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1. ERROR No TYPE DESCRIPTION 94 idp selector not implemented 95 idp internal error unpacking parameters 96 idp parameter out of range 97 idp timeout addressing register 98 idp slot is not occupied by a conditioner 99 idp unexpected response 100 idp defined slot does not match hardware 101 idp invalid slot def UND 0 AC 1 DC 2 EXT 3 102 idp invalid range 103 idp conditioner type is not defined 104 idp error scaling sgc or mux 105 idp error sending AD polarity to mux 106 idp time out waiting for mux or sgc resp 107 idp internal error packing parameters 108 idp invalid selector for extended AlO chan 109 idp error locking mux for range change 110 ilk internal error unpacking parameters 111 ilk selector not implemented 112 ilk received selector for wrong class 113 luc internal error unpacking parameters 114 luc sel not implemented 115 luc received selector for wrong class 116 luc parameter out of range time 117 luc parameter out of range key 118 luc parameter out of range 119 luc parameter out of range module id 120 mux received selector for wrong class 121 mux selector not implemented 122 mux internal error unpacking parameters 123 mux parameter out of range 124 mux couldn t find class from object id 125 mux specified event is not defined oe TestStar Reference Manual 299 gt lt TO eD er lt Firmware Error Codes
2. a font for the text in the pame Size TestStar windows Style Display This window also appears Normal Printer when you want to change the font in the Print Preview window Sample Emphasis O Outline O Underline abcdABCD eaxmples of font characters B Strikeout CONTROL FUNCTION Name Selects the font for text in the TestStar windows Size Selects the point size of the font Style Applies normal italic bold or bold italic to the selected font Use a style that is easy to view such as normal or bold Sample Displays the selected font size and style so you can see what it looks like before you assign it Emphasis OS 2 only Applies outline underline and or st keext to the selected font DO NOT use these selections The TestStar text would become unreadable 5 S oO oO lt lt 76 TestStar Reference Manual Use the this window to view a summary of the current TestStar configuration in an outline format Display menu TestStar Reference Manual Print Preview Window Print Preview Window All of the TestStar configuration information available to this window is established with the Edit menu Enables what information can be displayed in this window x TestStar configuration Prints the current File Display Help Print on u Displa
3. Control mode name x End level 0 units x Time 1 units z cancel CONTROL FUNCTION Control Mode Selects the control mode for the Home button End level Specifies the end level the control mode achieves when the Home button is pressed Select the units you want to use for the end level Time Specifies the amount of time the ramp executes The time value is seconds 222 TestStar Reference Manual How it works Pressing the Home button causes the home ramp to begin immediately TestStar Reference Manual Home Menu Option Window The Home Menu Option window defines a mode that is assigned to the Home button Pressing the Home button causes the servo command to ramp from the current servo control setting to the defined end level The Home function can be defined as a ramp in a test or to return the actuator to its starting position at the end of a test The home ramp does not have a ramp rate The ramp executes from any starting position to the defined end level in the amount of time specified time 0 reference home ramp mean level yore re percrcperrr porn pee homing Home pushbutton pressed A common use of the Home function is to return the actuator to its starting position typically the zero reference at the end of a test This is sometimes called return to zero One way to accomplish this is as follows 1 Select
4. CONTROL FUNCTION Define Defines the servo loop command sets up the counter and establishes the home function Stop Ends the test and causes the program command to return to the mean level Hold Suspends the program command until you press the Run or Stop button Run Starts the program command described in the Definition area Home Executes a ramp you define from the ending output to a predefined output You can define the Home button to return the actuator to its starting position Select Home in the Define menu to define the ramp Mean Adjusts the mean level of the command Pressing the Mean button displays a Set Scroll Range window where you can change the maximum and minimum values of the Mean adjustment Amplitude Adjusts the peak to peak amplitude of the command Pressing the Amplitude button displays a Set Scroll Range window where you can change the maximum value of the Amplitude adjustment Frequency Adjusts the frequency of the command Pressing the Frequency button displays a Set Scroll Range window where you can change the maximum value of the Frequency adjustment Enable Compensator Enables the compensator function selected in the Command Menu Options window units Displays the units of the selected control mode Definition Shows the current command definition as established with the Command selection in the Define menu Status Shows the status of the test and counter Using the wind
5. Opens a previously defined set Creates a new load path stiffness set Saves the current stiffness settings you are editing Displays the Save As Save as window where you name F the load path stiffness set ampression platen 000HZ N Print Preview tastomer Print to File Print Setup Global Default Exit 7 Angle Strain Deletes a previously defined stiffness set Assigns a default load path stiffness set when this editor is started xl Closes the Load Path Define Stiffness Stiffness Editor The load path stiffness parameters compensate for the amount of deflection that is produced from the actuator through the grips extension rods load cell and load frame everything in the load path except the specimen All of these components act together as the load path The load path stiffness editor defines a set of stiffness values for the displacement sensors and saves it in a data base A stiffness set consists of stiffness values for an LVDT accelerometer and in some cases an ATD Any unique combination of the components of the load path should have a stiffness set defined for them For example assume you have a system that uses compression platens with extension rods to accommodate a temperature chamber for one type of test For another t
6. Signal Label Sensor Range Note The sensor you assign should be connected to the rear panel connector J1 J14 that corresponds with the module slot location of the ac or dc conditioner Rear Panel DC Conditioner Connector Sensor Module lt Sensor Location 3 Feedback E The sensors available match the Dimension selection If you do not see the sensor you are looking for check the Dimension selection in the Edit Input Signals window See the Assign Sensor window description for more information Assign Sensor list of calibrated sensors p Cancel Calibration Info TestStar Reference Manual Input Signals External Signal Types The external signal type applies to both external feedback and external command sources These inputs may be used differently but the signal interface is the same ies ou j 0 mk An external feedback signal can be input from a conditioner that is not located in the TestStar chassis An external command source can be from a function generator or other program source that is not part of TestStar An optional Extended Analog I O hardware package offers sixteen additional external inputs If you have this option you will have additional Signal Selections labeled Extended 1 16 See Chapter 2 in the Installation manual for detailed information about the Extended Analog I
7. __ enabled The meters can be arranged vertically Scope eee horizontally or in a box Quits TestStar Shows the scope hy TestStar a Opens TestStar File Edit Adjust Display Help windows The toolbar __ BS Feo Aa D gt Al a0 Aa Ay a can be configured to show the window buttons you want Control Channel 1 HPS Pressure Off Shows the status of a control channel Program State Stop Hydraulics Off Current Mode Undefined Defines input signals from APC State Off Next APC Mode Undefined x sensors calculations and external signals Sets the upper and lower X limits for each input signal K gt along with zero and range Defines the signals assigned to the 6 rear panel output connectors Edit g Signals Defines the control channels Output Signals Ni Defines the control modes Control Modes for each control channel Defines constant values that can be referenced in calculated inputs Control Channels adjustments Adjust Tunes each control mode Input Sigs j Tunin Specifies the type of Ti g gt compensation applied Compensators to the command Calculation Con Detector Actions Load Path Stiffness Error Detectors Underpeak Detectors Sets up the error detectors for each
8. 1 These signals are available only for dual 252 drives 2 These signals are available from a Model 490 17 Valve Driver These signals are associated with the 490 21 22 DC AC Conditioner modules They are available only when a sensor signal is selected for the analog bus SIGNAL DESCRIPTION Transducer The conditioned sensor feedback signal before it is converted into digital form Transducer Zero The amount of offset introduced by the sensor zero adjustment Pre Amplifier The sensor signal output from the preamplifier stage of the conditioner Positive Excitation The excitation signal output to the sensor is a Negative Excitation differential signal The actual excitation voltage is the difference between the positive and negative components of the signal Filter The output of the 3 pole filter Summing Amplifier The sensor feedback signal with Ak zero and the filter but before gain is applied Raw AC Feedback The 10 kHz feedback signal before it is demodulated Only available from the Model 490 22 AC Conditioner TestStar Reference Manual Readout Use this window to select a signal and scale it for output Output Signals x j tp ies ou j 0 5 Signal Selection lA iz Signal Definition Signal Name Signal Type Readout Signal input signal valve signal Gain 1 00000 units Offset 0
9. A Selects the font size and attributes of the text in the TestStar windows and displays l Displays the TestStar configuration All the settings of the TestStar windows are recorded Select Font Print Preview Exit Quits TestStar If you changed any TestStar window settings you are given a chance to save the configuration file TestStar Reference Manual 71 5 S oO oO lt lt Open Window y Prerequisite Use this window to open a Open Window You must have a saved TestStar configuration file before you can use this window Open filename Directories TestStar configuration file AANE Cancel The default path for this x ie a are 7 window is C TS2 config conta Some systems have the default TS2 directory SF Si located on the D drive List Files of Type Drive TestStar tcc x c DISK1_VOL1 x Network CONTROL FUNCTION Open filename Displays TCC in the entry field Type the name you want to call the configuration file here files Lists the configuration files in the current directory Selecting a file name displays it in the File Name entry field List Files of Type Selects the type of files displayed in the File list By default lt All Files gt is selected Select file type TCC to display
10. Defining a scope Channel selection TestStar Reference Manual The Sweep Type Refresh Time and Trace Time controls work together to configure the scope for any kind of signal Note The shorter the trace time and the longer the refresh time the better the resolution of the waveform more data points defining a waveform For example assume you want to watch a 90 minute ramp Set up the scope with a single sweep type and a 90 minute trace time This lets you see the entire waveform Set the refresh time of 5 minutes Another example assume you want to monitor a 2 Hz cyclic waveform Set up the scope with a continuous sweep type and a 0 5 second trace time This lets you see a single cycle Set the refresh time to 10 seconds You must define at least one Y Channel and the X Channel to obtain a display The X channel is usually defined as time You can define X as an input channel to obtain a Lissajous waveform When you want to use both Y axes the X axis must be set for time 143 Edit Menu Scope 144 TestStar Reference Manual Chapter 4 Adjust Menu TestS tar IT rol Syst Adjust Input Signals Signal Selection Some of the controls in the lower half 2 J ad j Sona name of this window are not available for Limits some types of input signals Upper Limit 0 000000
11. TO eD er x 312 TestStar Reference Manual Debug Options Select Output Log File Window E Open Log Fie O O O O OOOO OO Open filename Directories Use this window to create c ts2 contig a TestStar log file or overwrite an existing log 4 Sic z file ar lt config List Files of Type Drive TestStar tcc x c DISK1_VOL1 x Network Note The default path for this window is the TestStar directory path C ITS2 your path may be different CONTROL FUNCTION Open filename Displays LOG in the entry field Type the name you want to call the configuration file here files Lists the log files in the current directory Selecting a file name displays it in the File Name entry field List Files of Type Selects the type of files displayed in the File list By default lt All Files gt is selected Select file type LOG to display only the files with the LOG extension in the Files list Directories Lists the available directories for the selected drive Double clicking a different directory displays the files of the directory in the Files list and any other directories in the Directories list Drive Displays the current drive All root directories of the drive are listed in the Directories list Network Pressing the Network button displays the Connect Network Drive window where you can define new network drives an
12. TestStar Reference Manual 287 Tuning Tuning Procedure Tuning Procedure Step 1 288 Tuning is affected by the type of mechanical components in your test system the response of your test system and the type of specimen being tested The following procedure provides general guidelines that will assist you in the tuning process Note Remember adjust one control at a time and note the results before adjusting another control Prer equisite You must be familiar with the information in the About Tuning section We also assume that you already have a good knowledge of the TestStar software and how to load a specimen Procedure e SM f Getting things ready 288 Adjust gain rate and or feed forward 289 Adjust reset 290 Tune each control mode and save your work 290 Getting things ready This step describes what must be done before you can adjust the tuning controls A B Set up an oscilloscope to monitor the sensor feedback If necessary install a dummy test specimen Select or set up a tuning test command Be sure your test uses the control mode you want to tune Open the Tuning window and note the settings for the tuning controls you may need to re establish these settings if your tuning efforts go un rewarded Start the test command TestStar Reference Manual Tuning Procedure Step 2 Adjust gain rate and or feed forward Your goal is to establish the best possible waveform tha
13. Digital Controller Error Codes gt lt TO eD er x 308 TestStar Reference Manual Appendix C Servo Loop Update Rate Servo Loop Update Rate Use this window to check or change the servo loop update rate Accessing the window 2 TestStar Reference Manual The servo loop update rate shows how quickly the servo control loop can be updated This represents the speed of the digital controller and limits the maximum frequency you can select for a test command When this window opens the maximum update rate is displayed factoring in the number of control channels calculated inputs and other things that can slow it down I lt Update Rate Maximum Rate 5000 00 Hz Update Rate 5000 00 Hz Maximum Rate You can enter a value less than the maximum rate in the Update Rate entry field Press the Maximum Rate pushbutton to return the update rate to the maximum value possible Access to the Performance Rate window is accomplished with the TestStar toolbar or the hotkey combination Press cntl u Go to the Edit Toolbar window if you want to access this window with a toolbar button 309 gt az ge ou j 0 gt lt Servo Loop Update Rate Things that slow TestStar has a number of features that can slow down the servo loop update rate The number of features you use determines what the TestStar down maximum servo loop
14. Sweep Type Trace Time Refresh Time X Channel Y1 Channel Y2 Channel enabled disabled I lt I lt single continuous Sec Sec I lt Input signal valve signal time I lt Input signal valve signal I lt Input signal valve signal TestStar Reference Manual CONTROL Scope Selection Enable Display Scope FUNCTION Selects one of the two scopes to be configured Enables or disables the scope The scope must be enabled to display it Disable the scope when it is not needed or if you wish to configure It and use it later ies ou j 0 5 Sweep Type Trace Time Selects a single sweep of the screen or continuous sweeps A single sweep draws a signal on the screen once A continuous sweep draws over the old signal trace with new data Specifies the amount of time for a trace to cross the scope One hour is the maximum trace time Refresh Time Specifies how often the data being drawn on the screen is updated Shorter refresh times require more processing time this reduces the computer processing time X Channel Y1 Channel Y2 Channel Selects an input signal or time for the Y1 Y2 or X channel The X channel is usually set for time The X channel axis is the bottom of the screen The Y1 channel axis is the left side of the screen The Y2 channel axis is the right side of the screen
15. on the load unit control panel with no specimen installed Note For dual 252 servovalves select separate balance controls if each valve is used for different tests select combined balance controls if both valves are used for the same test Auto zero force Set up for a Force Pod control mode be sure it is tuned Monitor the force sensor output on the display Turn On the Actuator Positioning Control but DO NOT adjust it If the actuator holds its position valve balance is not needed If the actuator moves adjust the valve balance Note Performa mechanical adjustment if the electrical valve balance cannot be achieved Go to the appropriate servovalve product manual for the mechanical valve balance procedure When a mechanical valve balance is complete perform this procedure again Adjust the Valve Balance control in the Adjust Drive window to stop the actuator movement Make the adjustment before the actuator reaches its maximum displacement otherwise you will need to reposition the actuator and continue the adjustment 276 TestStar Reference Manual About Tuning About Specimens Tuning without dummy specimens Tuning force without a specimen TestStar Reference Manual Specimens can be very expensive A dummy specimen is an inexpensive material that has similar characteristics to the specimen selected for testing The most important characteristic is the specimen s spring rate A dummy spe
16. Assign Cancel Using the window select a unit set from the list of defined unit set names The selected set of units is shown in the entry field at the top of the window Press the Assign button to assign the unit set as the default units for users who have not selected a default set of unit j 0 ee gt Nn N bic ae oO ee WN Oo ee er ou j 0 ee You can assign a different set of default units with the Assign TestStar Configuration window accessed through the TestStar File menu In this manner a set of default units are assigned only to the user who logged onto TestStar TestStar Reference Manual 253 5 an e5 N e5 ove _ N N lt t a Defining a Unit Assignment Set Defining a Unit Assignment Set Procedure Step 1 The Unit Assignment Set Editor is ready to define a new set of units 254 This procedure shows you how to create a set of units or open a predefined unit set 1 Open the Unit Assignment Set Editor program 254 Assign a unit to a dimension 255 Repeat step 2 for each dimension you expect to use 255 Save the unit assignment set 256 Assign a unit set as the default set 256 a ot oe a iy Close the Unit Assignment Set Editor 256 Open the Unit Assignment Set Editor program A Double click the MTS TSII icon on the desktop OS 2 only Then double click the Utility
