28A HSM O Ch 1 4 Ch 1 4 Ch 1 4 03 Jt Bout 2o A Ic s 1133 EEE 8 88 38 2 ne a2 m SS 88 onsu
141. nics II e 053 070 201 Temposonics III ADDA mezzanine The ADDA module requires special mezzanine cards to support encoders and cards Temposonics sensors Mezzanine cards for encoders and Temposonics sensors support four input channels Mezzanine cards for multiturn encoders Heidenhain 417 425 and Temposonics III position sensors support two channels e The encoder mezzanine card counts pulses from the encoder to determine the displacement of an actuator e The Temposonics mezzanine card interprets the pulses from the Temposonics sensor to determine the displacement of an actuator Optional ADDA II For the optional ADDA II configuration using the Model 493 50 ADDA II configuration module each encoder requires installation of a Model 493 59 Universal Encoder mezzanine card on the Model 493 50 ADDA II module Models FlexTest IIm GT SE Controller Hardware FlexTest Ilm Controller Connections 201 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 Daughter Board 2 Daughter Board 3 Daughter Board 4 ADDA II Configuration 202 FlexTest Ilm Controller Connections Models FlexTest IIm GT SE Co
142. nnect to pin 13 9 N C No connection 10 N C No connection 11 N C No connection 12 xhead power 24 V crosshead unlock power output from HSM high relay contact 13 HPU E stop E stop loop from HPU connect to pin 8 14 xhead power return 24 V common for crosshead unlock power output 15 N C 232 Cable specification FlexTest SE Controller Connections 15 contact type D male EMI connector e Backshell EMI metallized plastic Cable 24 AWG 4 connector with braided shield with the braid connected to a metallized plastic backshell at the chassis and to ground at the emergency stop station Models FlexTest Ilm GT SE Controller Hardware 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 3 4 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 So even though Pin 6 is a NO normally open relay contact it is actually normally closed when no interlocks are active Similarly the intlk out relay Pin 8 is normally closed when no interlocks are active so even though Pin 8 is a NC normally closed relay it is actually normally open when no interlocks are active J43 Connector Pin Assignments PIN NAME F
143. ns OFF ON will appear on the Station Manager Station Controls panel For the other selections 3 HSM control buttons will appear OFF LOW HIGH Models FlexTest IIm GT SE Controller Hardware FlexTest GT Controller Connections 135 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 424V DC 1 configured for contacts with eobewiod ul i x jumpers X and Xt or a logic X 4 7 WM 4 Cross signal without jumpers X and AT 2 3 a an XI Ie 2 VW Station X Jumper X2 for Channel A 24V DC 13 alo Stop Jumper X1 for Channel B CRM Relay me LJ i Emergenc Xt Jumper X4 for Channel A sf l Stop pele i Jumper X3 for Channel B E Stop 7 tO e 5 Pins 5 7 8 and 13 maintain v the continuity of the Sic 9 Shield emergency stop interlock 424V HSM hi o HSM ti Ae Crosshead Cross Head Unlock a Solenoid DC Common V Cable specification e P29 isa 15 contact type D male EMI connector e Cable for load frames with crosshead locks built after 1985 18 AWG 8 conductor with overall foil shield Alpha 5388C or equivalent with drain wire connected to pin 9 at both ends of the cable e Cable for all load frames without crosshead locks 22 AWG 6 conductor with overall foil shield Alpha 5386C or equivalent with drain wire connected to pin 9 at both ends of the cable pin 9 may be pin E
144. nte position an error may have been made during the assembly Take a small straight blade screw driver and carefully remove the covers 13 loosen all screws and remove the handle assembly from the controller Reassemble the handle side leg assemblies according to steps 1 through 7 Models FlexTest IIm GT SE Controller Hardware Connecting the Console and Chassis Power Installing 497 498 Electronics FTIlm Contents Connecting the Console and Chassis Power 61 Grounding the Console and Chassis 62 Model 497 01 Analog Chassis 63 About Analog Chassis Slots 63 Analog Chassis Plug in Modules 64 Analog Chassis Transition Modules 66 Adding an Analog Chassis to Your Console 69 Model 497 05 Hydraulic Control Panel 71 Test Processor Plug in Modules 72 Test Processor Transition Modules 74 Connecting the Console and Chassis Power Each chassis installed in your console can be configured for 115 or 230 V AC service To configure each chassis for 230 V AC service refer to the following product manuals e Model 497 05 Hydraulic Control Panel 100 036 577 e Model 497 01 Analog Chassis 100 036 577 e Model 498 22 498 23 Test Processor 100 036 578 for FlexTest Im How To Connect the Chassis Power Cables You can plug the hydraulic control panel and the test processor chassis into the AC power strip inside the console The analog chassis requires an external power supply Typically it is connected to the hydraulic control panel If
145. ntroller Hardware 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 _ 498 RS 485 Transition Module Cable the RSC to the proper J50 serial s connector usually J50A using cable PN 055 634 3XX Remote Station Controller r w q g Use Jumper Plug 055 634 101 o ea in these connectors a 055 634 3XX Ti oo z ri n ol hwi file additions In order to use one or more RSCs with your FlexTest controller two sections must be added to your hwi file an RSC section and a GRES III section Note Ifyou specified RSC support when you ordered your test system these sections will be added to your hwi file at the factory Note For information on editing your hwi file to accommodate RSCs see the Hwi File Editor manual Models FlexTest IIm GT SE Controller Hardware FlexTest Ilm Controller Connections 203 Cabling and Programming External Controllers Cabling and Programming External Controllers Cabled properly you can use your FlexTest controller to send test commands to another contro
146. o sensn Giso iso iso 38 o8 KO a S O EEEa Models FlexTest IIm GT SE Controller Hardware Installation 47 Installing the Transition Panels Note Other transition modules may be used contact MTS Systems Corporation for additional information Rear Panel Transition Panels MODEL 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 72 Digital I O Contains sixteen general purpose digital input channels and sixteen general purpose digital output channels 493 73 HPU Transition Board Interfaces the controller with a hydraulic power unit 493 74 HSM Transition Board Interfaces the controller with a hydraulic service manifold and other devices up to two stations 493 75 Analog In BNC Provides six BNC channels for analog input signals The input signals must be within 10 V DC 493 76 Analog Out BNC Provides six BNC channels for analog output signals The output signals are within 10 V DC 493 77 Filtered Analog Input Provides filtering for the Model 493 45 A D analog to digital modules 493 78 Accelerometer Transition Interfaces with up to three low impedance voltage mode Boar
147. o another The master controller will have an open Box In connector and a cable attached to the Box Out connector A middle run dependent controller will have cables attached to both the Box In and Box Out connectors The end of run dependent will have a cable attached to the Box In connector and a jumper plug attached to its Box Out connector Models FlexTest IIm GT SE Controller Hardware FlexTest SE Controller Connections 221 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 Also if a cable becomes disconnected from a dependent controller s Box In connector or if a cable is inadvertently connected to the Box In connector on the master controller an interlock is set which cannot be reset until all controllers are restarted 222 FlexTest SE Controller Connections Models FlexTest IIm GT SE Controller Hardware Cable Part Numbers Cable Part Numbers System cables current and additional cable part numbers Model 493 02 Chassis Cables CABLE DESCRIPTION PART NUMBER MODULE JUMPER PLuct CONNECTOR 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 xx 3 stage N A Valve 055 439 6XX 493 40 J4