17. Control channel Selects the control channel for the test command For a single channel system one choice is available typically called axial Control mode Selects the control mode for the test command Units Shows the current units of the control mode Select the units you want to use for the Initial Ramp Rate the Mean adjustment and the Amplitude adjustment Initial ramp rate Specifies the ramp rate from the starting level of the actuator to the mean level setting when the test begins The starting position of the actuator is usually the zero reference of the program command The ramp rate value represents units per second Ampl ramp time Specifies the amount of time the program amplitude ramps from zero to full scale and vice versa This is only available when using an external command source Waveshape Specifies the type of waveform Three waveforms are available Sine Square Triangle Select the waveshape you want to use Compensator Specifies if a compensation circuit is used e Peak Valley provides amplitude mean control e PAC provides phase and amplitude control Waveshape order Determines if the waveshape starts positive or negative Normal Order Inverted Order EF 5 ie e j 0 5 ap Oo 5 a TestStar Reference Manual 215 Command Menu Options Window How it works After you define a function generator program and press the Run button the following occurs
18. MTS Test Control Sys 150194 08C Proprietary data This manual and the software it describes are both copyrighted with all rights reserved Under the copyright laws neither this manual nor the software may be copied in whole or part without written consent of MTS Systems Corporation except in the normal use of the software or to make a backup copy of the software The same proprietary and copyright notices must be affixed to any permitted copies as are made for others whether or not sold but all of the material purchased with all backup copies may be sold given or loaned to another person Under the law copying includes translating into another language or format This software may be used on any computer but extra copies cannot be made for that purpose Copyright information 1997 MTS Systems Corporation All rights reserved Trademark information MTS is a registered trademark of MTS Systems Corporation TestStar and TestWare SX are trademarks of MTS Systems Corporation IBM and OS 2 are registered trademarks of International Business Machines Microsoft and Windows NT are registered trademarks of Microsoft Corporation Publication information The following is the history of this manual eCa ET SOFTWARE RELEASE MANUAL NUMBER PUBLICATION DATE Release 1 1A 50194 01A April 1991 Release 1 2A 50194 02A September 1991 Release 1 3A 50194 02B February 1992 Release 1 4A 50194 03
19. Meters 30 Max Min Data m tI e mk Displays the highest and lowest values of an input signal recorded during a test or since the Data Display was reset gt Select an input signal that you want monitor max and aye 5 min levels a ies Meter Selection Select the units for the a amp a data Meter Definition Type x Display x Running Max Min Definition Signal input signals valve signal z The max value is the most positive Ceast negative level The min value is the most negative least positive level Maximum 1st Max This waveform shows the no Max initial maximum and minimum detections along with the maximum and minimum points 1st Min 2nd Min Minimum TestStar Reference Manual 141 Edit Menu Scope Scope Use this window to define a digital scope to display a waveform The scope can display a graphic representation of up to two input signals 142 A scope is a graphical display on the computer screen that shows test related signals in a fashion similar to an oscilloscope Note The scope requires processing time when it is enabled this affects the communications with the digital controller and slows the data exchange rate between the digital controller and the computer z Scope Selection GI tJ scope 1 or scope 2 ks Define Scope Enable Display
20. Setting up external sensors Installation Manual 10 Setting limits to input signals Upper and lower limits on page 151 Sensor cartridge shunt cal resisters Installation Manual 2 Sensor cartridge bridge completion resistors nstallation Manual 2 87 ies ou j 0 mk 5 Edit Menu Input Signals Edit Input Signals Window Input signals need to be defined when sensors are added to your system or existing sensors are changed Use this window to define in ignals i f putSignais Signal Selection lot 1 14 Calculated 1 Controls are added to the 4 E Slot Calculated 128 bottom of the window Signal Definition according to the Signal Signal Name Type selection Signal Type none conditioner external calculation Dimension length force strain etc Display Units mm cm in ft m micron etc Signal Label dimension number CONTROL FUNCTION Signal Selection Assigns the sensor to one of the 14 slot locations which correspond with the plug in modules or creates one of the 8 possible calculated inputs Up to 22 input signals can be defined Signal Name Names the input signal The name you enter is used throughout the TestStar windows to identify this input signal Enter any name you wish The default name is the same as the Signal Selection name Signal Type Specifies the type of signal to define Controls needed to defin
21. 0 Amplitude l 2500 N cycle at 1 Hz cycle triangle continuously 2500 N TestStar Reference Manual Designing a Test Program Step 2 Open the Function Generator program A Double click the MTS TSII icon on the OS 2 desktop B Double click the Function Generator icon C You may need to login to open the Function Generator program Enter your user name and password in the MTS Login window K m MTS TSII Icon View al X MTS TSII Sle TestStar Utility TWSX Function Config Generator Function Generator Define Help sep hea r Controls _____ Definition Channel name Mean 0 units Control Mode name lt gt WaveShape sine square triangle Amplitude 0 units Preset Count 0 lt gt n Status 0 05 H ps 5 Current Count 0 gt Total Count 0 O Amplitude Mean Control Status Stopped TestStar Reference Manual 225 Le fom 5 ie gt e 5 ap 5 a aa Designing a Test Program Step 3 Define the command waveform A Select Command in the Define menu B Complete the Command Menu Options window as shown below This window defines the Command Menu Options triangle waveform and the control mode Control channel Axial y The name of your force Control
22. Avoiding hazardous actuator movement 17 TestStar Reference Manual Base control mode 115 Before you call 27 C Calculated Input signals defining 93 examples 95 functions 94 Calculation constants 122 CASC block diagram 168 Cascade control mode 167 Caution symbol 25 Channel limited channel 164 changing adjustment range 165 example 166 how it works 165 tuning 166 Clearing a detector action 54 Clearing an interlock 56 Command amplitudeCommand initial ramp rate 215 compensation circuits 215 defining 216 226 external 218 initial ramp rate 215 waveforms 215 window 214 Command source 119 Compensators 170 171 Compensators 219 Configuration file 50 default 51 folder 315 format 78 opening 73 saving 75 323 Index username 51 Configuration files 236 Contacting MTS 26 Continuous cycle 226 Control channels 110 252 valve adjustments 181 256 257 valve adjustments 184 adjusting dither 182 adjusting valve balance 182 connections 110 defining 112 definition 114 drive types 115 drive window 181 184 drives 111 modules 66 underpeak detector 177 valve adjustments 180 window 112 LUC 66 Control modes 116 auto tuning 115 auto tuning 160 base 283 cascade 116 Cascade CASC 121 channel limited channel 116 CLC 120 command source 119 max number 159 PIDF 116 118 tune CASC 167 tune CLC 164 tune PIDF 161 types 116 160 Convergence rate 172 Creating user names 240 Crush point hazar
23. Boldface text TestStar Reference Manual The following techniques are used to highlight special types of information Warnings alert you that something hazardous can occur if you do not follow the instructions carefully Physical injury to you or to the machine or both will likely be severe The plain unbolded text below the initial bolded sentence gives you additional instructions about how to avoid the hazard Cautions alert you that something hazardous can occur if you do not follow the instructions carefully However the personal injury or equipment damage will likely be moderate Cautions are also used for procedures that can cause loss or corruption of computer programs or data Notes are used to point out especially important information that you should know before performing an operation but failure to do so is not likely to result in a hazard Boldface terms such as Emergency Stop are direct references to physical controls and indicator labels on the test system 25 Preface How to Obtain Technical Assistance How to Obtain Technical Assistance Address Telephone Telex Fax Internet 26 If you have any questions about an MTS system or product contact the MTS corporate service center Note Review the following pages for information about what to expect when you contact us MTS Systems Corporation Service Support Group Technical Support Department 14000 Technology Drive Eden P
24. Constant Name Pi radius Modulus S Dimension Unitless Length Pressure Display Units none mm MPa Current Value 3 14 12 5 10 Referenced In Area Area Corrected Axial Calculations Axial Stress Axial Stress Strain The following shows how a calculated input signal could also be used as a calculation constant Area This example calculates the area of a cross section of a specimen The constant Area the calculated input below may be referenced by other calculated inputs even though it is not defined with the Calculation Constants window However its components are calculation constants Pi power radius 2 Where Piis a calculation constant radius is a calculation constant that represents half the diameter of the specimen cross section TestStar Reference Manual 123 Edit Menu Detector Actions IA Detector Actions 124 Defining actions Standard actions A detector action is an event that occurs when conditions of a detector are true This is also called a detector fault Four standard actions are always available You can define up to six hold or ramp hold actions The detector actions are available for all TestStar detectors You need to know the following before you define an action How do you want the actuator to be controlled when a detector action occurs What control mode is the best to prevent specimen damage or control actuator movement when a
25. Control Mode Selection Master P lt gt LimitP _ lt gt Upper Limit units lt gt Lower Limit units lt gt CONTROL FUNCTION Master P Adjusts the gain of the master control channel Limiting P Adjusts the gain of the limiting control channel Lower Limit Defines a range for the limiting control channel The limiting channel range Upper Limit ensures the command does not exceed the upper and lower limit values You select values based on the modulus of the specimen Units Shows the units of the upper and lower limit values The units are set by the input signal used for the master and limiting control modes 164 TestStar Reference Manual Changing the adjustment range How it works The CLC control mode uses one of three error signals The Limit P adjustment acts as a conversion factor to scale the limit feedback to similar units as the master feedback Tuning Pressing the Master P or Limiting P button displays the Set Scroll Range window where you can set the range of adjustment for the control Each adjustment can have a different range A CLC control mode uses one input channel to control the servo loop master channel while using a second input channel limiting channel to restrict the master channel The limiting channel uses a limit range to ensure the s
26. DRP Overrun The data reduction process is overwhelmed when collecting too much data too quickly Review the characteristics of any data acquisition process Emergency Stop Any one of the Emergency Stop switches has been pressed Twist the switch clockwise to release it Feedback Conditioner This is caused by a loss of excitation to or from a sensor Review the conditioner modules for a lit Fault indicator Check if the sensor cable is connected Otherwise replace the cable or conditioner module Hydraulic Interlock This interlock is caused by the hydraulic power supply or servomotor or Check for one of the following Servo Interlock low hydraulic fluid high hydraulic fluid temperature dirty hydraulic filter 5 ro a Q j 0 5 motor thermal overload Mechanical Interlock This is caused by an external device connected to the rear panel connector J23A or J23B Next Control Mode This is caused by a conditioner reaching its maximum saturated or minimum output Review the conditioner modules for a lit Fault indicator This usually happens before hydraulic pressure is applied TestStar Reference Manual 57 jo lt O jm ge Ho p Using the Fault Status Window Step3 Correct the cause of the interlock After you have determined the cause of the interlock you need to correct it Your course of action is dictated by the type of i
27. Enabled Pane Display message line The load unit control panel display can accommodate 16 rows including the title bar message bar and switch descriptions Each row can have up to 40 characters Use the F4 switch to toggle between TestStar Panel 1 and TestStar Panel 2 132 TestStar Reference Manual al Toolbar The toolbar is a row of buttons displayed below the menu bar These buttons that can open any TestStar windows Open Configuration File A Toolbar ies a j 0 5 Edit Scope Save Configuration File D Adjust Input Signals Select Font 1P Adjust Tuning Print Preview bi S amp RAR Adjust Compensators D Edit Input Signals Adjust Error Detectors 4 Edit Output Signals Adjust Underpeak Detectors Edit Control Channels Adjust Servovalve Edit Control Modes Display Input Signals Edit Calculation Constants Display Detector Actions A Edit Detector Actions Display Meters g Edit Load Path Stiffness Display Scope B Edit LUCP Display Servo Loop Update Rate Edit Toolbar Fault Status Edit Meters Debug TestStar Reference Manu
28. Feedback External Source n segment generatory ik slot 7 14 ik Edit Calculation Constants Constant Selection _ a E Constant 1 8 Display disabled enabled Edit Scope cope Selection a scope 1 or scope 2 Define Scope Enable Display Sweep Type Trace Time Refresh Time X Channel Y1 Channel Y2 Channel enabled disabled single continuous Sec Sec Input signal vaive signal time Input signal vaive signal ik Input signal valve signal ie Constant Name Dimension Display Units Current Value Referenced In Calculation Constant Definition _______ ss 7 m units List of calculated input signals that use this constant Chapter 3 Edit Menu nua Npa Contents Input Signals 85 Edit Input Signals Window 88 AC amp DC Conditioner Signal Type 90 External Signal Types 91 Calculation Signal Types 93 Assign Sensor Window 96 Define External Sensor Window 97 Output Signals 99 Edit Output Signals Window 101 Analog Bus 103 Readout 105 Programmable Output 109 Control Channels 110 Edit Control Channels Window 112 Control Modes 116 PIDF Con
29. Pressure line hoses for normal hydraulic service should have a burst pressure at least four times the operating pressure Preface Ensure all operators are familiar with any changes to the test system and provide training on how the changes affect operation and maintenance 22 TestStar Reference Manual Safety Precautions The Importance of Proper Maintenance Proper maintenance is important to system operating safety Without good maintenance practices system reliability and safety degrades to the point where potential hazards can become extreme dangers Study the manuals and the following paragraphs before beginning any type of system maintenance TestStar Reference Manual Service must be done only by qualified persons The service procedures in the individual product manuals are effective ways of maintaining the units Read the procedures before you start working on a unit then follow them carefully In other words don t get inventive Use only designated MTS replacement parts Parts not approved by MTS can adversely affect safety in addition to degrading reliability increasing maintenance downtime and voiding warranty coverage Perform all calibration procedures in the TestStar Installation Manual to avoid improper signal scaling Electronic signals between system components interact to operate the entire system Systems that use pneumatic devices e g accumulators certain tandem and high rate actu
30. Select the color of your choice for each parameter Press the OK button to return to the Digital Scope window and view the effect of your color choices The following is a list of colors you can select for any of the display parameters Black Light Gray Dark Gray Green Red Blue White Magenta a bio n ge S Gray E 3 Cyan S Yellow 201 Display Menu Display Scope 202 TestStar Reference Manual TestS tar II trol Syste Chapter 6 Function Generator Function Min Max Min E j a Min Max Time Generator KA O enerato in E Define _ Hel Command Count Hold Run Home Definition O and Menu Optio Mean nits c Cc Ki gt Control channel x W Amplitude um Pr trol mode xy Optio KY gt I Units x Frequency Hz A tial ra rm Preset Count ON OFF cai E iTo Ampl ri x J Enable Gompensator St Wavesh z Spio Cu Wavesh Control Mode o ui Endlevel I lt units units OK j Cancel Help j Help 1 lt Chapter 6 Function Generator Contents Prerequisites TestStar Reference Manual The function generator is a program that generates a waveform to command the servo control loop Function Generator Window 206 Se
31. The initial ramp executes to achieve the mean level setting The waveshape order selection applies the waveshape from the mean level to the amplitude end level The waveshape cycles according to the requirements of the amplitude frequency and preset count Cycles count from one end level to the next end level of the same value When the cycle count is complete or the Stop button is pressed the waveshape continues from the amplitude end level to the mean level The Home button executes a ramp to the home position For example assume the function generator is set up with these characteristics PARAMETER SETTING PARAMETER SETTING Command Home Ramp Control Mode length Control Mode length Units cm End Level 0 cm Waveshape sine Time 1 sec Waveshape Order inverted Frequency 1 5 Hz Initial Ramp Rate 1 cm sec Mean Level 1 5 cm Preset Count 2 cycles Amplitude 1cm time 7 0 reference initial gt The figure shows the initia ramp components of a program command meanilevel l 2 5 PEIRE E EI PEAS A EE TE inverted N iZ waveshape order _____ 2 cycles gt returns to mean i 3 cm Neen ene n eee i Veen eee eee ene s Continued i g o eD D 0 a 216 TestStar Reference Manual Command Menu Options Window How it works Another example assume the function generator is set up with these continued charact
32. loop that happen to use the same terminology Program f i m Rica Outer Loop fa P UJ i SS Inner Loop D Command gt Inner Loop Vv 4 P T H 3 Valve i Command A Displacement Angular I Force Feedback Feedback Proportional gain and integral gain reset are the inner loop tuning controls Use the proportional gain and integral gain values from a tuned PIDF control mode that uses the same feedback as the inner loop The inner loop typically uses a length feedback with the inner loop command from the outer loop Proportional gain and derivative gain rate are the outer loop tuning controls Adjust the outer loop using the same technique as a PIDF control mode after values are established for the inner loop The outer loop typically uses force feedback with a command from a segment generator the function generator or a TestWare application TestStar Reference Manual 269 Tuning About Tuning About the Tuning Controls Inadequate adjustment Proportional gain P The tuning command is shown as a gray square waveform and the black waveform is the sensor feedback 270 TestStar includes four tuning controls You do not need to use all of the controls to properly tune your system
33. size and Open attributes of the text in the saei TestStar windows and displays 3 Select Font Displays the TestStar configuration All the settings of the TestStar windows are recorded Print Preview Exit Shows the current output of each input signal Also allows signal zero and can jump to the Adjust Input Signals window Shows the setting and action of each limit detector Also shows the action selections for the error and underpeak detectors Any detector action can be changed Display here Input Signals DetectorActions Shows any meter that is enabled The meters can Meter be arranged vertically Scope pe horizontally or in a box Shows the scope Quits TestStar ka TestStar n Opens TestStar File Edit Adjust Display Help windows The toolbar zf A can be configured to 4 SiBA AMA show the window HPS Pressure Off buttons you want Program State Stop Shows the status of a control channel Control Channel 1 Hydraulics Off APC State Off Defines input signals from Current Mode Undefined Next APC Mode sensors calculations and external signals Defines the signals assigned to the 6 rear panel output connectors Edit Input Signals Output Signals Control Channels Control Modes D
34. stops and hydraulic pressure is turned off Setting Unknown limits TestStar Reference Manual Input Signals The upper limit defines the most positive or least negative level for the limit detector The lower limit defines the least positive or most negative level of the limit detector The difference between the upper and lower limits represents the normal operating range of the sensor When set correctly a sensor output beyond this range represents a change in the test that deserves attention Limits can also protect your equipment if a specimen breaks If the sensor output exceeds either limit the digital controller performs the action that you assign with the limit action fields upper limit a le a E a al upper limit 1 1 cm 1 cm ge em breaks 0 cm ACM heen nen e NE eee ee eee nanea NT onnen lower limit 1 1 cm Set the limits to establish a normal operating range for the sensor during a test then select an action you want performed if a limit is detected For example assume you are testing a specimen using a displacement control mode Also assume the LVDT has a displacement of 5 mm and you design the test to operate over the range of 2mm Setting the limits for either the displacement signal at 2 1 mm and 2 1 mm should protect the specimen from damage If you do not know what the limit setting should be for a test you will need to run the test and monitor the sensor signal Set up a peak valley o
35. 0000000 V CONTROL FUNCTION Signal Selects one of the following signals to be assigned to the output e any input signal e the valve command signal from any control channel e the program command signal to the active control mode e the error signal from the active control mode Gain Specifies a multiplier for the output signal The Gain setting of 1 default scales the readout signal to 1 volt per unit Use gain to customize the amplitude of the output signal for your needs Offset Specifies a mean level offset of the output signal The Offset setting of 0 default references the signal to O volts Use offset to calibrate the TestStar output with your monitor device TestStar Reference Manual 105 Output Signals How it works Note A monitoring device should be connected to the rear panel connector T J71 J76 that corresponds with the DAC you defined Monitor Device 66 6 50 50 Scaled Loof a e ad O Signal i OT oT J73 20 DC Conditioner Outputs Pees al ORO o Module Rear Panel Location 3 Gain calculation 106 Connectors Sensor lt q sr Feedback J3 Assume you use a 3 cm displacement sensor A full scale displacement sensor output of 3 cm would produce a readout signal of 3 volts with the Gain set to 1 Remembe
36. 1129 TSERR_CALC_PREV_NOT_DEFINED 1130 MTSERR_CALC_DEF_OUT_OF_ORDER 1131 MTSERR_CTRL_NOT_INITIALIZED bd 1132 MTSERR_CTRL_INUSE 3 1133 MTSERR_CTRL_DEF_DEFINED 5 1134 TSERR_CTRL_DEF_ERROR gt 1135 TSERR_INVALID_CTRL_CHAN_LABEL 306 TestStar Reference Manual Digital Controller Error Codes ERROR No MESSAGE 1136 MTSERR_INVALID_CTRL_CHAN_NAME 1137 MTSERR_INVALID_INP_CHAN_TYPE 1138 MTSERR_INVALID_INP_CHAN_NAME 1139 MTSERR_INVALID_INP_CHAN_LABEL 1140 MTSERR_INVALID_CALC_CONST 1141 MTSERR_INVALID_CALC_CONST_NAME 1142 MTSERR_INVALID_OUTP_CHAN_TYPE 1143 MTSERR_INVALID_OUTP_CHAN_NAME 1144 MTSERR_INVALID_OUTP_CHAN_LABEL 1145 MTSERR_INVALID_CTRLMOD 1146 MTSERR_INVALID_CTRLMOD_CMDSRC 1147 MTSERR_INVALID_CTRLMOD_TYPE 1148 MTSERR_INVALID_CTRLMOD_NAME 1149 MTSERR_INVALID_CTRLMOD_LABEL 1150 MTSERR_CHAN_IN_USE_AS_FEEDBACK 1151 MTSERR_SGC_ACTION_INTERLOCK 1152 MTSERR_INVALID_CTRL_CHAN_TYPE 1153 MTSERR_TC_RAMP_RANGE 1154 MTSERR_LW_INVALID_FILE 1155 MTSERR_LW_INVALID_TYPE 1156 MTSERR_LW_INVALID_NUM_RANGES 1157 MTSERR_LW_INVALID_ENABLEBIT 1158 MTSERR_LW_INVALID_RANGE 1159 MTSERR_INVALID_COMPENSATOR 1160 MTSERR_INVALID_COMP_TYPE 1161 MTSERR_CANNOT_CREATE_DRO 1162 MTSERR_DRO_NOT_STARTED 1163 MTSERR_CANNOT_CONNECT_DRO_TO_OM gt az ge len j 0 gt lt TestStar Reference Manual 307
37. 300 ERROR No TYPE DESCRIPTION 126 mux specified channel does not adjust cal 127 odp received selector for wrong class 128 odp selector not implemented 129 odp internal error unpacking parameters 130 odp parameter out of range 131 odp timeout addressing register 132 odp invalid address for desired function 133 odp slot is not occupied by a valve driver 134 odp unexpected response 135 rom internal error unpacking parameters 136 rom oid already allocated for object specified 137 rom out of oids to allocate 138 rom cannot deallocate a connected object 139 rom object not allocated 140 rom object already connected 141 rom object name not found allocated 142 rom state var index out of range 143 rom object currently in allocated state 144 rom invalid object ID 145 rom selector not implemented 146 rom received selector for wrong class 147 rtc internal error unpacking parameters 148 rtc rate is too slow for current base frequency 149 rtc selector not implemented 150 rtc received selector for wrong class 151 rtc not a valid range selector 152 rtr object not connected 153 rtr don t do common selectors 154 rtr selector not implemented 155 rtr received selector for wrong class 156 Sgc no error TestStar Reference Manual Firmware Error Codes ERROR No TYPE DESCRI
38. 62 Hold 62 Run Resume 62 Test control Switches Stop 62 Switches Hold 62 hydraulic power supply 63 hydraulic service manifold 66 Run Resume 62 Stop 62 Test control 62 System Administration 231 applications window 234 adding an application 238 assigning applications 237 assigning users 239 deleting an application 234 editing an application 238 configuration files 236 usernames 231 users window 234 adding a user 235 configuration file 236 deleting a user 234 editing a user 235 how it works 236 unit assignment 236 System administration application access 242 TestStar Reference Manual defining users 240 opening 240 T Technical assistance 26 Telephone number 26 Telex number 26 Temporary sensor prerequisite 97 window 97 Test control switches 62 TestStar configuration files 50 debug options 312 main window 49 things that slow it down 310 TestStar starting 48 The 224 235 This 9 Timed data 138 139 Toolbar buttons 133 configuring 135 Tuning 159 about 260 about the controls 270 adjusting something wrong 261 amplitude 275 auto 163 automatic 281 auto tune 283 auto tuning 285 CASC block diagram 168 defining 121 tuning changing adjustment range 167 tuning guideline 168 CASC control mode 269 checklist 262 CLC defining 120 how it works 165 tuning guideline 166 CLC control mode 268 command sources 265 control modes 265 controls adjustment range 169 TestStar Reference Manual creating a program 274
39. Adjusts the amount of proportional gain Proportional gain affects the servo loop response to a servovalve command l Adjusts the amount of integral gain Integral gain affects the system steady state dc error D Adjusts the amount of the derivative gain Derivative gain affects stability at higher proportional gain settings F Adjusts the amount of feed forward gain Feed forward affects the system performance at high frequency operation Auto tune Displays the Auto tune window where you configure the auto tune feature This feature in only available with the PIDF control modes TestStar Reference Manual 161 Adjust Menu Tuning Changing the Pressing any of the adjustment buttons displays the Set Scroll Range adjustment range window where you can change the adjustment range of the slider boxes Each adjustment can have a different range How it works 0 1 gt Feed Forward d Gain gt BRE dt This is a block diagram 10 0 that shows the B interrelationships of the Proportional n ain various gain controls Program gt z Servovalve Command Ea Command Ea 1 0 E Integral Gain gt o 0 1 gt Derivative Sensor d Gain gt Feedback dt Using the controls You should be familiar with the concept of tuning th
40. Control Modes Control Channel Selection l a Y Control Channel 1 4 ies ou j 0 5 Control Mode Selection a v Control Mode 1 10 Control Mode Definition Mode Name Mode Type PIDF CLC Mode Label PARAMETER FUNCTION Control Channel Selects the control channel for the control mode that is created with this window Control Mode Selects one of the 10 control modes you can define Mode Name Names the control mode Type a name you want to call the control mode This name is used throughout TestStar to identify the control mode Mode Type Specifies the type of control mode you want to define Your selection displays appropriate controls at the bottom of the window that define the control mode e PIDF provides the highest level of servo loop response and is used primarily for specimen testing and can be used for specimen installation e Channel Limited Channel CLC is a special control mode used for specimen installation e Cascade CASC provides a high degree of stability and is primarily used for dynamic testing with force control Mode Label Selects a letter to distinguish control modes of the same dimension TestStar Reference Manual 117 Edit Menu Control Modes PIDF Control Mode A PIDF control mode type has several gain adjustments to stabilize the servo control
41. Control Modes 285 Tuning Procedure 288 Appendix 294 Firmware Error Codes 295 Digital Controller Error Codes 303 Servo Loop Update Rate 309 Debug Options 311 Debug Options Window 312 Select Output Log File Window 313 Bypassing the Login 315 Load Path Stiffness Editor 317 Using the Load Path Stiffness Editor 319 Index 323 TestStar Reference Manual Preface What this manual does What this manual does not do What you need to know Who should use this manual TestStar Reference Manual Note While the formal name for this product is TestStar ll throughout this manual we use TestStar and TestStar II interchangeably This manual provides detailed information about TestStar windows and menus It is intended to serve as a continuing reference when you need to know detailed information about a specific subject This manual also includes references to other chapters or manuals where related information may be found This manual does not provide detailed operating instructions to run a test It is your responsibility to ensure that all test methods you use are accurate and safe TestStar is available for both IBM OS 2 and Microsoft Windows NT operating systems You need to have a reasonable knowledge of your operating system before attempting to use this manual You should know how to open and close windows manage files and so on TestStar Version 3 1 use Operating System 2 OS 2 Warp 3 0 TestSt
42. For example Elvis can open the only Function Function Generator Generator and TestWare Load Path Stiffness SX applications Sensor Calibration System Administrator IGSS EU TestWare SX Unit Assignment Set Editor Cancel Repeat steps 2 and 3 for each new user you want to create Step 4 Close the program Close the program by double clicking the system menu icon upper left corner of the window 242 TestStar Reference Manual TestS tar IT trol Syste Chapter 8 Unit Assignment Set Editor Open Unit Assignment Set x Unit Assignment Set Editor Unit Assignment Set Editor selected unit set Unit Set Names list of unit sets Description h for the unit set Units A A e e list of dimensions list of available units for the selected dimension e e e e v Save Unit Assignment Set selected unit set Unit Set Names e e e list of unit sets Delete Unit Assignment Set selected unit set Unit Set Names list of unit sets Assign Default Unit Assignment Set selected unit set Unit Set Names list of unit sets Assign Cancel Help Chapter 8 Unit Assignment Set Editor Contents What is a unit What is a unit set TestStar Reference Manual The unit assignment set
43. Installation manual oO Calibration a Q The Diagnostics program checks each hardware circuit card in the l digital controller See Appendix D in the Installation manual Diagnostic The Load Path Stiffness Editor creates sets of values that compensate my for deflection in the load path This is used with the Model 790 31 Dynamic Characterization process and the Model 790 33 Static Load Path Deflections process See Appendix F Load Path Stiffness Editor on Stiffness Editor page 317 TestStar Reference Manual 47 Introducing the TestStar Software Starting TestStar When you double click the TestStar icon the Login window appears If your user name and password are valid the main TestStar window opens On new systems both the User Name and Password are MTS See Chapter 7 Creating a New User on page 240 to create user names and assign passwords with the System Administration program TestStar Il The information and design disclosed herein were originated by and are property of MTS Systems Corporation and may not be reproduced or disclosed in any form without the written consent of MTS Systems Corporation MTS Systems Corporation reserves all patent proprietary design manufacturing reproduction use and sales hereto and to any article disclosed herein except to the extent rights are expressly granted to others Copyright c 1990 1993 MTS Systemss Corporation Type in your name and password
44. LU Servovalve Feedback lt gt gt Command Proportional Gain Note The easiest way to tune a CLC mode for average use is to use the same values as the proportional gain P values from any tuned PIDF control mode of the same signal type range and specimen type for the master P and limiting P values It typically uses length feedback to move the actuator and force feedback to stop actuator movement when a force limit is detected It gets its command from the Actuator Positioning Control on the load unit control panel and is designated Pod If you want tighter control use higher gain levels for the limiting channel Adjust the Master P control for adequate actuator response to an Actuator Positioning Control adjustment Monitor the force output and adjust the limiting channel control to minimize any delay to stop actuator movement when it reaches the specified limit 268 TestStar Reference Manual About Tuning Cascade control The cascade CASO control mode is used for specimen testing that mo d e requires a high degree of stability during dynamic tests It is like two control modes in series the output of the first control mode outer loop is the command source for the other control mode inner loop Note The inner and outer loops of a cascade control mode should not be confused with the inner and outer loops found in a system using a Series 256 or 257 Servovalve These are two different parts of a servo
45. Limits selection shows the input channel detectors The Control selection shows the control channel detectors Limits Shows the upper and lower limits and actions for all input signals Signals Lists the names of the defined input signals Pressing the signal button displays the Adjust Input Signals window Upper Limit Shows the value of the limit and the selected action Both the value and Lower Limit the action may be changed in this window Control Shows the actions for the underpeak and error detectors for all the defined control channels Underpeak Selects an action for the underpeak detector Minimum Error Maximum Error Selects an action for each error detector The minimum error is usually set to indicate and the maximum error is set to stop the test Using the limit window Using the control window Display Menu 194 The limit window mode shows the current upper and lower limit settings for each input signal You can change any limit value by typing in a new value in the entry field You can also change the detector action For example assume you did not know what values to use for a strain input channel While the test is running note the high and low output of the strain input signal use the Display Input Signals window or set up a peak valley meter Once you determine the normal operating range for the input signal you can decide the margin for limit values The control window mode shows the
46. MESSAGE 0 NO_ERR 1001 MTSERR_FIRST_CONNECT 1002 MTSERR_PIPE_BROKEN 1003 MTSERR_BAD_PID 1004 MTSERR_PROCESS_CONNECTED 1005 MTSERR_MAX_CONNECTIONS 1006 MTSERR_BAD_PIPE_TYPE 1007 MTSERR_PIPE_CONNECTED 1008 MTSERR_PIPE_PARTIAL_WRITE 1009 MTSERR_NO_MEMORY 1010 MTSERR_BAD_RETURN 1011 MTSERR_PIPE_CLOSED 1012 MTSERR_O_FULL 1013 MTSERR_WRITING_PID 1014 MTSERR_WRITING_PIPE_TYPE 1015 MTSERR_READ_TIMEOUT 1016 MTSERR_WRITE_TIMEOUT 1017 MTSERR_TIMEOUT 1018 MTSERR_CANNOT_OPEN_WSCI 1019 MTSERR_FILE_NOT_FOUND 1020 MTSERR_FIRMWARE_BAD_DOWNLOAD 1021 MTSERR_CONNECT_HIO_POD 1022 MTSERR_UNKNOWN_COMMAND 1023 MTSERR_UNKNOWN_FIRMWARE_ERROR 1024 MTSERR_UNAVAILABLE_RESOURCES 5 1025 MTSERR_CANNOT_CREATE_MQ 1026 MTSERR_CANNOT_CREATE_RO 1027 MTSERR_NO_SUCH_LINK oa TestStar Reference Manual 303 gt lt cs eD er lt Digital Controller Error Codes 304 ERROR No MESSAGE 1028 TSERR_LINK_NUM_OUT_OF_RANGE 1029 TSERR_MAX_CLASSES_EXCEEDED 1030 MTSERR_BAD_DIO_BIT 1031 MTSERR_UNKNOWN_POD_KEY 1032 MTSERR_TIMEOUT_CREATING 1033 TSERR_TIMEOUT_FW_RESP 1034 TSERR_BAD_INPUT_CHAN 1035 TSERR_BAD_OUTPUT_CHAN 1036 MTSERR_PARAM_RANGE_ERR 1037 MTSERR_INITIALIZING_FW_OBJECTS 1038 MTSERR_NO_SYM_MATCH 1039 MTSERR_NO_INPUT_FILE 1040 TSERR_SCALE_EQ_ZERO 1041 TSERR_NO_DIM_MATCH 1042 MTSERR_IDS_NOT_EQUAL 1043 MTSERR_MONITOR_NOT
47. Manual Input Signals 148 Adjust Input Signals Window 149 Set Zero Scroll Range Window 156 Shunt Cal Window 157 Tuning 159 Tune PIDF Window 161 Auto Tuning 163 Tune CLC Window 164 Tune CASC Window 167 Set Scroll Range Window 169 Adjust Compensators 170 Error Detectors 174 Underpeak Detectors 177 Adjust Drive 180 Adjusting 252 and Dual 252 Valves 181 Adjusting 256 and 257 Valves 184 nu w snfpy for each input signal along with Sets the upper and lower limits zero and range adjustments 4 TestSta File Edit Adjust Display Help HPS Press Input Signals Control Chanr Tuning Hydraul Compensators APG Si Error Detectors Underpeak Detectors Drive Tunes each control mode Specifies the type of compensation applied to the command Sets up 2 error detectors for each control mode for each control channel 7 lt Sets up the underpeak pe XN ES the servovalve or atte parameters 147 Adjust Menu Input Signals Input Signals What you need to know More information 148 Each defined input signal can be adjusted to meet the needs of your test Each input signal can be set up with the following Sensor limits allow you to detect undesirable conditions such as a broken specimen or to detect significant points in a test such as a transition in the test where the specimen