148. oller 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 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 Operations are controlled through the controller s front panel An easy to read color display shows the status of the parameter currently being adjusted or monitored A simple scroll through menu provides quick access to any parameter or function All parameters are entered through a keypad or adjusted by a single multi turn dial The current settings are saved in a flash disk and are recalled at start up In addition to providing the means to adjust and monitor the test parameters the front panel also provides program control system hydraulic pressure control and an Emergency Stop button that shuts down the system hydraulics in an emergency situation BNC monitor connectors are also provided to allow you to connect easily to external readout devices mol e O a Power 4 FlexTest SE Front Panel 15 6436 Models FlexTest IIm GT SE Controller Hardware Specifications FlexTest SE stand alone A function generator with a built in cycle counter in the controller provides function generation basic sine square t
149. ompletion resistors can be installed into sockets on the I O Carrier printed wiring board The shunt calibration resistor sockets are accessible from the I O Carrier front panel Models FlexTest IIm GT SE Controller Hardware FlexTest GT Controller Connections 103 I O Carrier Module The following figures show three typical bridge configurations for a DC conditioner installed on an I O Carrier module 4 Wire Full Bridge VO Carrier Conditioner Gauge Rshunt 3 Wire Quarter Bridge NO Carrier 104 FlexTest GT Controller Connections Models FlexTest Ilm GT SE Controller Hardware I O Carrier Module 7 Wire Full Bridge Bridge VO Carrier Conditioner FBR O FB loam p ae AS EXS e a o D EXS I o o FBR aml Rshunt 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 ina sensor calibration file When you load a station that does not ha
150. on Models FlexTest Ilm GT SE Controller Hardware Digital I O Connections Digital outputs Digital outputs provide an optically isolated open collector open emitter output e 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 e Each digital output connector located on the Digital I O Access Panel supports two channels e Each digital output is an open collector open emitter rated at 30 V DC max at 50 mA max This igure shows howto P aos Doaa bighallO connect Oran erral Transition Module Access Panel External Device circuit using an external power supply J3 4 Ext Voltage Opto Coupler CH4 T i Ea CH4 4 common Connector pinouts The pin connections for the digital inputs and digital outputs are the same Each D style connector supports two channels For example the pins associated with channels 1 12 V DC and 2 are outlined Odd Channel The 12 volt supply is reserved for the digital inputs and should not be used to power external devices it is rated for maximum 250 mA current Even Channel Odd Channel 12 volt common 12 volt common H2VDC Even Channel Models FlexTest IIm GT SE Controller Hardware FlexTest Ilm Controller Connections 199 Encoder Temposonics Connections Encoder Temposonics Connections
151. on requires a DC conditioning mezzanine card TO 24 V 493 74 AUX POWER COM L Ei TO Data 493 40 CARRIER MODULE 10 TEMPOSONICS III DAUGHTER BOARD 12 Clock 13 OUTER BRAID Models FlexTest IIm GT SE Controller Hardware 24 V COM Data FROM TEMPOSONICS III SENSOR 4 Clock FlexTest GT Controller Connections 91 Model 493 21B DUC B Jumpers Force strain sensor Force and strain sensors require a DC conditioning mezzanine card connections __ Backshell GND Fo Whe See nd E79 4 Inner E3 Guard ff ere es aan FB E5 f i FBR Future E ii Transducer ID Module FB E45 FBR Future EX E2 EXS Future EX E1 EXS Future Remote Cal Remote Cal Clk Data to ID ID Circuit Data from ID Sig Gnd Model 493 21B DUC B Jumpers The following jumpers are for the Model 493 21B 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 Active guard is usually not required In particular environments active guard drive may reduce transducer noise E Enable Disable z EB v E D Default
152. onditioners provide transducer excitation and output signal amplification for both low level and high level transducers e Valve drive signals Valve drivers provide drive current for two and three stage servovalves according to command inputs received for each channel This chassis shows the maximum complement of modules for a standard FTIlm system Customized systems can use all the module locations Note This chassis has rear panel transition modules and I O connectors to support up to four independent test stations Analog Chassis Front Panel 30 Introduction Models FlexTest IIm GT SE Controller Hardware Model 497 05 Hydraulic Control Panel Model 497 05 Hydraulic Control Panel The hydraulic control panel provides the following functions e Control of up to four independent hydraulic service manifolds e Hydraulic power supply control e Interlock shutdown and latched indicators to show interlock status e Programmable interlock station assignment e Electrical power outputs to the hydraulic service manifolds and a 497 01 Analog Chassis e Built in Emergency Stop button and connections for a remot
153. onnection Two different cables can be used to connect the converter to the temperature controller e For Eurotherm Temperature Controllers used with Series 651 chambers use cable assembly PN 056 719 6xx e For MTS Model 409 83 Temperature Controllers equipped with Eurotherm control modules use cable assembly PN 056 719 7xx 4 n 5 2 S s S 6 T RS 485 D 9P D 25P al f pa hz C BLUWHT i 3 al WHT BLU si ie Ia p L 651 XX 8 i Oi 2 HE CHAMBER l COMMUNICATION 6 ORN WHT 7 HD COM LI WHT ORN al C T T J N C pii NIC gi j 056 719 6XX RS 485 D 9P Dsp 7 WHT lt wie TO HFC 409 83 g BLK BLK HE TEMPERATURE CONTROLLER essere oul Rock To use a temperature controller with your FlexTest SE Controller you must add a temperature controller resource to the Controller s hardware interface file hwi This adds a temperature controller resource to the inventory of hardware resources available for station configuration files To do this use the MTS Hwi File Editor application installed with MTS 793 software to open the controller s hardware interface file The typical path to this application is Start gt Programs gt MTS Systems Software gt Service Tools gt Hwi File Editor Models FlexTest IIm GT SE Controller Hardware FlexTest SE Controller Connections 241 Eurotherm Temperature Controller Connection To add
154. ons two or more independent Model 407 Controllers each run different test programs e Master dependent station one master Model 407 Controller daisy chained with other dependent Model 407 Controllers together run a single test program The following figure shows how to cable interlocks for a single station Model interlock connections 407 Controller 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 P28 Digital ps PC 4P I O Connector ee a Q Hydraulic 24vo 3 yaraull i wM K DIcITAL Interlock T S 5 2 7 7 ActiveLow 107 1 5 1 omita Run Stop Controller 4 BS ss OUT 1 f ActiveHigh YU P43 To D 9P 493 74 HSM 24V OW 1 Transition gt Jumper DNK wE 4 Jumper v 24V ow 5 gt l 6 a ee OFF INTLK Jumper g er 1456 FlexTest GT Controller Connections Interlock Cable PN 056 455 0XX Models FlexTest IIm GT SE Controller Hardware How to jumper the hydraulic terminal on a single station Model 407 Controller Connecting Interlock Signals to 407 Controllers The following figure shows how to cable the hydraulic terminal on a single station Model 407 Controller 407 Controller No Connection Jumper Plug PN 049 635 901 No Connection Jumper Plug PN 049 635 901 Models FlexTest IIm GT SE Controller H
155. or the shunt calibration signal e Ifpurchased as an option each sensor includes one cable with a transducer ID module and a system extension cable A system cable is required between the transducer ID cable and the controller s chassis 100 _ FlexTest GT Controller Connections Models FlexTest IIm GT SE Controller Hardware Sensor Cable Part Numbers Sensor Cable Part Numbers Models FlexTest IIm GT SE Controller Hardware FlexTest GT Controller Connections Sensor cables without See the System Cable Jumper Plug 493 Package Selection drawing PN 700 000 ID Module 656 for the most current sensor cable part numbers Sensor Cables and Connectors CABLE DESCRIPTION CABLE CONNECTOR ADT 120 056 234 8XX 493 40 J4 J7 300 056 253 1XX 493 40 J4 J7 Extensometer 633 capacitive 051 649 5XX 493 40 J4 J7 Force Transducer w PT connector 046 440 2XX 493 40 J4 J7 with MS connector 046 440 6XX 493 40 J4 J7 with PC 056 252 9XX 493 40 J4 J7 LVDT 046 440 3XX 493 40 J4 J7 AP control 047 927 6XX 493 40 J4 J7 Pressure Control Sensotec 056 253 0XX 493 40 J4 J7 Strain with Amphenol connector 056 233 6XX 493 40 J4 J7 with PT connector 050 120 0XX 493 40 J4 J7 Temposonics 049 153 2XX 493 40 J4 J7 Temposonics II low power conditioner 056 253 2XX 493 40 J4 J7 Temposonics Ill 056 316 7XX 493 40 J4 J7 RVDT with MS connector 051 202 8XX 493 40 J4 J7 101 Sensor Cable Part Numbers Sensor cables with ID