48. Not Selected OK Cancel Help Fields Pushbuttons Using a MOUSE The left and right mouse buttons can have different functions In TestStar unless otherwise noted all mouse activity selecting single and double clicking uses the left mouse button Most functions are easier to use with the mouse 5 mk m ro a Q q te 5 Using the keyboar d The keyboard can emulate the mouse functions The keyboard can be useful for menu and list selections Alt Esc move between windows Tab step between window controls up and down arrows step up and down a list of selections Enter make a selection Alt letter display menu letter menu selection or list selection TestStar Reference Manual 37 Introduction How to Use This Manual Title bar Moving around a window Using a mouse Using the keyboard 38 The title bar shows the name of the window The title bar may include a small version of the program icon for the System Menu Icon The System Menu Icon is primarily used to move size or close the window A single click from either mouse button displays a menu of window functions or press the Alt key Double click this icon or type Alt and F4 to close the window The Minimize Icon changes the window into an icon located in the at the bottom of the screen or the OS 2 Minimized Window Viewer To reopen the window double click the minimized icon or For OS 2 press b
49. O option Note Detailed instructions to install and define an external sensor or external command can be found in Chapter 10 of the Installation manual When you select the External signal type you will see this window configuration x edit Inp Signal Selection a iv Slot 7 14 Extended 1 16 Use the Assign Sensor button to crane select an external sensor from the f calibrated sensor data base Signal Type Dimension Use the Assign Temporary Display Units button to set up a temporary Signal Label calibration file Sensor Use the list icon to select a Range Range units from the list of calibrated ranges Assign Sensor Assign Temporary TestStar Reference Manual 91 Edit Menu Input Signals How it works o Signal 10 ae es ee Assign Sensor When you press the Assign Sensor button this window opens Assign Temporary When you press the Assign Temporary button this window opens 92 The sensor you assign should be connected to a rear panel connector 977 J78 or J42 that corresponds with a module location slots 7 14 Rear panel connectors J63 and J64 are associated with the optional Extended 1 16 selections Assign a slot with Define the external signal Use the external signal the Edit Input with the External Signal with the Edit Control Signal window Definition
50. Pod Axial Sensors Current Value Load Cell 0 1009 kip CAT in 0 0009Rin in Length Strain Contents Area message bar lt 4 Message Line lt Function Key F1 F2 F3 F4 The default display shows the current control mode the selected LUCP control mode and the current output for each sensor Continued TestStar Reference Manual Using the Load Unit Control Panel Display screen Use the Display screen as follows continued FUNCTION KEY FUNCTION F1 When a sensor Press F1 to Auto Zero the selected sensor You can Auto Zero a sen is selected sor if it is not locked this is set up in the Sensors window and either of the following Hydraulic power is off or The selected sensor is not the feedback source for the existing LUC control mode In the sample window shown on the preceding page it would not be successful because a displacement sensor has been selected and the Current Mode is Length A SG When the LUC The F1 label changes to Next Mode Pressing F1 selects the next mode is selected available defined LUC control mode Note The LUC mode does not change until you actually press to turn on the Actuator Positioning Control switch If the switch is already on when you change the LUC control mode you need to set the switch off then back on again for the mode change to be recognized F2 and F3 Press either of these function keys to move the selection bar This se l
51. Select the Control radio button to display this window TestStar Reference Manual Display Detector Actions The detector actions window puts all the detector action selections established with the Adjust menu into one window The window works like two separate windows Any change you make in this window can occur while a test is running You must set the error and underpeak levels with the Adjust Error Detectors and Adjust Underpeak Detectors windows before you can use the Control section of Display Detector Actions window Note You can make all the limit settings with this window or the Adjust Input Signals window x Display Detector Actions pee F Control Signal Upper Limit Lower Limit load disabled value 1 lt action 1 stroke indicate value action 1 calculated 1 interlock value action 1 external Length hydraulic off a a a value action 1 lt Detectors l Q Limits 4 Display Detector Actions aI Channel axial torsional Underpeak Minimum Error Maximum Error disabled indicate interlock action 1 10 action 1 10 hydraulic off 193 nua Avyjdsiq Display Detector Actions SELECTION FUNCTION Detectors Selects which detectors are displayed in the window The
52. Selecting one of the list items makes that selection active A scroll bar that is grayed out indicates that all the possible selections are being displayed Using the mouse Press the list button and highlight your selection Use the right mouse button to close the list without making a selection Using the keyboard Use the up or down arrow keys to step through the selection list You can also type the first letter or two of a selection from the list and it will be selected The step switches work in conjunction with a list icon Press the list icon to see the list of selections The step switches let you step up and down through the selection list Function a x Current Selection List Item A List Item List Item Si Using the mouse Press the up or down step switch until the your selection is displayed Or press the list icon and highlight your selection Using the keyboard Use the Tab key to select the up or down step switch Press Enter to step operate the button You can also type the first letter or two of a selection from the list and it will be selected 43 5 mk m ro a _ Q q homie 5 Introduction How to Use This Manual Dialog box TestStar is located in the MTS TSII folder on the Desktop Optional applications like TestWare SX are also placed in the MTS TSII folder 44 A dialog box is a screen display that requests information
53. Status window that the detector has been triggered Hydraulics Off turns off the hydraulic pressure at the service manifold displays a message in the Fault Status window and lights the Aux indicator on the LUCP Interlock turns off the hydraulic pressure generates an interlock signal clamps the servovalve and displays a message in the Fault Status window You must correct the reason for the interlock and use the Reset button located on the load unit control panel to clear the interlock Customer defined these actions can be defined to ramp or hold the control channel output These actions may also be identified with a customer defined name or as Action 5 10 Note Customer defined actions are created with the Edit Detector Actions window When using both error detectors set the Minimum error to a value that indicates the onset of a failure at a lower error level and configure the Maximum error to a value that stops the test at a higher error level Perform the following for each control channel 1 Select a control channel using the step switches or the list icon 2 Select an appropriate action for each error detector Note Repeat the following steps for each control mode 3 Select a control mode using the step switches or the list icon 4 Use the scroll bars or enter a value in the entry field to establish the Minimum and Maximum values for the selected control mode 5 Repeat steps 1 4 for any oth
54. Stops udating the data meters l Starts displaying data on all data meters Stop Run Clears the data meters so new values can be acquired J Display Meters o Controls Alignment Timed 7 Slot1 0 000000 units Slot2 0 000000 N Controls Alignment Slot 1 Peak 0 000000 units Display Meters Valley 0 000000 units eoo Sti Span 0 000000 units 4 Vertical Timed Horizontal Slot 2 Unde Mean 0 000000 units Slot 1 Maximum 0 000000 units Box ined Minimum 0 000000 units Controls Alignment isplay Meters Timed Slot 0 000000 units Peak 0 000000 units Slot2 0 000000 N Valley 0 000000 units Mean Slot 1 Slot 1 0 000000 units Maximum 0 000000 units 4 000000 units Minimum 0 000000 units d Display Meters G Controls Alignment Timed stroke stroke 0 000000 in Span 0 000000 in load 0 000000 kip Mean 0 000000 in stroke Control Channel 1 Valve Peak 0 000000 in Maximum 0 000000 v Valley 0 000000 in Minimum 0 000000 v nu w ejdsiq Display Menu Display Scope Prerequisites Use this window to monitor test related signals The scope works like an oscilloscope See
55. The inner and outer loops are not the same as those used with 3 stage servo valves Tuning You must define a CASC control mode for the control channel with the Edit Control Channels window before you can use this window J Adj Control Channel Selection A E Control Mode Selection a CASC Mode Tuning Outer Loop P lt Outer Loop D lt Inner Loop P nua isnl py lt Inner Loop lt ee SET FUNCTION CONTROL Outer Loop P Adjus s the level of proportional gai n for the outer loop Proportional gain affects the servo loop response to a servovalve command Outer Loop D Adjus affects stability at higher proportion s the level of the derivative g ain for the outer loop Derivative gain al gain settings Inner Loop P Adjus s the level of proportional gai n for the inner loop Inner Loop Adjus s the level of integral gain Integral gain affects the system steady state dc error Changing the adjustment range TestStar Reference Manual Pressing any of the adjustment buttons displays the Set Scroll Range window where you can change the adjustment range of the slider boxes Each adjustment can have a different range 167 Adjust Menu Tuning How it works The cascaded control
56. _ N N lt t a How it works Default units Default units are identified with brackets 246 When you log into TestStar your unit preferences are applied Having a preferred set of units saves time Whenever you select a dimension for a TestStar parameter the preferred unit is automatically assigned You can always manually change the default unit assignment for any parameter For example assume millimeters is the assigned unit for length When you define an input signal for the LVDT you will select the dimension length Since mm is automatically selected as the unit you can skip the unit selection unless you want to change the unit to something else such as cm or in Several windows in TestStar require values to be assigned and units selected for test parameters When a window is opened the default units are assigned to each parameter The default units can be changed in each window Units can be selected for specific parameters by using a list icon of the units field Selecting a unit without brackets prevents that unit from being changed even if the default units are changed Default units are assigned to each dimension used by TestStar Each parameter that uses units can be defined with default units these selections are identified with a set of brackets All other units are considered hard units these are the units you select from a unit list icon and are not affected by sets of defa
57. a system using a Series 256 or 257 Servovalve These are two different parts of a servo loop that happen to use the same terminology The auto tuning feature is available for PIDF control modes using the segment generator SG command source It produces a low to moderate level of tuning You can then fine tune the control mode for a higher level of tuning General tuning information About Tuning on page 260 Auto tuning procedure Auto tuning on page 281 General tuning procedure Tuning Procedure on page 288 TestStar Reference Manual Tuning Tune PIDF Window Prerequisite PIDF proportional integral derivative and eed forward are a group of gain adjustments that une the servo loop response Use the PIDF control mode or specimen testing The proportional derivative and integral adjustments are also called gain rate and reset respectively You must define a PIDF control mode for the control channel with the Edit Control Channels window before you can use this window x Adjust Tuning a Control Channel Selection 4 x Control Channel 1 Control Mode Selection t T _ 4 Ly Control Mode 1 x PIDF Mode Tuning A B 1 00000 l lt gt N 0 000000 S D 0 000000 gt E 0 000000 gt Auto Tune CONTROL FUNCTION P
58. adjustment The Set Scroll Range Amplitude window reduces the range of the amplitude adjustment Scroll Range Max units OK Cancel Help Using the window The window displays the full scale value of the selected control mode range The default value represents the span between full scale You can change the maximum setting of the Amplitude control to a value less than full scale but not below the current amplitude setting The maximum setting cannot be set below 0 To change the scroll range value type the new value in the entry field For example assume the control mode range is 3 cm The default scroll range is 6 cm Changing the range to 2 cm ensures the test cannot exceed 2 cm Amplitude 1 cm Amplitude 1 cm gt gt The Amplitude control is 1 cm Changing the scroll range to with the scroll range of 3 cm 2 cm also changes the 1 cm reference i g o eD D 0 a 212 TestStar Reference Manual Function Generator Window Set Frequency Scroll Range Setting the scroll range of the Frequency adjustment ensures the control is within the capabilities of your equipment Reducing the scroll range also increases the resolution of the control adjustment The Set Scroll Range Frequency window sets the maximum Freq
59. and Dual 252 Valves 181 Adjusting 256 and 257 Valves 184 Chapter5 Display Menu 189 Display Input Signals 190 Display Detector Actions 193 Display Meters 196 Display Scope 198 Set Scroll Range Window 200 Scope Display Options Window 201 TestStar Reference Manual Chapter6 Function Generator 205 Function Generator Window 206 Set Mean Scroll Range 211 Set Amplitude Scroll Range 212 Set Frequency Scroll Range 213 Command Menu Options Window 214 Count Menu Option Window 220 Home Menu Option Window 222 Designing a Test Program 224 Chapter 7 System Administration 231 System Administration Window 233 New Edit User Window 235 Application Access Window 237 New Edit Application Window 238 User Access Window 239 Creating a New User 240 Chapter8 Unit Assignment Set Editor 245 Unit Assignment Set Editor Window 248 Open Unit Assignment Set Window 250 Save Unit Assignment Set Window 251 Delete Unit Assignment Set Window 252 Assign Default Unit Assignment Set Window 253 Defining a Unit Assignment Set 254 TestStar Reference Manual s a _ Oo C3 5 5 e N Chapter 9 Tuning 259 About Tuning 260 About Control Modes 265 About the Tuning Controls 270 Nn S o S T o o Q iS About the Tuning Program 274 About the Servovalve 276 About Specimens 277 Monitoring Waveforms 278 Auto tuning 281 Auto Tuning the First Control Mode 283 Auto Tuning Additional
60. before you can use the window This section lists those requirements Each window is illustrated in its generic form that is usually no values are shown This serves as a guide when you are using this manual without an operational work station in front of you Words shown in italics are generic names describing a selection This category of information gives a concise explanation of the various controls available in the window The descriptions are intentionally kept brief to serve as memory joggers for experienced users or as a quick introduction for the novice Most of these descriptions have a table that describes each parameter and selection Some items in the Basic Explanation table require additional explanation These paragraphs provide extended descriptions to provide the necessary details 35 5 ro a Q j 0 5 Introduction How to Use This Manual 36 Using the window More information How it works Random topics Many of the TestStar windows can be completed intuitively that is there is a logical progression such as from the top to the bottom However some windows require that you work through them in a specific order or that certain selections require additional considerations More information consists of a list of related topics that include an italicized title of the window menu or topic where related information is located along with the chapter numbe
61. can monitor a signal in one of four display modes Defines a scope to display signals in a graphical form 84 TestStar Reference Manual Input Signals Input Signals ies ou j 0 mk 5 Input signals are from sensors transducers Each sensor signal must be defined for use with TestStar You need to know the following to define an input signal What type of sensor are you defining ac dc external calculated Where is the sensor connected to the digital controller Has the sensor been calibrated with the Sensor Calibration program Types of sensors Determine what type of sensor you are going to define Knowing the type of sensor helps you determine the appropriate dimension such as length force and angle for the sensor and your preference for display units Knowing the type of sensor helps you determine the signal type The sensor signal can be processed conditioned by an ac or de conditioner plugged into the digital controller or by a conditioner located somewhere else TestStar supports four types of sensor signals Anac conditioner signal type is conditioned by a Model 490 22 AC Conditioner plugged into the digital controller Adc conditioner signal type is conditioned by a Model 490 21 DC Conditioner plugged into the digital controller An external signal type is conditioned outside the digital controller An internal or external signal type can have additional signal
62. channel axial torsional or pressure helps you determine what kind of control modes you need to define TestStar Reference Manual Control Channels Kinds of drives A drive can be a servovalve or a servomotor You need to determine what kind of drive is associated with the control channel you are going to define The drive servovalve or servomotor type configures the Adjust Drive window with appropriate controls to adjust the drive signal ies a j 0 mk 5 Note During the software installation the system configuration is set for hydraulic or electromechanical The system configuration determines what selections are available for the drive type References to the term servovalve in this manual should be considered servomotor if your system configuration is set for electromechanical Compensators Compensators are methods that ensure a programmed command is reached While methods may vary compensators monitor sensor feedback and adjust the command until the programmed level is achieved The peak valley compensator amplitude control is always available to all control channels The phase amplitude PAC compensator must be enabled to become available When it is enabled system resources are allocated to the control channel This means that the maximum servo loop update rate is reduced More information Tuning Tuning on page 259 Adjusting the valve Installation Manual B Defining contr
63. channel is associated with a module location in the digital controller A control channel can be assigned to one of the module locations 11 14 The following table shows the recommended assignments CONTROL CHANNEL MODULE LOCATION 1 14 2 13 3 12 4 TI Control Channel 1 Control Valve servovalve _ Mode Driver control Control Channel 2 drive signal to the servovalve Control Mode Driver control 114 Valve servovalve TestStar Reference Manual Drive type Auto tuning control mode Phase and amplitude control TestStar Reference Manual Control Channels Each control channel provides a drive signal to a servovalve The valve type specification tells TestStar what kind of signal to output to the servovalve You can determine which servovalve you have by checking the valve driver module located in the digital controller or by looking at the actuator manifold ies a mk fo TestStar checks the module ID for the slot location that is associated with the control channel The module ID 490 14 or 490 17 determines which Drive Type selections is available A Model 490 14 Valve Driver supports 252 and dual 252 servovalves A Model 490 17 Valve Driver supports 256 and 257 servovalves The valve type selection also configures the Adjust Drive window with appropriate controls for the valv
64. characteristics change Sensor zero allows you to remove any offset to the input signal that can be caused by specimen installation or the installation of test fixtures The auto zero feature can be locked out Shunt calibration allows you to check the accuracy of the input signal sensor and a conditioning module to a calibrated reference Sensor range scales the input signal to a level that is appropriate for the test Before you can adjust the input signals you need to know the nature of the test When you know what the test is designed to do you can determine the following What is the expected output for each sensor What is the appropriate range for each sensor If you do not know the expected sensor output select the highest sensor range or set the limit detectors to a level 1 to 10 below the range of the sensor and select an action that stops the test Note We recommend that you establish limits for at least one input signal This can prevent damage to the test equipment if the servo control loop is broken such as a cable becomes unplugged or the specimen breaks The best input signal for this purpose is from the LVDT sensor Defining input signals Edit Input Signals Window on page 88 Setting the shunt cal reference Installation 8 9 TestStar Reference Manual Input Signals Adjust Input Signals Window Use this window to adjust each input signal The window configures itself with appropriat
65. detector action occurs For example if the specimen breaks and force control is used the actuator continues to move until the required force is detected this could cause damage But a length control mode can still ramp or hold the actuator when the specimen is broken What command ramp or hold is best for each detector The following are the four standard actions available for every detector Disabled turns the detector off Indicate displays a message in the Fault Status window that the detector has been triggered Hydraulics Off turns off the hydraulic pressure at the service manifold displays a message in the Fault Status window and lights the Aux indicator on the LUCP Interlock turns off the hydraulic pressure generates an interlock signal clamps the servovalve and displays a message in the Fault Status window You must correct the reason for the interlock and use the Reset button located on the load unit control panel to clear the interlock TestStar Reference Manual Fault status window All detector actions that occur are reported in this window The window remains on screen until the detector condition s is resolved More information TestStar Reference Manual Detector Actions The source of a detector action is identified by the name of the input signal or control channel as defined by the Edit Input Signals window or Edit Control Channels window The type of det
66. displacement 283 dummy specimens 277 Ext command 265 feed forward 273 frequency 275 haversine waveform 275 if you ve never tuned 261 inadequate adjustment 270 monitoring waveforms 278 optimizing 264 overview 260 PIDF adjustment range 162 defining 118 tuning guideline 162 Pod command 265 procedure 288 rate derivative 271 reset integration 272 saving parameters 261 SG command 265 sine waveform 275 square waveform 274 triangle waveform 274 waveform 274 what to do first 263 when to tune 262 tuning waveforms 260 U Underpeak detector actions 179 causes 55 controls 177 how it works 178 max min definition 179 Underpeak detectors 177 Unit Assignment Set Editor 245 assign default unit set 253 defining 254 dimension list 247 file menu 249 open unit 250 opening 254 save unit set 251 standard sets 247 units 245 Units 329 Index creating preferences 254 default 246 definition 245 dimensions 247 preferences 254 sets 245 se 251 sername 231 configuration file 51 defining 241 sing a mouse 37 sing an oscilloscope 280 sing on line help 59 sing sensors 88 sing the digital scope 280 sing the keyboard 37 GE Co GGO V Valve balance adjustment procedure 182 276 Valve driver 115 W Warning symbol 25 Waveforms see com mand 215 When to tune 262 Window controls 37 dialog box 44 menu bar 39 selecting 38 title bar 38 Windows Adjust Compensators 170 Adjust Drive 252 181 Adjust
67. editor allows you to establish preferred sets of units that can be used as default units in TestStar Note When the TestStar software is installed one of the standard unit assignment sets is assigned as the default unit set Unit Assignment Set Editor Window 248 Open Unit Assignment Set Window 250 Save Unit Assignment Set Window 251 Delete Unit Assignment Set Window 252 Assign Default Unit Assignment Set Window 253 Defining a Unit Assignment Set 254 j 0 ee gt Nn N bic ae oO ee WN Oo ee er ou j 0 ee Units define parameter values They are measurements such as inches pounds centimeters and kips Units are grouped by types called dimensions For example a length dimension includes the units microns millimeters centimeters inches feet meters etc A unit is an engineering unit a unit of measurement A unit set is a group of dimensions with a type of unit assigned to each dimension You can create different groups of default units for different tests or to reflect your preference in units Each user name can have a different unit set assigned to their login For example a unit set may have centimeters assigned to the length dimension Parameters that use length dimensions are automatically assigned to centimeters You can always change the default unit assigned to a specific parameter 245 5 an e5 N e5 ove
68. from you or requires you to acknowledge information Typically it is similar to the box shown below Make sure to read the statement in the box carefully before pressing OK you may be confirming an operation that has an effect opposite to the one you actually want Ask Option This type of dialog box will ask you for information or offer you a selection of choices C ftiim OK Cancel Information This type of dialog box displays information you should be aware of This type of dialog box cautions you that your next action could cause a change of information in a file or the potential for personal injury or equipment damage Cancel Using the mouse Press the pushbutton representing your choice Using the keyboard Type the underlined letter of the pushbutton you want to choose Use the Esc key to select Cancel TestStar Reference Manual Abbreviations How to Use This Manual Because of screen space limitations some of the TestStar prompts or labels have names other than the official names of functions or equipment These shorthand terms are SHORTHAND TERM ACTUAL NAME APC Actuator Positioning Control CLE Channel Limited Channel Pod control mode CASC Cascade Control Mode Cmd Command Ctrl Control key ESC Escape key HPS Hydraulic Power Supply HSM Hydraulic Service Manifold or actuator man
69. increase the scroll range unless the maximum adjustment proves to be inadequate Increasing the scroll range reduces the resolution of the adjustment TestStar Reference Manual 169 Adjust Menu Adjust Compensators Adjust Compensators This window lets you adjust the peak valley and PAC phase and amplitude compensation functions Each selection displays the appropriate adjustments at the bottom of the window The Adjust Compensators window provides adjustments for the peak valley compensator and phase amplitude compensator PAC The compensators are methods that ensure the command end levels are reached Control Channel Selection 4 m Control Channel 1 x Convergence Rate 1 00000 LS a A Compensator Selection 4 Ra Peak Valley EA Compensator Adjustments Limit 100 000 as A CONTROL FUNCTION Control Channel Selection Selects the control channel for compensation adjustment Compensator Selection Selects the type of compensation method to be adjusted None disables compensation Peak Valley provides amplitude mean control PAC provide phase and amplitude control It must be enabled with the Edit Control Channels window before it is listed here Convergence Rate Sets how quickly the differences between the command and sensor feedback are reduced Limit Limits the maximum amount of PAC compensation The peak valley compensator has a fi
70. is not connected 25 buf out of buffer data 26 buf couldn t find class from object id 27 buf specified event is not defined 28 cis internal error unpacking parameters 29 cis selector not implemented 30 cis received selector for wrong class TestStar Reference Manual Firmware Error Codes ERROR No TYPE DESCRIPTION 31 cis index id out of range 32 cmd error packing interpreted command 33 cmd timeout object not created 34 cmd object responded with incorrect class 35 cmd rtr config error wrong oid responded 36 cmd invalid parameter 37 cmd object already exists 38 cmd not enough parameters supplied 39 cmd BYTE parameter out of range 40 cmd error converting BYTE parameter 41 cmd error converting INT16 parameter 42 cmd error converting INT32 parameter 43 cmd error converting INT64 parameter 44 cmd too many parameters supplied 45 cmd error converting REAL32 parameter 46 cmd error converting REAL64 parameter 47 cmd error in selector syntax 48 cmd error in name syntax 49 cmd selector for class not found 50 cmd object does not exist 51 cmd selector out of range 52 cmd selector not implemented 53 cmd coding error vector parameter must be alone 54 cmd received selector for wrong class 55 dio internal error unpacking parameters 56 dio parameter out of range 57 dio selector not implemented 58 dio received selector for wrong class 59 dio rec
71. is potentially dangerous It is very important that you remain aware of hazards that apply to a test system Contents How to Use This Manual 34 Window Controls 37 Abbreviations 45 Introducing the TestStar Software 46 Starting TestStar 48 Main TestStar Window 49 Using TestStar Configuration Files 50 Using the Fault Status Window 52 Clearing a Detector 54 Clearing an Interlock 56 vononposuy Using On line Help 59 Using the Load Unit Control Panel 61 Main Module Controls and Indicators 62 Control Channel Modules 66 TestStar Reference Manual 33 Introduction How to Use This Manual How to Use This Manual If you intend to read this manual from beginning to end you will discover that it is really a sleeping aid But if you want to find a specific piece of information you will find that it is more than adequate As you have probably noticed the chapters are arranged by the TestStar menus and the support programs Each chapter is organized according to a menu selection Many of the TestStar windows change according to your selections each window variation is documented For example when you select a Mode Type in the Edit Control Channels window new controls are added to the bottom of the window The controls to define the different types of control modes the Mode Type selections differ from each other Types Of The information in this manual can include any combination of the wormatonr Pe meron shown
72. level Sets the end level for the ramp The units of the control mode are assumed Using ramp actions 128 You really need to know how the test behaves when using a ramp action Be sure to set up a detector appropriate for your test For example assume the test is designed to break the specimen and a detector is set to sense the break A ramp could be designed to move the actuator back to a specimen installation position for the next test However if the detector activates before the specimen breaks the system would stop the test program and ramp the actuator to a predefined position This could pull the specimen apart or possibly damage equipment TestStar Reference Manual Load Path Stiffness Load Path Stiffness ies a j 0 mk 5 The load path stiffness set compensates for the amount of deflection in the load path This includes the grips extensions load cell and load frame All of these components act together along with the specimen as the load path Note Load path stiffness sets are created with the Load Path Stiffness Editor The Load Path Stiffness Editor is described in Appendix F Load path stiffness is only needed when running any 790 3x TestWare processes How it works The load path stiffness parameters compensate for the amount of deflection that is produced from the actuator through the grips extension rods load cell and load frame everything in the load path except the specim
73. loop PIDF represents proportional integral derivative and feed forward gain adjustments These adjustments are also called gain reset rate and feed forward respectively Control Channel Selection Selecting the PIDF Mode Type displays this window configuration Control Mode Selection Sp Control Mode Definition Mode Name Mode Type Mode Label PIDF Mode Definition Command Source segment generator pod external Feedback External Source slot 7 14 PARAMETER FUNCTION Command Source Selects the source of the command signal The selections are e Segment Generator e Pod e External Feedback Selects an input signal as the source of feedback for the control mode External Source Specifies the location of the external command source if external is the selected command source 118 TestStar Reference Manual Control Modes Command source The command for a PIDF control mode can come from one of three sources Segment generator The source is from TestStar Function Generator or TestWare application ies a j 0 5 Pod The command source is from the Actuator Positioning Control APC on the load unit control panel External The command source is from an external device connected to the rear panel of the digital controller This selection is available only if you select a feedback i
74. mk The order of items in the Selected Windows column represents the order that they will be seen in the toolbar from left to right Items in the Selected Windows column can be returned to the Available Windows column by selecting them and pressing the left arrow button A Configure Toolb Available Windows Selected Windows The toolbar can have any combination of the window buttons Open Settings File A Save Settings File Edit Meters Edit Scope Display Input Signals Display Detector Actions Display Meters Display Scope Fault Status TestStar Performance Rate a Settings Print Preview Edit Input Signals Edit Output Signals Edit Control Channels Edit Calculation Constants Edit Detector Actions Edit LUCP Display Edit Meters Contro In this case the standard configuration is shown HPS Pressure Off Control Channel 1 Hydraulics Off Current Mode Undefined APC State Off Next APC Mode Undefined Program State Stop TestStar Reference Manual 135 Edit Menu Meters Meters Define up to four meters A meter must be enabled to display it from the Display menu Types of meters This waveform shows the type of data that can be displayed The peak
75. name you type into the Program title entry field is the how the application is listed in the main System Administration window The Program file name is the complete path for the application EXE file Use the following form to type the program file name where filename is the name of application file and EXE is the extension C TS2 filenmame EXE For example select the TestWare SX application and press the Edit button Notice that the Program tile is TestWare SX and the Program file name is C TS2 TWSX EXE Press the Cancel button to return to the main window After you add or edit an application you select which users can run the application TestStar Reference Manual System Administration Window Nn e n mee S User Access Window a z j j 0 This window shows the DP name of the application name of application S and all the user names e A E jo P jam Use this window to select list of user names the users can access the application d OK Cancel Help Using the window select highlight each user name you want to have access to the application then press the OK button TestStar Reference Manual 239 S jo a g N o E g lt eD Nn a N Creating a New User Creating a New User This procedure describes how to define user names their passwords and what TestStar programs the user name can
76. need to run the same test or a similar test The configuration file is saved with a TCC extension that represents TestStar controller configuration Throughout this manual a TestStar controller configuration file is simply called a configuration file The configuration file contains the settings for all the window parameters entered with the Edit Adjust and Display menus even the window positions are recorded The configuration file allows you to open TestStar with a set of predefined test parameters A configuration file is loaded when you log into TestStar this ensures that the servo loop has known parameters assigned You can also open and change the configuration file after you ve logged into TestStar This allows you to recall a file with predefined parameter settings so you don t have to enter them again TestStar Reference Manual Using TestStar Configuration Files The advantage of Although the flexibility of TestStar permits setting up a wide variety of c onfigu ration files a many users need to pesien repetitive ung of asia specimens or else have tests performed by persons relatively inexperienced in materials testing In either event these files permit you to store almost all of a specific test s parameters for recall later In addition having a configuration file open when you start TestStar ensures that the servo control loop has known parameters assigned Define a file for Fach type of test you use s
77. only the files with the TCC extension in the Files list Directories Lists the available directories for the selected drive Double clicking a different directory displays the files of the directory in the Files list and any other directories in the Directories list Drive Displays the current drive All root directories of the drive are listed in the Directories ist Network Pressing the Network button displays the Connect Network Drive window Windows NT only where you can define new network drives and paths 72 TestStar Reference Manual Open Window Using the window Be sure you know where you saved your configuration files The default path for this window is C TS2 config Note We recommend that you have a configuration file for each type test you perform Each user can have a configuration file automatically open when they log into TestStar and they can change it once they are logged in 1 Use the list icon for the Drive field to select the drive where your configuration files are located In this case the C drive should be displayed 2 Double click the desired directory in the Directory list this causes all its files to be displayed in the Files list and it also displays any additional directories In this case the Config directory in the TS2 directory should be displayed 3 Select the TestStar configuration file you want to open from the File list The selection will be displayed in the Open fi
78. or Applications Configures the window to define users or applications list of users or applications After adding a new user you After adding a new application Displays a window where you select which applications the you select which users can can change the information user can access access the application entered with the New User or New Application windows Press the Add button to define a new user or application Select a user name or application title before pressing the Edit button to change user or application definition 234 TestStar Reference Manual System Administration Window New Edit User Window iS lt Nn ak 5 gt ou z jam ji o Nn 2y a pi 0 jo The New User and Edit User windows are the Username required entry same Password required entry Use this window to define Last name a new user or edit an ae Middle initial existing user First name Pela H a Configuration none or C TS2 Config finename TCC isplays the ication play pp j i x created with the Unit Assignment Set Editor Access window Unit Assignment Add Cancel Help CONTROL FUNCTION Username The Username represents an individual s access to selected TestStar applications Each individual must enter a Username when logging onto TestSta