156. ou Begin 15 Conventions 16 Documentation Conventions 16 Chapter 1 Introduction 19 FlexTest GT Controllers 20 Model 493 10 Chassis 20 Hydraulic Control 22 Interlocks 22 Specifications 23 FlexTest SE Controllers 24 Model 493 02 Chassis 26 Hydraulic Control 26 Interlocks 26 Specifications 27 FlexTest IIm Controllers 28 Model 497 01 Analog Chassis 30 Model 497 05 Hydraulic Control Panel 31 Model 498 22 Chassis with Test Processor FTIIm 32 Specifications 33 Models FlexTest IIm GT SE Controller Hardware Contents Chapter 2 Installation 37 Installing the Model 493 10 Chassis FTGT 37 Connecting Electrical Power 38 Installing the Plug in Modules 42 VMEbus Modules 43 Installing the Transition Panels 47 Installing the 493 02 Chassis FlexTest SE 49 Installing the Plug in Modules 49 VMEbus Modules 50 Chassis Installation Options 51 Connecting Electrical Power 53 Installing the Handle Kit 58 Installing 497 498 Electronics FTIIm 61 Connecting the Console and Chassis Power 61 How To Connect the Chassis Power Cables 61 How To Cable the Analog Chassis to the Hydraulic Control Panel 62 Grounding the Console and Chassis 62 Model 497 01 Analog Chassis 63 About Analog Chassis Slots 63 Analog Chassis Plug in Modules 64 How to Install or Remove a Plug in Module 65 Analog Chassis Transition Modules 66 How To Install a Transition Module 66 Transition Module Connectors 67 Adding an Analog Chassis to Your Console 69 Model 497 05 Hyd
157. ower Type HSM Only Interlock Hydraulics TERE 056 316 0xx A J28 HSM TNIJ28HSM 056 126 4xx 056 126 4xx HSM 1 HSM 2 For this multiple controller configuration Each controller has an independent hydraulic service manifold HSM No hydraulic power unit HPU is connected Select HSM Only for Power Type on each connected controller Path Config gt Edit Hardware gt Power Options gt Power Type gt HSM Only Models FlexTest Ilm GT SE Controller Hardware Independent HSM shared HPU Independent HSM shared HPU Power Type HPU HSM Power Type HPU HSM Interlock Hydraulics 056 316 Oxx 7S J28 HSM i 056 126 4xx HSM 1 039 713 5xx HSM 2 HPU Converter 039 710 7xx For this multiple controller configuration e Each controller has an independent hydraulic service manifold HSM e An HPU is shared by all connected controllers via Y cables e Select HPU HSM for Power Type on each connected controller Path Config gt Edit Hardware gt Power Options gt Power Type gt HPU HSM Shared HSM with HPU Power Type HPU HSM Power Type Slave HSM es eA Interlock Hydraulics 7 ag Pq 056 316 0xx 056 126 4xx 039 713 7xx HSM Models FlexTest Ilm GT SE Controller Hardware Hydraulic Configurations 247 Shared HSM no HPU Shared HSM no HPU 248 Hydraulic Configurations For this multiple controller configuration The HS
158. pliant Cabling on page 83 Stand alone Cabling Overview 218 Automated Cabling Overview 219 Multiple Controller Connections 220 Cable Part Numbers 223 Model 493 40 I O Carrier Connections 225 Sensor Connections 226 Valve Connections 226 Analog I O Connections 226 Encoder Connections 228 Workstation Connection 229 Service Connection 229 Model 493 42 System I O Connections 230 J25 Hydraulic Power Unit Connection 230 J28 Hydraulic Service Manifold Connector 231 J29 Emergency Stop Connections 232 J43 Interlock 233 J49 Auxiliary Power 234 CJ51 Box In 234 J52 Box Out 235 J54 Digital Inputs 236 J55 Digital Outputs 237 Eurotherm Temperature Controller Connection 239 Models FlexTest IIm GT SE Controller Hardware FlexTest SE Controller Connections 217 Stand alone Cabling Overview Stand alone Cabling Overview Force Sensor 100 240 VAC 5 a 50 60 Hz 12 6A 2 i O 052 544 2xx Actuator Manifold le lel HSM E ts 056 126 4xx if oO Je Ele aa Ods Ja D ial ol oe _ Servovalve 039 708 3xx PS Intik LVDT 046 440 3xx Juenper Plug 100 057 245 HPU 039 713 7xx E Stop Jumper Plug Box Out 100 007 94
159. ppendix B Model 493 07 Converter Box on page 251 15 contact type D female EMI connector at J25 of the Model 493 73 HPU Transition module in the rear panel of the Model 493 10 Chassis Backshell EMI metallized plastic 14 contact type CPC male connector at J1 of the Model 493 07 Converter Box chassis Cable 24 AWG 10 conductor with overall foil shield Carol C0745 or equivalent with drain wire connected to metallized plastic backshell at the 493 10 chassis and pin 14 at the Model 493 07 Controller Box chassis 24 contact type CPC female connector at J25 of the Model 493 07 Converter Box chassis 14 contact type MS connector at J1 of the HPU Cable 18 AWG 14 conductor with overall foil shield Alpha 2248C or equivalent with drain wire connected to pin 4 of connector J25 and pin A of the pump connector The following diagrams show how to connect the chassis to a hydraulic power unit Single 493 chassis with a 24 V PLC programmable logic controller pump or 505 pump Single 493 chassis with a non PLC pump Multiple 493 chassis with a non PLC pump Compatible controllers controlling a pump Models FlexTest Ilm GT SE Controller Hardware Hydraulic Configurations 243 Single Model 493 02 chassis with a 24 V PLC pump 506 52 92 or 505 pump 493 02 Chassis J25 HPS Single Model 493 02 chassis with a non PLC pump 039 713 8XX 24 V DC 039 714 6XX 115 V AC 493 02 Chassis J25
160. r Cable specification The J25 HPU and J51 Box In connectors are 15 pin type D male connectors 15 contact type D female EMI connector e Cable 24 AWG 10 conductor with braided shield with drain wire connected to metallized plastic backshell to the chassis Jumper plug required If connector J25 HPU is not used you must install a jumper plug to maintain the integrity of the interlocks Use jumper plug PN 039 713 301 or jumper pins 1 7 2 3 5 6 9 8 10 11 12 6 9 For an electrical diagram of J25 see page 132 J28 Hydraulic Service Manifold Connector See J28 Hydraulic Service Manifold Connector on page 134 Models FlexTest IIm GT SE Controller Hardware FlexTest SE Controller Connections 231 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 J29 Connector Pin Assignments PIN NAME FUNCTION 1 xhead 24V Fused 24V 2 xhead intlk com 24V common 3 Program interlock low Low side of opto isolator jumpered to common xhead interlock low 4 Program interlock high High side of opto coupler pulled up to 24V opto on intlk xhead interlock high 5 Local E stop Local E stop loop connected to pin 7 6 N C No connection 7 Local E stop Local E stop loop connected to pin 5 8 HPU E stop E stop loop from HPU co
161. raulic Control Panel 71 Test Processor Plug in Modules 72 Test Processor Transition Modules 74 UPS Systems 76 UPS Systems for FlexTest 60 100 200 and GT Controllers 76 UPS Systems for FlexTest 40 and FlexTest SE Servocontrollers 77 Specifications UPS Systems Used with MTS Controllers 78 UPS Connections for the Model 493 73 HPU Board FT60 FT100 FT200 FTGT 79 UPS Connections for the Model 493 42 System board FlexTest SE 80 4 Contents Models FlexTest IIm GT SE Controller Hardware Chapter 3 FlexTest GT Controller Connections 81 CE EMC Compliant Cabling 83 Typical Cabling 84 Cable Part Numbers 85 Model 493 40 I O Carrier Connections 87 Sensor Connections 88 Model 493 21B DUC B Jumpers 92 Digital Universal Conditioner DUC BC Switches 94 Full Range Digital Universal Conditioner FRDUC Jumpers 97 Sensor Cables 100 Sensor Cable Specifications 100 Sensor Cable Part Numbers 101 Shunt Calibration Bridge Completion Resistor Installation 103 T O Carrier Module 103 Transducer Identification Modules 106 Valve Connections 108 Multiple Universal Driver Connections 112 Analog I O Connections 114 Accelerometer Connections 119 Encoder Connections 121 Remote Setpoint Adjust Connections 123 ADDA II Connections 124 Emergency Stop Connections 129 J25 Hydraulic Power Unit Connection 131 Station Connections 134 J28 Hydraulic Service Manifold Connector 134 J29 Load Unit 136 J43 Interlock 137 J44 Run Stop 138 J49 Auxiliary Power 140 Digi
162. relay contact out both of which must be wired to the controller s UPS monitoring interface A UPS with an AC Fail relay contact wired to the controller provides a mechanism for the controller to identify that the UPS has switched over to battery power due to a detected AC power failure condition from the facility s power grid This fault signal from the UPS can be used by the controller to start a safe shutdown sequence ramp command s to a safe state s and then shut off the power source 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 Models FlexTest IIm GT SE Controller Hardware UPS Systems for FlexTest 40 and FlexTest SE UPS Systems for FlexTest 40 and FlexTest SE Servocontrollers UPS requirements Battery power considerations 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 It is important to note that the UPS will not prevent any unexpected motion if the controller or any other electrical subsystem required for control of the system has an internal failure including a HPU or a motor drive e The UPS must be wired to provide power to the servocontroller and any peripheral equipment that is instrumental in