79. pane cannot be seen unless it is enabled TestStar Reference Manual 131 Edit Menu LUCP Display Standard items The following items are standard in the LUCP Display window The Input Signal Header displays Sensors and Current Value above a list of input signals The Control Channel Header displays Controllers Current Mode and LUCP Mode above a list of control channels Five blank lines can be used to separate items in the LUCP display Using the window Select items one at a time in the Available Items column and use the right arrow button to move it to the Selected Items column More than one item can be selected and moved at a time The order of items in the Selected Items column represents the order in which they will be seen in the load unit control panel display Items in the Selected Items column can be returned to the Available Items column by selecting them and pressing the left arrow button Edit LUCP Display Control Channel Selection 4 Ly TestStar Panel 1 Available Items I lt Selected Items TestStar Control Blank 2 A Control Channel Header Controllers Current Mode LUCP Mode Blank 3 Axial Axial Length Control Pod Force Blank 4 Blank 1 Blank 5 Input Signal Header Current Value mpat an i 0 0009 in in nput Load Cel 0 1009 kip Hy E h j putreng Length 0 0010 in v
80. processing applied in the form of a mathematical formula A calculated input signal type uses one or more defined input signals and calculates a new signal according to a formula you create TestStar Reference Manual 85 Edit Menu Input Signals Signal connection All sensor signals are input to a rear panel connector Each input signal is assigned a slot Sensor calibration Detailed calibration procedures 86 Knowing where the signal is connected to the digital controller you can determine the slot location number that is assigned to the sensor input External Sensors J63 and J64 optional J77 J78 J42 Internal Sensors J1 J14 Slots 1 through 14 correspond with connectors J1 J14 when using internal sensor signals C Jo J00 Connectors J77 and J78 correspond with slots 13 and 14 Expanded Inputs 1 16 correspond with the external inputs at J63 and J64 see Extended Analog I O in Chapter 2 of the Installation manual You have access only to calibrated sensors that are included in your data base There are two ways to add a sensor to your data base Using the sensor calibration program to calibrate a sensor Loading calibration data from a disk this could be from a sensor calibrated at MTS or from your archives The sensor calibration program creates a data base record for each sensor that is calibra
81. signal Y can be any input signal including calculated inputs or variable constant X can be 1 to 100 This cannot be used with other functions constants Constants should be defined with the Edit Calculation Constants window A constant is always entered with curly braces constant name cos x Returns the cosine of x x is in radians Domain 12868 0 12868 0 Range 1 0 1 0 exp x Returns ex Domain 88 72 Range 0 0 In x Returns the natural log In x Domain 0 0 3 438 Range 103 28 88 72 log x Returns log10 x Domain 0 0 3 488 Range 44 85 38 53 power x y Returns xy Domain x gt 0 0 yl 2 Range 2 prev x A special function that returns the input x input signal and stores the last 100 samples of that signal in a circular buffer The stored samples may be accessed in an indexed mode using braces x where x is the sample to be indexed This cannot be used with other functions Input Signal Name The signal name defined in the Input Signals Definition window A signal name is always entered with curly braces signal name round x Rounds off the value of x sin x Returns the sine of x x is in radians Domain 12868 0 12868 0 Range 1 0 1 0 tan x Returns the tangent of x x is in radians Domain 6434 0 6434 0 Range time Increments at the servo loop update rate Time is always entered with curly braces time The clock is reset when the Function G
82. signal must change to detect a peak or valley Setting the Sensitivity too high may cause low amplitude signal changes to be missed Setting the Sensitivity too low may cause signal noise to be recognized as a peak valley value This waveform shows the Peak peak and valley for each cycle not detected K iuiu this much Sensitivity 1 change Valley TestStar Reference Manual 139 Edit Menu Meters Select an input signal that you want monitor span and mean levels Select the units for the data and set the sensitivity This waveform shows the span and mean of each cycle 140 Bol Span Mean Data A span mean meter displays the amplitude and mean level values of an input signal during each cycle of a dynamic test Meter Selection J i Meter Definition Type Display Span Mean Definition Signal input signals valve signal Sensitivity gt zero units The span value is the peak to valley amplitude of a cycle The mean level is the midpoint of a cycle The sensitivity setting is the amount the signal must change to detect a peak or valley Setting the Sensitivity too high may cause low amplitude signal changes to be missed Setting the Sensitivity too low may cause signal noise to be recognized as a peak valley value Sensitivity a lt BA not detected Pe Mean TestStar Reference Manual
83. the Set Scroll Range window to see how to scale an axis Scaling the axis 198 Display Scope This window displays a graphic representation of up to two input signals Each signal can be displayed with different colors You can change the size of the window and the graph automatically sizes proportionately You must define the scope with the Edit Scope window before you can use this window This menu allows you to print the scope display and customize the appearance of the display This menu starts stops and resets all of the meters The tool bar buttons allow quick access to the scope features Double click any scroll bar to display the Set Scroll Range window where you can precisely scale the axis 2 0000 HE Drag the scale buttons to size the slider box and scale the graph The slider box in each scroll bar has an extra set of buttons These buttons can change the display range of the scope axis For example drag the upper button towards the center of the scroll bar This reduces the size of the slide box and reduces the maximum value of the axis TestStar Reference Manual Display Scope Tool bar Displays the Edit Scope window Press a button once to ay F Olja Prints the current Scope disp
84. the control mode you intend to tune Go to Monitoring a Waveform for help Balance the servovalve The electrical valve balance adjustment compensates for minor mechanical imbalance it s an intermediate adjustment Go to About the Servovalve and perform the electrical valve balance adjustment procedure Calibrate each sensor used for a control mode or data acquisition Go to the Installation manual and perform the appropriate calibration procedure Note MTS Systems Corp installs each TestStar system with an initial tuning setup We also provide sensor calibration files on disk if you purchase sensor from us If your system doesn t have a calibrated sensor or an initial tune contact MTS Systems for assistance If your sensor calibration schedule doesn t require calibration at this time perform a shunt calibration check to determine if your sensor dc conditioner is within tolerance If you have a three stage Series 256 or 257 servovalve tune the inner loop gain and rate before tuning the outer loop The rules for inner loop tuning are similar to those of the outer loop Go to Appendix B in the Installation manual for help TestStar Reference Manual 263 Tuning About Tuning Optimizing tuning A CAUTION 264 Optimal system operation may require a level of detuning to compensate for specimen changes during a test A precisely tuned system provides the greatest level of response but this places th
85. to dismiss the window without using the tuning values Use the File menu to select Save This adds the tuning values to the current TestStar configuration file 284 TestStar Reference Manual Auto tuning Auto Tuning Additional Control Modes Once you ve tuned a displacement control mode you can proceed to tune force or any other PIDF control mode Note Non linear specimens may produce invalid gains and should be rough tuned manually so you have an idea if the final tuning values are appropriate For example tuning a force control mode needs a tuned displacement control mode as the auto tuning control mode This allows the system to reliably control the actuator using the displacement control mode while monitoring the force sensor Monitoring the force sensor data ensures the specified end levels are achieved Step 1 Getting things ready TestStar Reference Manual This step prepares your system for auto tuning When tuning additional control modes you need to know what range is selected for the input signal of the control mode A If you want to auto tune a control mode that requires a specimen to be installed you may want to install it now You will be prompted to do it later Use a specimen that has characteristics similar to the specimen to be tested Use the length control mode to install the specimen since it should already be tuned B Use the Edit menu to select Control Channels Check that the Auto tuning Co
86. transition to begin here Pressing the Frequency button allows you to change the range of the control the default setting is 10 Hz by entering a different maximum frequency for the control Status The Status display shows the current count total count and test control status The counter display updates each time the program command definition completes one cycle When the current count equals the preset count the current count automatically resets to zero To reset the total count enter zero in the Count Menu Options window The test control status displays the following STATUS CONDITION Ramping While the program ramps to the mean level Running While the program is working Holding After pressing the Hold button Stopping After pressing the Stop button and while the program ramps to the mean level Stopped After pressing the Stop button and after the program reaches the mean level or after the Home ramp is complete Homing While the program ramps to the home level i g o eD D 0 a 210 TestStar Reference Manual Function Generator Window Set Mean Scroll Range Setting the scroll range of the Mean adjustment ensures the control is within a safe range Reducing the scroll range also increases the resolution of the control adjustment The Set Scroll Range Mean window changes the range of the Mean adjustment Max unis Min un
87. tuning utilizes the full range of the input signal i e full range of motion for a displacement control mode or full system capacity for a force control mode The first auto tuned control mode is automatically selected to replace the undefined Auto tuning Control Mode in the Edit Control Channels window Auto tuning begins by moving the actuator using the auto tuning control mode While the actuator is moving the feedback for the control mode being tuned is monitored to determine the response of the control mode Once the feedback is evaluated tuning parameters are calculated The tuning values are displayed in the Accepting New Gains window You may want to setup a cyclic test using an amplitude and frequency that is found in your test Enable a compensator such as amplitude control Set up a TestStar meter and monitor the peaks and valleys If the peaks and valleys of the cyclic command are being achieved the tuning is adequate If the peaks and valleys of the cyclic command are not being realized go to the manual tuning procedure at the end of this chapter to achieve a higher level of tuning higher response 281 Tuning Auto tuning 282 Error messages The following are possible error messages related to auto tuning The range between end levels is too small Signal noise may be too large to use the selected end levels Setup a min max meter and monitor the feedback while in the hold state Note the differ
88. underpeak minimum error and maximum error detector action selections You can change any action For example assume you had set the underpeak detector action to Interlock and that it is tripping too often You may want to change the detector action to indicate so you can determine what is causing the underpeak detector problem TestStar Reference Manual Display Detector Actions Actions An action determines what happens when the associated limit level is crossed The following are the actions you can use Disabled turns the detector off Indicate displays a message in the Fault Status window that the detector has been triggered Hydraulics Off turns off the hydraulic pressure at the service manifold displays a message in the Fault Status window and lights the Aux indicator on the LUCP Interlock turns off the hydraulic pressure generates an interlock signal clamps the servovalve and displays a message in the Fault Status window You must correct the reason for the interlock and use the Reset button located on the load unit control panel to clear the interlock Customer defined these actions can be defined to ramp or hold the control channel output These actions may also be identified with a customer defined name or as Action 5 10 TestStar Reference Manual nua Avyjdsiq 195 Display Menu Display Meters a0 Display Meters Prer equisite You must define and enable
89. update rate can be servo loop The following slow down the servo loop update rate update rate Each control channel reduces the servo loop update rate The software installation program specifies the number of control channels available For example assume you have a biaxial system and are running a single axis test Since have no need for the extra control channel select none for the Drive Type in the Edit Control Channels table Each calculated input signal reduces the servo loop update rate The complexity of the calculation determines how much the input signal reduces the update rate The type of processor module installed in TestStar can affect the servo loop update rate The new T805 processor increases the servo loop update rate You have the T805 processor if the calculated input signals can be selected in the Edit Input Signals window Some TestWare applications have features that slow down the servo loop update rate See the appropriate product manual computer The following don t affect the servo loop update rate but do slow processing down the processing rate of the computer This affects the rate communications with the digital controller and slows the data exchange rate between the digital controller and the computer Each digital scope requires processing time Each meter requires processing time Disable any meter that is not needed Edit Meter window The display of the load unit control panel
90. uses processing time This can be disabled in the Debug Options window Using the message log feature in the Debug Options window slows down the computer communications gt lt TO eD er lt 310 TestStar Reference Manual Appendix D Debug Options Debug Options Accessing the window rs Error codes TestStar Reference Manual If you encounter a problem you can view the activity between the computer and the digital controller You can also record the activity to a file This file can be used by MTS to evaluate the communication between your computer and digital controller Access to the Debug window is accomplished with the TestStar toolbar or a hotkey combination Go to the Edit Toolbar window if you want to access this window with a toolbar button Press cntl d The computer translates your selections in the TestStar windows and sends messages to the TestStar digital controller The messages configure the digital controller to act on your selections The digital controller in turn sends messages to the computer which performs tasks like updating values showing the results of a selection etc For example assume you are setting up the command in the Function Generator and you forget to enter the initial ramp rate When you try to close the window a dialog box displays the message Initial ramp rate is out of range Valid range 0 lt value What is happening is for
91. valley and span mean modes update data each cycle The max min maximum and minimum data mode monitors the entire waveform The timed data mode displays a signal value every second 136 lt 4 Edit Types of meters e Timed Meter Selection E F Meter 1 4 e Span Mean Meter Definition A meter is a digital display on the computer screen that shows test related signals Peak Valley Max Min Type Display disabled enabled 100 4 Peak Each type of meter defines what information is displayed for a given input signal Maximum 0 Valley Span Mean Minimum c 100 lt _titititiilttity Timed Data TestStar Reference Manual Meter Definition Window Prerequisite Use this window to define a data display Each Type selection adds appropriate controls to the bottom of the window Meters You must have input signals defined before you can define a meter ies ou j 0 5 Meter Selection la Ly Meter 1 4 Meter Definition Type Display disabled enabled CONTROL FUNCTION Meter Selection Type Selects one of the four meters you want to define Selects the type of data you want to display The selections are Timed Peak Valley Span Mean Running Max Min Display Enables or dis
92. window Channel window SNA sensor f eima feedback p gt Length gt OR 5 cm servovalve control assign slot and units assign range and polarity The sensors available match the Dimension selection If you do not see the sensor you are looking for check the Dimension selection in the Edit Input Signals window See the Assign Sensor window description for more information Assign Sensor list of calibrated sensors Cancel Calibration Info Use this window if you have not defined an external signal with the Sensor Calibration program The information in this window is saved with the TestStar configuration file See the Define External Sensor window description for more information 4 Define External Sensor Sensor Name Sensor Range 1 00000 units Offset 0 000000 v m Inverted TestStar Reference Manual Calculation Signal Types When you select the Calculation signal type you will see this window configuration Use the calculation area to express a formula A calculation always starts with the equal symbol Use the algebraic rules that you learned in school so long ago Also use only SI units A WARNING TestStar Reference Manual Input Signals When you select the calculation signal type you assign a formula to one or more input signals to create a un
93. window concentrates information from each of the Adjust Input Signals windows into a single window You must define the input signals with the Edit Input Signals window before you can use the Display Input Signals window Signal Load 0 000000 0 000000 Calculated 1 0 000000 External Length 0 000000 SELECTION FUNCTION Signal Lists the names of the input signals The signal names are assigned in the Edit Input Signals window Pressing a signal button displays the Adjust Input Signals window where you can adjust the test parameters of the input signal Current Output Displays the current output of the input signal Sensor Zero Allows you to zero the sensor output when the button is present and enabled This control is enabled or disabled in the Adjust Input Signals window Range Selects the range of the input signal Choose the range with the highest resolution for the test the range that is closest to but greater than the maximum expected output for the test 190 TestStar Reference Manual Signal Zero IVDT sensor Force sensor Extensometer TestStar Reference Manual Display Input Signals All signals defined with the Edit Input Signals window are listed at the left of the window Some types of signals do not have all the display functions available Calculated input signals cannot be zeroed because they are created using one or
94. you reproduce the problem Were any hardware changes made to the application or system operating software before the problem started Have the following information available If relevant print outs of configuration files and test procedures The type or model number of your test frame load unit etc 27 Preface How to Obtain Technical Assistance The type of model number of your controller Model number and size of your hydraulic service manifold Serial number of any suspect component If you are experiencing a computer problem please have the following information available Manufacturer s name Manufacturer s model number Type of system memory Amount of system memory Floppy drive information model number size and capacity Hard drive information model number size and capacity Manufacturer of printer plotter and model number Mouse information bus serial connected to what port Graphics board information manufacturer and model What other boards are installed in the computer Is the system part of a network If you are experiencing a software problem please have the following information available 28 Operating software information What type of operational software are you running What version level of operating system is running What window type is used Application software information What applications are you running Mu
95. 00000 units J 7 Stroke 0 000000 units 1 Some types of input Calculated 1 0 000000 units signals do not have Zero or Range controls External Length 0 000000 units v Kim Li D or an l etectors Limits Control Channel Underpeak Minimum Error Maximum Error axial disabled indicate interlock z e a o File Edit Adjust l Display Help torsional action 5 hydraulic off E Selecting Limits or Contol HPS Pressure off ow h Input Signals n 2 Z changes this window Control Channel 1 D j pA Detector Actions Hydraulics off low h aa Detectors Limits Control eter APC State off on definea 5 Signal Upper Limit Lower Limit Scope sage load value disabled x value action 5 El units stroke value indicate x value action 6 El units x I I culated 1 ir x ji i 7 5 calculate value interlock x value action 7 El units external Length value hydraulic off _ value action 8 E units x Km 5 Display Scope File Controls 0 00 v x gt 0 25 0 50 0 0000 1 0000 Time Sec 0 5000 1 5000 i Se i Displays 1 to 4 meters horizontally vertically or in a box like this J stroke stroke 0 000000 in Span 0 000000 in load 0 000000 kip Mean 0 000000 in stroke Control Channel 1 Valve
96. 086 MTSERR_CANNOT_OPEN_LOG 1087 MTSERR_NO_POD 1088 MTSERR_CANNOT_CONNECT_MQ_TO_OM 1089 MTSERR_CANNOT_CONNECT_RO_TO_OM 1090 MTSERR_CANNOT_CONNECT_TO_ML 1091 MTSERR_NO_FW_INIT_RESP 1092 MTSERR_NO_CHAN_MAP 1093 MTSERR_TOO_MANY_SEGMENTS 1094 MTSERR_SGC_SYNCHED_ALREADY 1095 MTSERR_INTERNAL_BAD_SGC_POS 1096 MTSERR_TOO_MANY_UPK gt 1097 MTSERR_ILLEGAL_UPK 1098 MTSERR_SGC_NO_SKIP S 1099 MTSERR_CONNECTION_BROKEN 2 gt lt TestStar Reference Manual 305 Digital Controller Error Codes ERROR No MESSAGE 1100 TSERR_INTERNAL_PIPE_ERROR 1101 TSERR_ZERO_RATE 1102 MTSERR_BAD_MESS_TAG 1103 MTSERR_COMMAND_FOR_MASTER_ONLY 1104 MTSERR_NO_PANE_AVAILABLE 1105 TSERR_INCORRECT_BUF_TYPE 1106 TSERR_INTERNAL_NO_BUFOBJ 1107 TSERR_CHAN_ALREADY_CONNECTED 1108 MTSERR_INVALID_PANELID 1109 MTSERR_INVALID_RANGE 1110 MTSERR_PRINTER_ERROR 1111 MTSERR_FILE_LOPEN_ERROR 1112 TSERR_FILE_WRITE_ERROR 1113 TSERR_FILE_READ_ERROR 1114 MTSERR_PROF_READ_ERROR 1115 MTSERR_TC_NOT_ENABLED 1116 MTSERR_TC_READ_WRITE 1117 TSERR_TC_TEMP_RANGE 1118 TSERR_TC_PORT_ERROR 1119 MTSERR_TC_NOT_INITIALIZED 1120 MTSERR_TC_INVALID_CHANNEL 1121 MTSERR_TC_CONV_ERROR 1122 TSERR_TC_INVALID_DEVICE 1123 MTSERR_TC_NOT_REMOTE 1124 TSERR_TC_INVALID_HANDLE 1125 MTSERR_TC_ALLOCATED 1126 MTSERR_TC_MONITO_NOT_DEFINED 1127 MTSERR_CALC_INVALID_EQUATION 1128 TSERR_CALC_NOT_DEFINED
97. 100 full scale range D Use the Adjust menu to select Tuning This displays the Adjust Tuning window TestStar Reference Manual 283 Tuning Auto tuning Step 2 Run the auto tune feature This step sets up and runs the auto tune feature Note During auto tuning the command as seen on a scope doesn t reflect A the actual command Press the Auto Tune button in the Adjust Tuning window This displays the Auto Tuning window TestStar displays two messages that remind you how auto tuning works The end levels are automatically set to the 100 full scale range of the displacement control mode which is what you want for this control mode Press the Run Auto tuning button The actuator will attempt to move through its full scale displacement It takes about 1 2 minutes for auto tuning to move through its full range of movement Note Ifthe actuator doesn t move for more than two minutes press the While the auto tuning feature works the Running Auto Tuning window is shown Use the Stop Auto tuning button to stop the process at any time Stop Auto Tuning button It is possible that the valve balance may need adjustment Running Auto Tuning Auto Tuning is being performed Please Wait Stop Auto Tuning Step 3 Save the settings A When tuning is complete the Accept New Gains window appears Press the Accept Gains button to use the tuning values Otherwise select cancel
98. 190 Sgc mode error command source must be SG 191 Sgc range error for adScale 192 Sgc must use extScale for Ext cmd source 193 Sgc Cle command source must be Pod 194 Sgc error getting event selector from dstOid 195 Sgc must resetErrCheck before start 196 Sgc 2 lt aux size lt 1025 197 Sgc 0 lt ampl convergernce rate lt 1 198 Sgc number of arb segments must be gt 0 199 Sgc invalid command out path 200 Sgc sac is being reset 201 Sgc sac pos must be gt 0 and lt SacSize 202 Sgc invalid control channel limits hi lo 203 Sgc SAC table overrun 204 Sgc cle low limit gt high limit 205 Sgc locked by action event must resetErrCheck LOCATION value defined 206 206 Sgc next mode has control channel fault 207 Sgc control channel not enabled 208 smp received selector for wrong class 209 smp selector not implemented 210 smp internal error unpacking parameters 211 smp parameter out of range 212 smp channel sample product exceeds 63 213 smp couldn t find class from object id 214 smp specified event is not defined 215 smp channel list overrun 216 smp can t reset while running TestStar Reference Manual Digital Controller Error Codes Appendix B Digital Controller Error Codes Following is a list of messages associated with the numbers that are returned when a digital controller error occurs ERROR No
99. 4 mm and a limit setting of 2 The maximum boost the compensator can produce is 8 mm Use the following as a guideline to set the Limit adjustment 1 Set up a test that runs your system at the maximum command and frequency expected during the test 2 Monitor the feedback for the control mode 3 Start the Limit at 10 Increase the Limit until the feedback equals the test command Increase the setting another 20 to provide an operating margin Note Ideally adjust the Limit to the smallest value that allows you to reach your command end levels This insures stability and allows you to detect changes in your system 6 ios lt Required Command 5 lt Limit Reached 4 3 Test Command 2 1 mm 0 ao a Initial Feedback Pressing any of the adjustment buttons displays the Set Scroll Range window where you can change the adjustment range of the slider box Each adjustment can have a different range 173 nus isn py Adjust Menu Error Detectors Error Detectors A WARNING Prerequisites Use this window to set up to two error detectors for each PIDF control mode Each error detector monitors the level of error between the test command and the sensor feedback signal for the associated control mode The HPS can cause unexpected actuator movement in systems where TestStar does not control the HPS Be sure to use the error detector as an interlock if hydraulic pressure is los
100. 63 HPS Switches 63 Hydraulic systems 180 Hydraulic HPS pressure control 63 service manifold control 66 Input signals 148 ac conditioner 90 acceleration compensation 155 adjusting 149 assigning 96 calculated signals 93 calibration 86 conditioners 90 connection 86 current output 190 de conditioner 90 defining external 97 display 190 display limitations 191 label 89 naming 89 range 192 ranges 154 sensor cartridge 87 sensor signals 88 sensor zero 152 shunt cal 157 signal definition 88 type of sensors 85 upper and lower limits 151 what you need to know 148 zero 191 Interlock actions 176 Actions 179 causes 57 correcting 56 58 Emergency Stop 62 326 fault status window 52 56 indicators 56 63 overview 53 possible causes 56 resetting 52 58 table 57 types 57 Interlock Reset switch 63 Internet address 26 K Keyboard shortcuts 37 debug options 311 servo loop update rate 309 L LCD where used 64 Limit actions 53 Limit detector actions 152 195 causes 55 sensor 151 setting 151 unknown levels 151 Load path stiffness 129 Load Path Stiffness Editor 317 defining sets 319 determining a stiffness value 319 Load unit control panel 61 configurations 67 defining display 131 Emergency Stop switch 62 HSM control switches 66 modules 66 test control switches 62 Load unit control panel actuator positioning control 66 display screen 64 HPS control switches 63 interlock indicators 63 Reset s
101. A July 1992 Release 2 0A 50194 04A December 1993 Release 2 0B 50194 05A April 1994 Release 3 0A 50194 06A January 1995 Release 3 1A 50194 07A September 1995 Release 3 1A 50194 07B January 1996 Release 4 0A 50194 08A October 1996 Release 4 0C 50194 08B May 1997 Table of Contents D a ge C3 5 5 e N Preface 9 Other Manuals 10 Safety Precautions 11 General Safety Guidelines 12 Safety Guidelines to Follow While Operating the Equipment 15 Load Units and Other Crush Point Hazards 16 Avoiding Hazardous Actuator Movement 17 Guidelines For Installing Specimens 19 Checking the Hardware Setup 20 Installation and Modification Guidelines 21 Supervising the System 22 The Importance of Proper Maintenance 23 Hazard Conventions Used in This Manual 25 How to Obtain Technical Assistance 26 What to Expect When You Call 27 TestStar Reference Manual 3 Chapter 1 Introduction 33 How to Use This Manual 34 Window Controls 37 Abbreviations 45 N S o S T o o Q iS Introducing the TestStar Software 46 Starting TestStar 48 Main TestStar Window 49 Using TestStar Configuration Files 50 Using the Fault Status Window 52 Clearing a Detector 54 Clearing an Interlock 56 Using On line Help 59 Using the Load Unit Control Panel 61 Main Module Controls and Indicators 62 Control Channel Modules 66 Chapter 2 File Menu 71 Open Window 72 Save Window 74 Se
102. About Control Modes PIDF control mode SG command Pod command Ext command The PID adjustments are also called gain P rate D and reset I which imply the order of their use TestStar Reference Manual A control mode uses sensor feedback and a program command to control the servovalve Each control mode has different tuning characteristics There are three types of control modes e PIDF e CLC e CASC PIDF stands for a group of gain controls proportional gain reset integration rate derivative and feed forward This is the most commonly used control mode The command source comes from a segment generator i e function generator TestWare application and used for specimen testing The command source comes from the Actuator Positioning Control on the load unit control panel and is also used for specimen installation A Pod command source operates fine if you use 50 100 of the proportional gain setting of a tuned PIDF SG control mode The command source comes from a segment generator from an external device G e a profiler function generator and is used for specimen testing See Chapter 10 in the Installation manual F 0 1 gt Feed Forward d Gain dt EE 10 0 gt Proportional Program gt 2 Gain gt S SUR C
103. Drive 256 257 184 Adjust Input Signals 149 Adjust Tuning CASC 167 CLC 164 PIDF 161 Adjust Underpeak Detectors 177 Application Access 237 Assign Sensor 90 92 96 Calculation Constants 122 Command Menu Options 214 Configure Toolbar 134 330 Count Menu Option 220 Debug Options 312 Define External Sensor 92 Display Detector Actions 193 Display Input Signals 190 Display Meter 196 Display Scope 198 Edit Application 238 Edit Control Channels 112 Cascade 121 CLC 120 PIDF 118 Edit Detector Actions 126 hold actions 127 ramp actions 128 Edit Input Signals 88 ac dc conditioner 90 calculated 93 Edit Load Path Stiffness 130 Edit LUCP Display 131 Edit Meters 137 max min 141 span mean 140 timed 138 139 Edit Output Signals 101 analog bus 103 programmable 109 readout 105 Edit Scop 142 Edit User 235 Fault Status 52 125 fault status 52 Font Fonts 76 Function Generator 206 Home Menu Option 222 Load Path Stiffness Editor 317 Login 48 New Application 238 New User 235 Open configuration 72 performance rate 309 Print Preview Printing configuration file Configuration file preview Configuration file ASCII 77 Save configuration 74 Scope Display Options 201 Select Output Log File 313 Set Amplitude Scroll Range 212 Set Frequency Scroll Range 213 Set Mean Scroll Range 211 Set Scope Axis Scroll Range 200 TestStar Reference Manual Set Scroll Range 169 Set Zero Scroll Range 156 Shunt Cal 157 System Administration 233 Te
104. Enable a selection i by clicking the selection name or the function associated radio button disable the Selected selection by clicking a different selection name or its associated radio Not Selected button D Not Selected Using the keyboard Use the Tab key to highlight a selection Use the space bar to enable the selection Disable the selection by enabling a different selection A check box is a small box next to an item that can be selected A function name accompanies the selections you can enable You can enable one or more of the selections A selection is enabled when the check box has an V or X in it Using the mouse Enable a selection by clicking the selection name or its function associated check box an appears in S elected the check box Disable the selection w by clicking the selection name or its Selected associated check box and the X J Not Selected disappears from the check box Using the keyboard Use the Tab key to highlight a selection Press the space bar to enable the selection Press the space bar again to disable the selection TestStar Reference Manual Scroll bar Vertical Horizontal TestStar Reference Manual How to Use This Manual TestStar uses two types of scroll bars horizontal scroll bars and vertical scroll bars Each scroll bar includes a slider box and arrow icons to control scrolling The slider box and arrow icons are grayed out if all infor
105. Fault Status Window Upper and The sensor feedback became less than the lower limit setting or more lower limits than the upper limit setting the characteristics of the specimen are changing the specimen is broken the limit values are incorrect for the test Underpeak The sensor selected for the underpeak detector failed to reach the minimum or maximum setting The characteristics of the specimen are changing or the underpeak values are incorrect for the test the characteristics of the specimen are changing the underpeak values are incorrect for the test Error detectors The difference between the test command and sensor feedback signals exceeded the error 1 or error 2 setting the characteristics of the specimen are changing the specimen is broken the error values are incorrect for the test 5 ro a cS Q j 0 5 TestStar Reference Manual 55 Using the Fault Status Window Clearing an Interlock Procedure 1 Determine the type of interlock 56 Determine the cause of the interlock 57 Correct the cause of the interlock 58 gt w N Clear the interlock 58 Step 1 Determine the type of interlock When an interlock occurs the Fault Detector window becomes active The first cause of an interlock is shown in the 4 Fault Status Window Fault Detectors window Detector Faults Generated input signal name upper limit detector Sometimes one int
106. In fact most testing can be accomplished with just the proportional gain adjustment The other adjustments introduce a signal to the command to compensate for specific situations Note Throughout this chapter the terms gain rate and reset represent proportional gain rate derivative and reset integration respectively It is possible and probable on a new system that the amount of adjustment for a control is inadequate If you reach the maximum adjustment value press the adjustment button such as P and use the Set Scroll Range window to change the range of the adjustment Proportional gain is used for all tuning situations It introduces a control factor that is proportional to the error signal Tuning proportional gain Higher gain settings increase the speed of the system response When monitoring the error signal increases in gain reduce the maximum amplitude of the error signal Too much proportional gain can cause high frequency oscillation The rule of thumb is adjust gain as high as it will go without going unstable VK Gain Too Low Optimum Gain Gain Too High TestStar Reference Manual About Tuning Rate derivative D Rate is used with dynamic test programs Rate introduces a derivative of the feedback signal This means it anticipates the rate of change of the feedback and slows the system response at high rates of change Overshoot Needs Rate Adjusting rate reduces ringi
107. Mean button and entering different minimum and maximum settings for the control TestStar Reference Manual Amplitude For example assume you want to run a sine wave between 1 cmand 1 cm Set the amplitude to 2 cm The amplitude changes when the current cycle reaches an end level TestStar Reference Manual Function Generator Window The Amplitude control establishes the peak to peak span of the command The amplitude value uses the units selected in the command definition You can adjust the Amplitude control within the span of the selected range a 0 Amplitude 2 PE Y You can adjust the amplitude level while the program is running Changing the amplitude while the current output is here y gt A aO oa T 7 A y New causes the transition to begin here Pressing the Amplitude button allows you to change the range of the control by entering a different maximum value for the control 209 EF a ie e p 0 5 ap Oo 5 a Function Generator Window Fr equency The Frequency control sets the number of waveshape cycles per second The frequency value is expressed in hertz You can adjust the Frequency control between 0 01 and 300 Hz You can change the frequency while the program is running Changing the frequency while The frequency changes the current output is here when the current cycle y reaches an end level causes the
108. Mode The Cascaded control mode is used for specimen testing that requires a high degree of stability such as dynamic load applications Use the cascaded control mode for special dynamic testing ies ou j 0 5 Control Channel Selection Selecting the CASC Mode Type displays this window configuration Control Mode Selection E Control Mode Definition kg a E hd Mode Name Mode Type X Mode Label x CASS Mode Definition Command Source segment generator pod external Outer Loop Feedback x Inner Loop Feedback slot 7 14 x CONTROL FUNCTION Command Source The source of the command signal can only be from a segment generator A segment generator can be the TestStar Function Generator or TestWare application Outer Loop Selects an input signal as the source of feedback for the outer loop of the control mode Inner Loop Selects an input signal as the source of feedback for the inner loop of the control mode TestStar Reference Manual 121 Edit Menu Calculation Constants Calculation Constants Use this window to assign aname and a value to a constant Use the name of the constant in the formula that defines a calculated input Calculation constants are used in calculated input signals Calculation constants are helpful when you use a constant in more than one calcu
109. PTION 157 Sgc invalid mode index 158 Sgc invalid controller type 159 Sgc invalid command index 160 Sgc invalid feedback index 161 Sgc params gt commandfeedbackcontrolintegrator 162 Sgc shapes gt O step 1 ramp 2 sin 3 aux 163 Sgc clock rate must be faster than 10 Hz 164 Sgc must be stopped for immediate call 165 Sgc message unpacking error 166 Sgc Internal Error invalid state 167 Sgc current count gt preset count 168 Sgc must be in hold state to change modes 169 Sgc selector not implemented 170 Sgc received selector for wrong class 171 Sgc Internal Error Invalid feedback mode 172 Sgc integrator states gt off 0 on 1 173 Sgc Internal Error Invalid integrator state 174 Sgc message packing error 175 Sgc error limit states gt off 0 on 1 176 Sgc last arb not fully defined 177 Sgc arb buffer overrun 178 Sgc seg buffer overrun 179 Sgc define new arb for current segment 180 Sgc aux shape table overrun 181 Sgc aux shape must start at 00 182 Sgc aux shape must end at 10 183 Sgc must be in hold state to reset aux table 184 Sgc aux shape table not filled 185 Sgc Arb queue is empty 186 Sgc no error limits in Clc control mode 187 Sgc error in event number 188 Sgc no class id for dstOid zj TestStar Reference Manual 301 gt lt TO eD er lt Firmware Error Codes 302 ERROR No TYPE DESCRIPTION 189 Sgc mux scaling error