163. res the excitation signal e Switch S1 6 configures the excitation signal Both switches need to be set for the same configuration Remote Local S1 6 OFF S1 6 ON S1 7 OFF S1 7 ON Default Single ended Jumper W8 connects EX to ground for situations requiring single ended excitation excitation EX EX EX GND Default CE B vs d BD vs 96 FlexTest GT Controller Connections Models FlexTest Ilm GT SE Controller Hardware 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 Enable Disable Short to Ground Cap to Ground EB v E Bv Default 4 or 8 wire Jumpers W2 and W3 establish the correct shunt calibration connections for 4 sensor cable 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 e Jumper W2 selects a 4 or 8 wire transducer for positive feedback e Jumper W3 selects a 4 or 8 wire transducer for negative feedba
164. riangle 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 FlexTest SE automated In the automated configuration the FlexTest SE Controller has added configuration capabilities it can acquire data perform automated testing apply complex control compensation techniques to the servoloop and execute sophisticated test procedures that include complex triggering mechanisms The automated configuration includes the controller a personal computer and the Model 793 00 System Software bundle It may also include optional MTS software for additional capability Models FlexTest IIm GT SE Controller Hardware Introduction 25 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 e A Series 498 Processor e A Model 493 40 I O Carrier module e A Model 493 42 System I O module Model 493 02 Chassis Except for two front panel BNC connectors all cabling is accessed through the rear panel controller s rear panel It is not necessary to remove the chassis cover to access jumpers or switches The chassis can be rack mounted or used
165. rlock 7 o OV 8 e 9 contact type D male EMI connector e Backshell EMI metallized plastic e Cable shielded twisted pairs 24 AWG minimum with drain wire s connected to the metallized backshell at the chassis Channel inputs can be 3 volts minimum and 26 volts maximum from an external voltage source If connector J43 is not used you must install a jumper plug to maintain the integrity of the interlocks Use jumper plug PN 100 007 948 or jumper pins 1 and 2 3 and 4 5 and 6 7 and 8 Models FlexTest IIm GT SE Controller Hardware FlexTest GT Controller Connections 137 J44 Run Stop J44 Run Stop Run Stop status Connector J44 Run Stop provides the run stop status of the controller to external devices e Two form C contacts provide the run stop status e The contacts are rated 1 0 A at 30 V AC or DC From J44 To Chassis External Devices r 2 Run Stop 0 3 4 _ Interlock Status zA S Output 5 a e o 7 Run Stop 1 8 Interlock status Connector J44 Run Stop also provides opto isolator outputs that indicate the interlock status of each station to an external device These interlock status outputs are normally on and will turn off when an interlock occurs For detailed circuit drawings see Digital outputs on page 143 138 FlexTest GT Controller Connections Models FlexTest Ilm GT SE Controller Hardware J44 Run Stop Output
166. rnal logic devices This transition module provides user digital I O the built in digital I O access panel FTIIm 046 442 302 Connects to back of built in module FTIIm A digital output produces a logic signal to an external circuit LO DIGITAL I O ACCESS PANEL DIGITAL IN1 16 DIGITAL OUTI 16 igital Output hannels A digital input can 049 792 201 be a mechanical Connects to J2 switch or a logic on back of signal module 1496 FlexTest Ilm Controller Connections J3 This transition module reserves system DIO For the connectors on this module see Interlock Connections on page 192 pe Cp Bp Model 498 22 Chassis Backplane pi pws o d a Paddle Board AJ wi Models FlexTest Ilm GT SE Controller Hardware Digital I O Connections Digital inputs e Digital inputs can be wired to allow the input from a switch contact a relay contact or a logic signal e All digital inputs are optically isolated at the Series 498 Digital I O transition module e For example an action defined in the can be selected in the Station Setup window s Digital Input panel as an Action e The digital inputs are used by the Digital Input process in the MultiPurpose TestWare application They can also be monitored from the Station Manager application e You
167. rovide 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 On the Station Manager application s Station Controls panel click Reset to clear the Program interlock H On the Station Manager application s Station Controls panel click the gt Program Run This step sends program from the 793 Controller to the 407 Controller Models FlexTest IIm GT SE Controller Hardware FlexTest GT Controller Connections 155 Connecting Interlock Signals to 407 Controllers Connecting Interlock Signals to 407 Controllers Single 407 Controller 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 There are three possible configurations e Single station one Model 407 Controller runs a single test program e Multiple stati
168. rrier 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 hwi file and the physical locations for each type of module and associated mezzanine cards must match Also the I O Carrier module address setting on the module must match the hwi file address For more information on the hwi file see the MTS 793 Utility Software manual e Transducer connections require a conditioner mezzanine card to be installed in the I O Carrier module The following conditioners can be installed Model 493 21B Digital Universal Conditioner Model 493 25 Digital Universal Conditioner Model 493 47 Encoder Model 493 48 Acceleration Conditioner e Valve connections require a valve driver mezzanine card be installed in the T O Carrier module The following valve drivers can be installed Model 493 14 Valve Driver Model 493 15 3 Stage Valve Driver e Analog I O connections require an A D or D A mezzanine card be installed in the I O Carrier module The following analog mezzanine cards can be installed Model 493 45 A D Converter Model 493 46 D A Converter Models FlexTest IIm GT SE Controller Hardware FlexTest GT Controller Connections 87 Sensor Connections Sensor Connections Sensor connections require a conditioner mezzanine card be installed in the I O Carrier module
169. s 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 Connector J28 HSM controls the pressure of a hydraulic service manifold The controller software can configure the connector for solenoid or proportional control of a 24 volt hydraulic service manifold Cable specification From Chassis J28 To HSM lo 24V O gt 1 Low Pressure 7 a Eo Solenoid oS ian S ommon i f i olenoid or Proportiona ic 3 Shield O Proportional es Valve Qi 4 High Pressure Proportiona P28 is a 4 contact CPC male connector AMP Incorporated Cable for on off HSMs 18 AWG 2 conductor with overall foil shield Carol C2534 or equivalent with drain wire connected to pin 3 at the chassis Cable for high low HSMs 18 AWG 4 conductor with overall foil shield Carol C2543 or equivalent with drain wire connected to pin 3 at the chassis 134 FlexTest GT Controller Connections Models FlexTest IIm GT SE Controller Hardware J28 Hydraulic Service Manifold Connector Proportional outpu
170. s The cable from the front panel of the I O Carrier module has the following specification 15 contact type D male EMI connector e Backshell EMI metallized plastic e Cable type up to 6 shielded twisted pairs each with the drain wire connected to the signal source Encoder Connections See Encoder Connections on page 121 228 FlexTest SE Controller Connections Models FlexTest IIm GT SE Controller Hardware 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 The symbol shown here indicates that you must not connect telecommunications equipment to the equipment showing this symbol amp 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 Service Connection See I O Carrier service on page 150 Models FlexTest IIm GT SE Controller Hardware FlexTest SE Controller Connections 229 Model 493 42 System I O Connections Model 493 42 System I O Connections The Model 493 42 System I O
171. safe system operation and shut down In some cases it may be feasible and appropriate to provide UPS power to the hydraulic power unit HPU e The UPS must be sized to provide adequate electrical power for a period of three minutes after loss of input power e The controller must be configured to take appropriate actions for safe shut down of hydraulic equipment being controlled Appropriate actions depend on the particular system e Both UPS input power and UPS output power connections must include strain relief and a twist lock plug or equivalent e UPS systems used in the European Union must be CE marked e FT40 with Model 494 41 System board and FTSE controllers do not have dedicated UPS monitoring inputs The UPS must have input power loss AC Fail alarm relay contact out and a low battery alarm relay contact out both of which must be wired to two of the digital inputs that are part of general use DI O in the FT40 or FTSE controllers Note FT40 controllers that include a Model 494 44 or a Model 494 42 system board have dedicated UPS inputs e The controller s Event Action feature must be configured to take appropriate actions for safe shut down of hydraulic equipment being controlled Appropriate actions depend on the particular system A UPS with an AC Fail relay contact wired to the controller provides a mechanism for the controller to identify that the UPS has switched over to battery power due to a detected
172. ss head interlocks with solenoid power are not supported for 8 station configurations Remote Station Control RSC is not supported for 8 station configurations Only one set of six A D analog inputs is supported for 8 station configurations 256 Optional Station Configurations Models FlexTest Ilm GT SE Controller Hardware 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 42 System I O auxiliary power connection J43 234 E stop connection J29 232 HPU connection J25 230 HSM connection J28 231 Interlock connection J43 233 493 42 System I O module description 230 493 46 D A 493 76 Analog Out connection 117 127 187 497 01 Analog Chassis about 63 adding analog chassis 69 chassis slots 63 hydraulic control panel connection 62 install transition module 66 plug in modules 64 sensor valve connections 179 transition modules 66 497 05 Hydraulic Control Panel about 31 71 HPS HSM connections 189 rear panel connectors 71 497 36 Communication Module jumper switch settings 70 498 System Digital I O interlock jumpers 193 498 22 Test Processor about 32
173. st IIm GT SE Controller Hardware 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 e Fach readout signal is from a 16 bit digital to analog converter e Each output is a 10 V analog output e 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 82 Analog Out transition module for external devices DVM oscilloscope From T External D A Device gt 1 Output8 gt 2 1 gt 3 J Output 7 J11 J13 T 4 E J15 J17 5 7 Output 6 6 7 Output 5 gt g gt 9 Output 4 10 11 Output 3 J12 J14 12 J16 J18 gt 13 7 14 Output 2 gt 15 f 16 g Output 1 Models FlexTest IIm GT SE Controller Hardware FlexTest GT Controller Connections 127 ADDA II Connections ADDA II Universal Each encoder requires a Model 493 59 Universal Encoder mezzanine card Encoder connections 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 To From Encoder Transition Module Return Gn
174. state information between each other 493 50 ADDA Il This optional module supports up to four 8 channel A D Model 493 55 or D A Model 493 56 mezzanine cards This module also supports the 8 channel DSPAD 8 channel Delta Sigma A D and 4 channel Universal Encoder mezzanine cards 498 96 X Processor Provides an interface between the controller and an external computer The processor module also manages the plug in modules and transition panels 498 71B GRES Ill Interfaces with a Remote Station Control RSC module and temperature controllers I O Carrier Mezzanine Cards part 1 of 2 MODEL MOobDULE 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 21B Universal Conditioner Processes the signals from either an AC or DC type sensors 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 Models FlexTest IIm GT SE Controller Hardware Installation 45 VMEbus Modules MODEL 493 46 I O Carrier Mezzanine Cards part 2 of 2 MoDuLE NAME D A FUNCTION 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
175. 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 e 4 optically isolated station interlock inputs J8 e 4 station interlock outputs with relay contacts J9 e Box In J51 and Box Out J52 to connect multiple MTS controller boxes to share station interlock status and the master synchronization clock 32 Mb FLASH disk on board e Box address switch software readable allows you to set a unique address for each controller in a multi box chain Connector J8 Interlock IN provides four station interlock inputs that can be connected to external interlock chains Inputs 1 through 4 are dedicated as a station interlock e All inputs are optically isolated Refer to the following table for input electrical specifications PARAMETER SPECIFICATION Input type Contact Open Interlock Logic 0 Interlock Input debounce time 12 16 msec Input resistance 2 7 KQ Minimum input off voltage 0 8 V Interlock Maximum input voltage 26 V Minimum input on voltage 3 V 1 mA No Interlock 172 FlexTest GT Controller Connections Models FlexTest IIm GT SE Controller Hardware J9 Interlock OUT Cable specifications Connector 25 contact type D male EMI e Backshell EMI metalized plastic e Twisted pairs with overall braided shield Braided shield is terminated to conductive backshell a
176. t 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 e Electromechanical material test system e Hydromechanical material test system e Vehicle test system e Vehicle component test system e Aero test system Prepare to perform troubleshooting while on the phone e Call from a telephone close to the system so that you can implement suggestions made over the phone e Have the original operating and application software media available e Ifyou are not familiar with all aspects of the equipment operation have an experienced user nearby to assist you In case Technical Support must call you e Verify the notification number e Record the name of the person who helped you e Write down any specific instructions MTS logs and tracks all calls to ensure that you receive assistance for your problem or request If you have questions about the status of your problem or have additional information to report please contact Technical Support again and provide your original notification number Problem Submittal Form in MTS Manuals 12 Technical Support Use the Problem Submittal Form to communicate problems with your software hardware manuals or service that are not resolved to your satisfaction through the technical support process The form includes check boxes tha
177. t 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 1 0 Carrier Module Shunt calibration The I O Carrier module has a shunt calibration connector on its front panel that connector allows up to four shunt resistors 1 per slot to be plugged in The SHUNT CAL connector is labeled to indicate which slot the shunt calibration resistor is tied to Each shunt calibration resistor is soldered to a 2 pin holder MTS PN 011 433 826 This holder plugs into the front panel connector shown below Refer to the 493 40 41 Carrier I O Shunt Calibration Kit MTS PN 100 028 185 for more detailed information on kit components and installation i O SHUNT CAL 1 V A 10 Option Slot 1 Shunt Cal Resistor Location 2 A 4 1 0 Option Slot 2 Shunt Cal Resistor Location 3 Avy lt 4 I O Option Slot 3 Shunt Cal Resistor Location 4 AA lt 0 Option Slot 4 Shunt Cal Resistor Location ed Bridge completion Each of the four I O option card slots on the I O Carrier module provides support circuits for up to three bridge completion resistors as well as a shunt calibration resistor The bridge c
178. t 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 e The ramp rate from zero to high pressure can be set to two or four seconds The ramp rate from high pressure to zero can be set to zero two or four seconds The ramp rate is constant set to the two or four second rate The amount of time to reach low pressure depends on the low pressure setting hwi file settings The following items can be specified in the hwi file For more information see the MTS 793 Utility Software manual e HSM ramp rate from zero to high pressure HSM RATE SLOW zero to high pressure in approximately 4 seconds FAST zero to high pressure in approximately 2 seconds e HSM high pressure to zero mode HSM OFF MODE STEP HSM steps from high pressure to zero default RAMP HSM ramps from high pressure to zero Important Unless there is a special need HSM OFF MODE should not be set to RAMP For your safety keep this setting at STEP e HSM low pressure setting as a percentage of full scale LOW PERCENT e HSM high pressure setting as a percentage of full scale HIGH PERCENT e HSM type can be set to PROPORTIONAL SOLENOID or ON_OFF_SOLENOID If you select ON_OFF_ SOLENOID only 2 HSM control butto
179. t allow you to indicate the urgency of your problem and your expectation of an acceptable response time We guarantee a timely response your feedback is important to us Models FlexTest IIm GT SE Controller Hardware Problem Submittal Form in MTS Manuals Access the Problem Submittal Form Inthe back of many MTS manuals postage paid form to be mailed to MTS www mts com gt Contact Us gt Problem Submittal Form button electronic form to be e mailed to MTS Models FlexTest Ilm GT SE Controller Hardware Technical Support 13 Problem Submittal Form in MTS Manuals 14 Technical Support Models FlexTest Ilm GT SE Controller Hardware Before You Begin Preface Before You Begin Safety first 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 It is very important that you remain aware of hazards that apply to your system Other MTS manuals In addition to this manual you may receive additional manuals in paper or electronic form You may also receive an MTS System Documentation CD It contains an electronic copy of the manuals that pertain to your test system such
180. t be at least 115 V AC e Auxiliary power out of J49 on the Model 493 74 HSM Transition board is not supported 6 Station Configuration HSM power limits Interlocks RSC The 6 station configuration can provide either six or eight channels of control A typical 6 channel 6 station configuration requires 12 Digital Universal Conditioners and 6 two stage valve drivers A typical 8 channel 6 station configuration requires 16 Digital Universal Conditioners and 8 two stage valve drivers HSM power current is limited to 1 5 A per HSM For 6 station configurations the hwi file must contain the line INTERLOCKS 6 This line must be a discrete entry not part of any other hwi section Cross head interlocks with solenoid power are not supported for 6 station configurations Remote Station Control RSC is not supported for 6 station configurations Models FlexTest Ilm GT SE Controller Hardware Optional Station Configurations 255 8 Station Configuration 8 Station Configuration HSM power limits Interlocks RSC AID analog inputs 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 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 Cro
181. t the chassis Jumper plug 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 From J9 T Chassis External Devices 1 lt _ Interlock Status f 6e l Output 1 2 ae _ Interlock Status Output 2 7 3 gt _ Interlock Status Le g l Output 3 4 2 _ Interlock Status 9 Output 4 Electrical Normally Open Interlock 1 A maximum 30 V DC AC maximum specifications Cable specification e Connector 9 contact type D male EMI e Backshell EMI metalized plastic e Twisted pairs with overall braided shield Braided shield is terminated to conductive backshell at the chassis Models FlexTest IIm GT SE Controller Hardware FlexTest GT Controller Connections 173 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 J51 Box In clk in gt intlk in 1 gt intlk in 2 signal return gt intlk in 3 gt intlk in 4 gt signal return gt master dependent in clk in gt oOmAnN OO FF WD So intlk return out 1 lt intlk return out 2 lt z intlk return out 3 lt
182. tal I O Connections 141 Workstation Connection 145 Remote Station Controller Connection 147 Service Connections 149 Models FlexTest IIm GT SE Controller Hardware Contents Cabling and Programming Series 407 Controllers 151 How to Provide Program to a Series 407 Controller 151 Connecting Interlock Signals to 407 Controllers 156 Sending and Receiving Signals to a Model 407 Controller 162 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 168 Cabling and Using External Readout Devices 169 How to Send Signals to External Readout Devices 171 Multi Box I O Module 172 J8 Interlock IN 172 J9 Interlock OUT 173 J51 Box In 174 J52 Box Out 175 Chapter 4 FlexTest Ilm Controller Connections 177 Workstation Connection 178 Sensor and Valve Connections 179 ADDA Module Connections 183 ADDA II Connections 184 Hydraulic Connections 189 HPU Connections 190 HSM Connections 191 Interlock Connections 192 Interlock Jumper Plugs 193 Serial Communications 195 Digital I O Connections 196 Encoder Temposonics Connections 200 Remote Station Controller RSC Connections 203 Cabling and Programming External Controllers 204 How to Program an External Controller 204 Programming Eurotherm Temperature Controllers 209 6 Contents Models FlexTest Ilm GT SE Controller Har
183. tand 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 In the Station Setup window s navigation pane double click Digital Inputs Outputs and then click Outputs 4 On the Digital Outputs window use Assignment for Digital Output 1 to assign Run Stop 5 Use Polarity to select the required polarity Normal or Inverted for Digital Output 1 238 FlexTest SE Controller Connections Models FlexTest IIm GT SE Controller Hardware 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 Add a temperature controller resource to the hardware interface file hwi 4 Add a temperature control channel to the station configuration file
184. tch the chassis power off Models FlexTest Ilm GT SE Controller Hardware FlexTest GT Controller Connections 113 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 Analog Monitor g g g cha Front chs eI 3 Ried O 493 10 Chassis me eee a d nz n ALLTEELII SSC CCC RRR R Re eee LELLELLLEI nannannntt a a a mrs Front Rear Cable Conduit im mm L 1414 FlexTest GT Controller Connections Models FlexTest Ilm GT SE Controller Hardware 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 From AD J4 J7 A D 4 1 H nput 1 2 3 Analog z Ground 4 2 5 npu 6 Analog z __ Ground at 7 nput 3 8 9 nput 4 t 10 lt n nput 5 lt M 12 13 ala a Mte 15
185. teen 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 To From Encoder Transition Module Return Gnd Index Ser Clk B Interrogate A Serial Data Input 4 Return Gnd Index Ser Clk on OO FPF WY A Serial Data 10 Index Ser Clk 11 B Interrogate 12 A Serial Data Input 2 13 Return Gnd 14 Index Ser Clk 15 B Interrogate t lt _ lt P t _ lt gt lt _ lt _ lt gt 9 Return Gnd t lt gt gt lt lt gt t lt 16 A Serial Data 188 FlexTest Ilm Controller Connections Models FlexTest IIm GT SE Controller Hardware 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 o o o o o o o o o o o o o o o D0000 O qD Hydraulic Power Unit J28C J28B J28D fi HSM HSM FlexTest Iim Hydraulic Connections Models FlexTest IIm GT SE Controller Hardware FlexTest Ilm Controller Connections 189 HPU Conne
186. tems UPS Systems for FlexTest 60 100 200 and GT Controllers 76 UPS requirements Battery power considerations Installation 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 It is important to note that the UPS will not prevent any unexpected motion if the controller or any other electrical subsystem required for control of the system has an internal failure including a HPU or a Motor Drive e The UPS must be wired to provide power to the controller and any peripheral equipment that is instrumental in safe system operation and shut down In some cases it may be feasible and appropriate to provide UPS power to the Hydraulic Power Unit HPU e The UPS must be sized to provide adequate electrical power for a period of three minutes after loss of input power The controller must be configured to take appropriate actions for safe shut down of hydraulic equipment being controlled Appropriate actions depend on the particular system e Both UPS input power and UPS output power connections must include strain relief and a twist lock plug or equivalent e UPS systems used in the European Union must be CE marked The UPS must have input power loss AC Fail alarm relay contact out and a low battery alarm
187. the command signal with Station Manager on page 212 4 Start the External Command on page 212 210 FilexTest IIm Controller Connections Models FlexTest IIm GT SE Controller Hardware 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 Ifyou cable the hardware before you create a station configuration file note the connector you use on the FlexTest Iim rear console E E 6 498 Input Filter ae This module includes 8 BNC connectors that provide filtered ons analog inputs to the 498 65 ADDA module Four analog inputs are available gee with the standard ADDA module The other four inputs require a second ADDA module thes Task2 Allocate external command resources in Station Builder Using the Station Builder application allocate controller resources to receive programming from an external controller For more information see Enabling External Command Inputs in the MTS 793 Control Software manual Models FlexTest IIm GT SE Controller Hardware FlexTest Ilm Controller Connections 211 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
188. 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 700 000 656 224 FlexTest SE Controller Connections Models FlexTest IIm GT SE Controller Hardware 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 hwi file and the physical locations for each type of module and associated mezzanine cards must match Also the I O Carrier module address setting on the module must match the hwi file address Adding O Carrier For automated controllers a second I O Carrier module can be added to support a second channel or to expand sensor conditioning Its addition can also be used to support more A D and D A channels Note Ifyou are upgrading your system a faster processor may be required Contact MTS for information on system upgrade requirements To add a second I O Carrier module 1 Install the required mezzanin
189. 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 After updating the hardware interface file you must add a temperature control control channel to the channel to the Controller s station configuration file station configuration file To do this use the Station Builder application to open the station configuration file and then add temperature controller input Temp Control 1 Input and output Temp Control 2 Output resources to a Program w Feedback type channel This creates a temperature control channel For detailed instructions see How to Program a Eurotherm Temperature Controller in the MTS 793 Control Software manual for more information 242 FlexTest SE Controller Connections Models FlexTest IIm GT SE Controller Hardware Appendix A Hydraulic Configurations Models 493 Chassis to 493 07 Converter Box Model 493 07 Converter Box to HPU Hydraulic pump 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 _Forjumpering information see A
190. tion remove the shorting bar from the ground lugs and connect the chassis ground to the console rail e Fora stand alone configuration always connect the shorting wire to both ground lugs Stand alone Console 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 load 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 Models FlexTest Ilm GT SE Controller Hardware Installation 39 Connecting Electrical Power Power AC power disconnect 40 Installation Proper grounding is required for safe operation It is also required to meet EMC emission and susceptibility requirements 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 1000 W The current draw depends on the local voltage supply A 15 amp line should be adequate for the chassis and the computer The power supply automatically selects the proper voltage range and line frequency The power supply is protected with an external circuit breaker in the On Off switch that
191. to a sensor and a servovalve channel Valve Driver DC Conditioner AC Conditioner Signals Signals Signals ale oo olo en ato aln abn p 0000008000 pol zoooootdood hon pale DD OU Force load sensor LVDT displacement sensor Model 497 01 Analog Chassis Rear Panel 182 FlexTest Ilm Controller Connections Models FlexTest IIm GT SE Controller Hardware 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 DC AC Drive Conditioner Conditioner Signals Signals Signals J28 J27 J24 J23 J22 J21 0 OD DiD DOURDODDOD 00000 DOK 048 202 102 J1 axm 050 053 401 Models FlexTest IIm GT SE Controller Hardware 497 01 f Analog D Chassis l The analog inputs and outputs use the top com four connectors 050 053 401 047 808 502 J11 047 808 502 FlexTest IIm Controller Connections 183 ADDA II Connections ADDA II Connections ADDA I
192. to dangerous voltages Disconnect all cables from the Model 493 07 Converter Box before removing As shipped the HPU interface on the Model 493 07 Converter Box is compatible with Model 458 10 20 490 01 493 xx and 497 05 components The Model 493 07 Converter Box may be connected to other controllers as shown in the following table using a Y cable Models FlexTest IIlm GT SE Controller Hardware Model 493 07 Converter Box 251 Note If the Model 493 10 Chassis is the only device connected to the HPU the jumper settings do not matter COMPATIBLE WITH JUMPERS Model 458 05 10 20 40 Standard jumper setting Model 490 01 Model 497 05 E10 E11install E12 E13 install E14 E15 install E16 E17 install E10 E13 remove E14 E17 remove Model 413 05 Jumper change required Model 436 11 Model 407 05 E10 E11 remove E12 E13 remove E14 E15 remove E16 E17 remove E10 E13 install E14 E17 install Note The Model 493 07 Converter Box cannot be used with both groups of controllers at the same time If this functionality is needed use an HPU isolation box 252 Model 493 07 Converter Box Models FlexTest IIm GT SE Controller Hardware 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 Clea
193. to your hwi file an RSC section and a GRES III section Note Remote Station Controllers are not available with the optional 6 or 8 station system configurations Note Ifyou 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 hwi file to accommodate RSCs see the MTS 793 Utility Software manual 148 FlexTest GT Controller Connections Models FlexTest IIm GT SE Controller Hardware Service Connections Service Connections The Model 493 10 Chassis can have several service connectors There are two types of connectors e The chassis connection monitors the power supply e The connection on the I O Carrier module monitors the output of each mezzanine card Chassis service The J39 Power Monitor connector is located on the rear panel of the chassis It functions as test points for a service technician It allows you to check all of the power supply voltages along with the status of the overtemperature sensor and the power fail circuit 5 Volts 2 12 Volts 3 12 Volts 4 15 Volts 5 15 Volts 6 24 Volts 7 Ground 8 2 5 Volts Reference 9 Ground 11 Temperature 14 Models FlexTest IIm GT SE Controller Hardware FlexTest GT Controller Connections 149 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
194. trips at a 10 amp overload An internal fuse in the power supply is not user accessible or repairable An outlet strip is supplied with the floor standing chassis The computer components may be plugged directly into the outlet strip of a vertical console or a floor standing console Turn off the AC power switch Remove the AC power cord from the unit This will remove all AC power from the Model 493 10 Chassis Models FlexTest IIm GT SE Controller Hardware Connecting Electrical Power Note Be sure to locate the chassis so you have adequate access to disconnect the power cord from the chassis Outlet Strip 2 D 5 or 4 5 fo oO 2 D z a aH Line Voltage Outlet Strip Outlet Strip printer etc w circuit breaker Outlet Strip Power Panel Po SL E Voltage Models FlexTest IIm GT SE Controller Hardware Installation 41 Installing the Plug in Modules Installing the Plug in Modules 42 Installation 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
195. trollers have two processors installed in the Model 498 22 Chassis e The first processor in slot 1 communicates with the external computer e The second processor in slot 3 performs the digital control functions A third processor will be installed in slot 3 or 5 to handle time history data acquisition if you purchased the time history data acquisition option 498 71B Global Resources IIl GRES IlI Provides the digital input and output interface to devices like external temperature controllers and remote station controllers It provides four serial ports and monitors interlocks from the 497 modules 498 65 ADDA Provides analog to digital A D processing and digital to analog D A processing Each function is performed by a mezzanine card The standard ADDA module contains two A D mezzanine cards and one D A mezzanine card A fourth mezzanine card can be added as an option See the ADDA product manual 493 50 ADDA II This optional module supports up to four 8 channel A D Model 493 55 or D A Model 493 56 mezzanine cards This module also supports the 8 channel DSPAD and Universal Encoder mezzanine cards 498 70 Digital I O 72 Installation Provides the means to monitor external logic levels and contact status and to provide logic level outputs for external device control Models FlexTest IIm GT SE Controller Hardware Test Processor Plug in Modules ADDA II mezzanine cards MopuLE NAME
196. u 31 31 13 13 h 3 Channel 13 O Channe npu 33 _ 7 32 utpu Channel 14 Inpu 14 j hs Channel 14 Outpu 33 33 Channel 15 Inpu 15 ol 15 Channel 15 Outpu 34 34 Channel 16 Inpu 16 16 Channel 16 Outpu 35 3 35 18 O 12 V DC 12 V DC o 18 19 19 36 36 37 37 v v Models FlexTest Ilm GT SE Controller Hardware FlexTest GT Controller Connections 141 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 e All of the inputs are optically isolated and support relay contacts or logic inputs see the following figure e Channel inputs can be 3 volts minimum and 26 volts maximum from an external voltage source e Jumpers select the debounce time for each group of four inputs Jumper X2 configures inputs 1 4 Jumper X3 configures inputs 5 8 Jumper X4 configures inputs 9 12 Jumper X5 configures inputs 13 16 Not using a jumper sets the debounce to 20 msec Jumper pins 1 and 4 to set the debounce to 10 msec Jumper pins 2 and 3 to set the debounce to msec Jumper pins 1 and 4 and 2 and 3 to set the debounce to 0 1 msec Digital I O 493 72 Digital I O Access Panel J3 Transition Module External Device e 18 S 9 0 412 M Opto i oc CH1 Coupl
197. ve a sensor file assigned to one or more of its signals by default the system software looks for calibration information in the transducer ID The molded ID module has a removable cover and includes provisions for e A shunt calibration resistor e Up to three bridge completion resistors e A transducer ID circuit card The circuit card has the bridge completion and shunt calibration resistors on one side and the transducer ID circuit on the other e R6 R7 and R8 are the bridge completion resistors R9 is the shunt calibration resistor LY 0 o maD bs E ee 1 e R6 Fe 0 ee 2 0 R7 e F 3 R8 e lathes 5 mxa e 1406 FlexTest GT Controller Connections Models FlexTest Ilm GT SE Controller Hardware Transducer Identification Modules The following is the schematic diagram of the bridge balance and bridge completion circuit Pre amp Note For information about assigning sensors and saving data with Transducer ID Modules see the MTS 793 Control Software manual Models FlexTest IIm GT SE Controller Hardware FlexTest GT Controller Connections 107 Valve Connections Valve Connections The following types of valve connections are supported e Single or dual Series 252 Servovalve s can be controlled with a Model 493 14 Valve Driver mezzanine card e A Series 256 Servovalve can be controlled with a Mod
198. ve 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 From J4 J7 To ESE I O Carrier Servovalve Controller 1 Test 2 Command Valve _ _ Command 3 Driver m 4 5 6 Actuator LVDT 7 Feedback de i a 9 Valve Command 10 n Valve Command 12 Valve 2 Command p 13 Valve 2 Command 14 15 Models FlexTest IIm GT SE Controller Hardware FlexTest GT Controller Connections 109 Valve Connections Series 256 Servovalve The Series 256 Servovalve is a 3 stage servovalve The Model 493 15 Valve connections 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 To From J4 J7 To From C 1 0 Carrier Servovalve Controller r yoe UDT iee 1o A j Feedback Inner Loop 1 1 Excitation 2 Excitation Festa 3 Test Valve S___ Command f Command Driver LI lt 1 4 Feedback gt y 5 Feedback 6 Signal Ground y 7 Actuator LVDT Outer Loop Feedback FA 9 Valve Command 10 o 11 Valve Command 12 13 14 141410 FlexTest GT Controller Connections Models FlexTest
199. voltage Pollution degree 2 Weight approximately 8 6 kg 19 Ib The specification shown conforms to CE Low Voltage Directive requirements The specification allows for 10 of the values stated The actual voltage the 493 02 chassis can operate is 90 264 V AC Models FlexTest IIm GT SE Controller Hardware Introduction 27 Specifications FlexTest Ilm Controllers The MTS FlexTest IIm Controller is a fully digital Proportional Integral Derivative Feedforward PIDF servocontroller FlexTest Ilm The FlexTest IIm configuration provides complete control of up to sixteen Controllers channels distributed among up to four stations in an MTS test system The FlexTest Im Controller is available in five standard configurations The FlexTest IIm Controller also supports optional components and custom configurations that can add features and capability to any standard configuration All configurations include the following components e Model 497 01 Analog Chassis The analog chassis includes a complement of valve drivers and conditioners Model 497 14 AC Conditioner module Model 497 22 Dual DC Conditioner module Model 497 26 Dual Valve Driver module Model 497 34 Multi Station Interlock module Model 497 36 Communications module e Model 497 05 Hydraulic Control Panel The hydraulic control panel controls at least one Hydraulic Power Unit HPU or actuator manifold e Model 498 22 Test Processor Chassis 28 Introduction Mo
200. ware L shaped brackets to support the chassis and mounting screws to secure the chassis to the console rack Rack Mount Option The Controller chassis is designed to fit into a standard electronics rack 52 Installation Models FlexTest IIm GT SE Controller Hardware 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 Local electrical codes supersede any information found here Grounding 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 NA TORO Signal Chassis Ground Ground e For the console configuration remove the shorting bar from the ground lugs and connect the chassis ground to the console rail e Fora stand alone configuration always connect the shorting bar to both ground lugs Grounding the chassis 3 p i ice p p DE E gt a a 10
201. ween 50 60 Hz 220 240 V AC at 6 A between 50 60 Hz LED Classification Class 1 Environmental Temperature Relative humidity Maximum altitude Insulation over voltage Pollution degree Models FlexTest IIm GT SE Controller Hardware For indoor use only 5 C 40 C 41 F 104 F ambient 0 85 relative noncondensing 2000 m 6562 ft Category Il Introduction 35 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 FTIIlm 61 Installing the Model 493 10 Chassis FTGT The chassis can be installed in an equipment rack console or in a standalone configuration The Model 493 10 Chassis weighs about 45 kg 100 Ib in stand alone configuration Improper lifting techniques can cause strained muscles and back injuries When lifting this chassis take the appropriate precautions to prevent injuries to yourself Models FlexTest IIm GT SE Controller Hardware Installation 37 Connecting Electrical Power Stand alone The stand alone chassis can be placed on the floor The chassis location is limited installation only by the length of the system cables The front panel of the chassis can be removed to access the VMEbus p
202. ws how to cable hydraulic terminals on multiple station hydraulic terminals on Model 407 Controllers where each Model 407 Controller can run an independent multiple station 407 test program Repeat this scheme for each additional Model 407 Controller Controllers 407 Controller No Connection Jumper Plug PN 049 635 901 No Connection Jumper Plug PN 049 635 901 No Connection Jumper Plug PN 049 635 901 No Connection Jumper Plug PN 049 635 901 Models FlexTest IIm GT SE Controller Hardware FlexTest GT Controller Connections 159 Connecting Interlock Signals to 407 Controllers Interlock connections The following figure shows how to cable interlocks when a master Model 407 for master dependent Controller is daisy chained with three other dependent Model 407 Controllers to 407 Controllers 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 os Digital cPe 4P I O Connector HSM LO z n Hydraulic 24V 1r 1 t 3 M prcitaL Interlock S J 4 IN 1 Active Low To zZ 7 407 Controller 2 2 1 orcitaL Run Stop Master L J 6 OUT 1 f Active High YW i P43 9P To m 10 FT 493 74 4r HSM PESE i Jumper on Transit
203. xternal readout device analog input 498 Analog Out Oo This module includes 8 BNC pail connectors that provide analog oH outputs from the 498 65 ADDA module C Four analog outputs are available with the standard ADDA module The other four outputs require a second ADDA module 6 6 o E3 Ne lt o 214 FlexTest IIm Controller Connections Models FlexTest Ilm GT SE Controller Hardware How to Send Signals to External Readout Devices Task2 Create a readout channel with Station Builder For more information see How to Create a Readout in the MTS 793 Control Software manual Task3 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 Models FlexTest IIm GT SE Controller Hardware FlexTest Ilm Controller Connections 215 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 120 048 341 1XX Remote E stop X head

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