110. Peak 0 000000 in Maximum 0 000000 v Valley 0 000000 in Minimum 0 000000 v Chapter 5 Display Menu Contents 4 TestStar File Edit HPS Pressure off low hi Input Signals Control Channel 1 7 Hydraulics off low h APC State off on Meter Use the Display menu to monitor test related signals or change detector actions Display Input Signals 190 Display Detector Actions 193 Display Meters 196 Display Scope 198 Set Scroll Range Window 200 Scope Display Options Window 201 Shows the current output of each input signal You can zero each output change the sensor range and jump to the Adjust Input Signals window een ee A EA i Display Help Shows the setting and action of each limit detector Also shows the action selections for the error and Detector Actions underpeak detectors Any detector Ping action can be changed from here Adjust Scope Displays up to 4 digital meters The meters can be arranged vertically horizontally or in a box TestStar Reference Manual Displays the digital scope that shows a graphical representation of any input signal error signal or valve signal 189 nua Avyjdsiq Display Menu Display Input Signals fs Display Input Signals Prerequisite Use this window to monitor the output of each input signal You can also zero each output or change ranges This
111. Selection Edit Output Signals a amp Signal Defi Signal Name Signal Type Output 1 6 Analog Readout Progrmmanble File TestStar HP Input Signals Output Signals Control Channels Control Modes Calculation Constants Detector Actions T Load Path Stiffness lam State offfon Edit Control Channels Control Channel Selection AA a a Control Channel 1 ie Control Channel Definition Channel Name Control Channel 1 Channel Type Controller E Channel Label Axial E Drive Type 252 Valve E Phase Amplitude PAC Disabled E Edit Adjust Display Be Available Windows Configure Toolbar Selected Windows TestStar Performance Rate Fault Status Window Open Settings File Save Settings File Settings Print Preview Edit Input Signals Edit Output Signals Edit Control Channels Edit Calculation Constants Edit Detector Actions Edit LUCP Display Edit Meters Le LUCP Display a Edit Control Modes Control Channel Selection ie Control Mode Selection a i Mode Name Mode Type Mode Label Control Mode Definition JATIINNA PIDF Mode Definitio Command Source
112. Signals Most of the signals in TestStar are converted to digital information for processing Some signals are available before they are converted The analog signals that are available are related to the plug in modules The analog bus is needed to monitor these signals Signal Definition Signal Name Signal Type 1 lt Analog Bus Device plug in modules 11 lt Signal conditioner signals valve signals I lt Connect an analog readout device such as a voltmeter or an oscilloscope to the appropriate rear panel connector Only Outputs 1 and 2 can be configured as analog outputs Monitor the analog outputs as follows Analog A Output 1 J71 Analog B Output 2 J72 103 ies ou j 0 mk 5 Edit Menu Output Signals 104 Valve signals Sensor signals These signals are associated with the 490 14 17 Valve Drive modules They are available only when a valve signal is selected for the analog bus SIGNAL DESCRIPTION Valve Current A The current of the servovalve command signal Valve Current B1 Balance A The amount of offset introduced by the valve Balance B1 balance controls Spool Positionz The inner loop LVDT feedback signal Rate2 The amount of signal applied with the Rate adjustment Error2 The difference between the command and the feedback of the current control mode
113. TestStar se os2 File Directory Program State off on g a OCA A bits OTs2 Save high Current Mode Undefined list of files ee c Configuration Select Font Next APC Mode Undefined z 5 a Print Preview lt i gt i xi gt E Font a Name Size font selection E 10 x Style Display Normal E B Printer i r Sample Emphasis Input Signal Display Section O Outline Slot 1 DO NOT use the Signal Source Slot 1 abcdABCD examples of font characters S is Settings Type AC Conditioner What you will see in this window or Calibration de 4 0000 mm to 10 000 lepends on your TestStar settings and 000 mm the Display settings for this window 10 mm Disabled ie isabled Zero Offset 0 000000 Unlock Output Signal Display Section Output 1 Type Readout Device Slot 1 y kim gt Chapter 2 File Menu The File menu provides the file management tools for the TestStar configuration files Note The windows shown in this chapter vary slightly between the OS 2 and Windows NT versions Contents Open Window 72 Save Window 74 Select Font Window 76 Print Preview Window 77 Opens a previously saved configuration file that includes the settings for all the TestStar windows menus Saves the current configuration of all the TestStar window settings
114. Username Press OK when you have completed these two entry fields Password jo ean O jm ge Ho The password is not displayed instead asterisks are used for password security The User Name opens a TestStar configuration file This file can have all TestStar controls and settings set up for a specific kind of test See Using TestStar Configuration Files in this chapter See Appendix E Bypassing the Login on page 315 for a way to bypass the login procedure 48 TestStar Reference Manual Main TestStar Window Opens a previously saved configuration file that includes the settings for all the TestStar Introducing the TestStar Software Shows the current output of each input signal Also allows signal zero and can jump to the Adjust windows Saves the current configuration of all the TestStar window settings Selects the font size and attributes of the text in the TestStar windows and displays Displays the TestStar configuration All the settings of the TestStar windows are recorded File Open Save As Exit Select Font Print Preview Input Signals window Shows the setting and action of each limit detector Also shows the action selections for the error and underpeak detectors Any detector action can be changed Display here Input Signals Detector Actions Shows any meter that is Meter
115. _FOUND 1044 MTSERR_MAX_MONITORS 1045 TSERR_MQ_PIPE_BROKEN 1046 TSERR_CREATE_MO_THREAD 1047 MTSERR_SETTING_MQ_PRIORITY 1048 MTSERR_MO_NOT_STARTED 1049 MTSERR_READING_MO 1050 TSERR_RO_NOT_STARTED 1051 MTSERR_BUFF_MONITOR_GET_BUFFER 1052 TSERR_RAW_WRITE 1053 MTSERR_SGC_ARB_SIZE 1054 MTSERR_NO_CONTROLLER_LINK 1055 MTSERR_ILLEGAL_COMMAND 1056 MTSERR_SHAPE_SIZE 1057 TSERR_SGC_BINARB_SIZE 1058 MTSERR_RAW_WRITE_RSP 1059 MTSERR_INTERNAL_ERROR 1060 MTSERR_GET_HEADER_OID_BOUNDS 1061 MTSERR_GET_OBJ_NAME_OID_BOUNDS 1062 TSERR_CM_ALLOC_OID_BOUNDS 1063 TSERR_CM_DEALLOC_OID_BOUNDS TestStar Reference Manual Digital Controller Error Codes ERROR No MESSAGE 1064 MTSERR_XPID_GET_OID_BOUNDS 1065 MTSERR_XPID_SET_USERPTR_BOUNDS 1066 MTSERR_XPID_GET_USERPTR_BOUNDS 1067 MTSERR_DUP_XPID_ALLOC_EXCEEDED 1068 MTSERR_PROCESS_LINK_FAIL 1069 MTSERR_OM_MAIN_FAIL 1070 MTSERR_DRP_INIT_FAIL 1071 MTSERR_GET_BUFFER_LINK_FAIL 1072 MTSERR_OM_WRITE_RAW_FAIL 1073 MTSERR_OMXCR_INIT_FAIL 1074 MTSERR_OMXCR_INSERT_FAIL 1075 MTSERR_ILLEGAL_XPID 1076 MTSERR_NO_INTERLOCK_OBJ 1077 MTSERR_CONNECTING_MUX_TO_POD 1078 MTSERR_XCR_BROADCAST 1079 MTSERR_INVALID_CONTROL_CHAN 1080 MTSERR_INVALID_CONTROL_MODE 1081 MTSERR_INVALID_INPUT_CHAN 1082 MTSERR_INVALID_OUTPUT_CHAN 1083 MTSERR_SGC_RESERVED 1084 MTSERR_NO_SGC_FOR_VALVE 1085 MTSERR_SGC_NO_PRIV 1
116. a displacement length control mode 2 Enter an end level of 0 zero and select the units to define the end level 3 Enter a time in seconds such as 2 seconds Pressing the Home button causes the actuator to achieve a zero displacement in 2 seconds 223 EZF a ie e j 0 5 ap Oo a gt a i g o eD D 0 a Designing a Test Program Designing a Test Program This procedure describes how to define a waveform with the Function Generator program Note This procedure defines a tuning waveform for a force transducer The values in this procedure produce a 2500 N waveform for a system with a force train rating of 25 kN a p ge oe e Determine your test requirements 224 Open the Function Generator program 225 Define the command waveform 226 Define the counter 226 Define the home ramp 227 Parameterize the program command 227 Run the program command 228 Step 1 Determine your test requirements Sketch the waveform and identify significant information 224 The example in this section will create a cyclic triangle waveform that can be used to tune a force transducer A common tuning command is 10 of full scale cycling at 1 Hz Determine the components of the waveform Now you can establish the function generator settings using the Mean Amplitude and Frequency controls along with each of the Define menu options l
117. abled the meter When enabled the meter can be displayed from the Display menu TestStar Reference Manual 137 Edit Menu Meters Timed Data Updates the display once a second with the amplitude of two input signals Select two input signals The display will not display a single signal Meter Selection 4 i Meter Definition Type Display Timed Definition Signal input signals valve signal Signal input signals valve signal All defined input signals are available for display Ifa control mode is defined the valve signal is also available for display The display updates each signal once a second Display 1 Second Increments 138 TestStar Reference Manual Meters Peak Valley Data A peak valley meter displays the highest and lowest values of an input signal during each cycle of a dynamic test ies ou j 0 mk 5 Use this window to select the sensor signal you want monitor peaks and valleys Meter Selection isd Set the sensitivity Meter Definition Type Display Peak Valley Definition Signal input signals valve signal Sensitivity gt zero units The peak is the most positive least negative level The valley is the most negative least positive level The sensitivity setting is the amount the
118. access Note This is the same procedure as described in Task 6 in Chapter 5 of the Installation Manual 1 Open the System Administration program 240 Add or edit a user name 241 Select the TestStar programs the user can access 242 w Close the program 242 Step 1 Open the System Administration program A Double click the MTS TSII icon on the desktop OS 2 only Then double click the Utility folder B Double click the Administrator icon You may need to log into the Administrator program Enter your user name and password in the MTS Login window By default the System z Administration window is Z ready to define a new user MTS TSII name when the program TestStar Utilities first starts A Administrator Unit Assignment Set Editor Function Config eee Generator Cy A l Sensor Diagnostics Calibration 240 TestStar Reference Manual Creating a New User Step 2 Add or edit a user name A Press the Add or Edit button to display the New or Edit User window B Enter or edit the information in the window as shown below All the fields are mandatory except for the Last name Middle initial and First name C When you have completed the window press the Add button to bring up the Application Access window iS lt Nn na 5 gt z jam te Nn _ a j 0 jo If you are editing an existing user press the Edit button This als
119. al Strain 1 Strain 2 Strain 3 3 Where Strain 1 2 and 3 are three different strain input signals This example shows how to calculate true strain ln strain 1 Where In is the natural log function see the functions table Strain is the strain input signal This example references another calculation and a calculation constant Axial Strain Axial Stress Modulus Where Axial Stress is the result of another calculation Modulus is a calculation constant 95 Edit Menu Input Signals Assign Sensor Window Prerequisite Use this window to select a sensor from your sensor data base You must have a data base of calibrated sensors otherwise you must calibrate a sensor The sensor data base is established and maintained with the Sensor Calibration program see Chapters 6 9 in the Installation manual Assign Sensor Sensor list of calibrated sensors OK Cancel Calibration Info CONTROL FUNCTION Sensor Select the sensor you want assigned to the input signal Only calibrated sensors matching the selected dimension are displayed Be sure the sensor is connected to the rear panel connector that is associated with the input signal slot selection The Sensor Calibration selection lets you calibrate a sensor for the first time Calibration Info Displays some of the sensor calibration information entered with the Sensor Ca
120. al 133 Edit Menu Toolbar a Configure Toolbar Window Use this window to define the toolbar in the main TestStar window Configure your toolbar with buttons that represent the windows you open most often Note We recommend that you do not configure the toolbar until you are familiar with TestStar Use TestStar until you establish your working habits then you will know which windows you want to access quickly Available Windows Selected Windows TestStar Performance Rate Fault Status Window Open Settings File Save Settings File Settings Print Preview Edit Input Signals Edit Output Signals Edit Control Channels Edit Calculation Constants Edit Detector Actions Edit LUCP Display Edit Meters CONTROL FUNCTION Available Windows Lists all the TestStar windows Select each window you want to assign to the toolbar Selected Windows Lists the window in order as they would appear in the toolbar Moves highlighted items from the Available Windows column to the Selected Windows column lt Moves highlighted items from the Selected Windows column back to the Available Windows column 134 TestStar Reference Manual Toolbar Using the window Select windows one at a time in the Available Windows column and use the right arrow button to move it to the Selected Windows column More than one item can be selected and moved at a time ies a j 0
121. an ASCII file or printed Configuration File Name C ts2 Config default tcc Software Version 3 1A Printout Date 11 07 1994 02 25 21 PM System Information Extended AIO No High Speed Data Acquisition No Update Rate 5000 Hz Load Path Stiffness Set lt lt No Correction gt gt Input Signal Display Section stroke Signal Source Slot 1 Type AC Conditioner Sensor Name STROKE1 Sensor Full Scale 127 000 mm 127 000 mm Sensor Range 127 000 mm Upper Limit 127 000 mm Disabled Lower Limit 127 000 mm Disabled Zero Offset 0 00000 Unlock load Signal Source Slot 2 Type DC Conditioner Sensor Name FORCE_20KIP Sensor Full Scale 88964 4 N to 88964 4 N Sensor Range 88964 4 N Upper Limit 88964 4 N Disabled Lower Limit 88964 4 N Disabled Zero Offset 0 00000 Unlock Calculated 1 Signal Source Calculated 1 Type Calculation Calculation Range 1 0000 mm to 1 0000 mm Upper Limit 1 0000 mm Disabled Lower Limit 1 0000 mm Disabled Equation Pi power radius 2 TestStar Reference Manual Print Preview Window Display Output Signal Display Section Output 1 System Information Type Analog Bus Input Signals Device stroke Conditioner z Output Signals Wg Transducer Control Channels Type Readout Constants Device axial Valve Release Scale 1 0000 V Offset 0 00000 V Display Control Channel Display Section axial System Information Channel Control Channel 1 Inpu
122. any changes in the system configuration Stay Alert Avoid long periods of unvarying or monotonous work tasks that can contribute to accidents and hazardous situations Familiarity with the working environment can lead you to overlook potential hazards in that environment Stay clear of moving Keep clear of moving mechanical linkages equipment Also stay clear of connecting cables and ie hoses that move along with the specimen or equipment Objects may get tangled or dragged along with moving equipment Serious injury can be inflicted by very high forces that can be produced These forces could pinch cut or crush anything in the path of the moving equipment Be aware of To minimize potential electrical shock A electrical hazards hazards while the system electrical power is ra turned on avoid touching exposed wiring or switch contacts TestStar Reference Manual 13 Safety Precautions Use eye protection Have first aid available Practice good housekeeping Keep bystanders away Preface Wear proper clothing 14 Use adequate eye protection when working with high pressure hydraulic fluid or explosive specimens and in circumstances during which anything peculiar to the specimen setup could break apart and cause eye injury CJ Accidents happen even to careful people Arrange scheduling so that a properly trained person will be close by at all times to render first aid Keep work area floors clean Hy
123. ar Version 4 0 and newer use Microsoft Windows NT This manual is designed for anyone who wants detailed information about any TestStar feature and functions Other Manuals Other Manuals This manual is part of a set of TestStar manuals that describe TestStar which is a part of a complete testing system The following describe the TestStar TestWare SX and MTS system manuals The TestStar Installation Manual p n 150194 xxx describes how to install TestStar and how to use the utility programs such as sensor calibration and system administration to establish the initial data base The TestWare SX Application Manual p n 150197 xxx describes a general purpose application for TestStar This includes function generation data acquisition event detection and external control features Preface The optional C Programming Reference Manual p n 150195 xxx describes how to interface with TestStar using a high level programming language The Product Information Manual contains tabbed sections that describe the hardware components included with your system such as your load unit and grips This manual is primarily about hydro mechanical products The Assembly Drawings Manual contains tabbed sections that contain engineering drawings and part lists of many of the hardware components covered in the Product Information manual This manual helps you to service your equipment and is useful for MTS Service En
124. ar must be running before you can start the Load Path Stiffness Editor You should also have determined a stiffness values as in this appendix Manages your load path stiffness sets Help File Gets information about using the the editor S lays the name of the load Current Set 1000Hz Compression stiffness set that is open Shows the description of the D This is for a compression platen setup on the 1000Hz Elastomer Test machine current load path stiffness set Click in this area to enter or edit the description Displacement Acceleration 1 Angle Strain Lists the input signals that can have a stiffness value defined Highlight each input signal you want to define Displays the Define Stiffness Define Stiffness window where you enter a stiffness value for each of the selected input signals TestStar Reference Manual xIpueddy 317 gt lt gel eD er lt Load Path Stiffness Editor File menu Displays the current stiffness value of each input signal in the set XN Prints the current stiffness set Copies the current stiffness set as an ASCII file 7 Sets up your printer How it works 318 NI Delete Ji Print Use the File menu to manage your load path stiffness sets
125. ate to 10 of the proportional gain setting You may want use the max min display to monitor the mean level reset the display and check it again May want to use the max min display to monitor the mean level reset the display and check it again oo Reset Too Low Mean Level Stability Reset Too High Way Too Much Reset A ramp and hold waveform illustrate different levels of reset In a cyclic waveform peak and valley values drop the same amount if reset is not adjusted correctly The Reset 1 Adjustment determines how much time it takes to improve the mean level accuracy 272 TestStar Reference Manual Feed Forward F This waveform shows the results of a moving load cell However don t use a square waveform to adjust feed forward Adjusting feed forward causes the command to begin sooner so the feedback may track the original command more closely TestStar Reference Manual About Tuning Feed forward is like the Rate control except that it introduces a derivative of the command signal It anticipates how much valve opening is needed to reach the required response and adds that to the valve command like compensating for phase lag It does not compensate for normal changes during testing such as temperature changes servovalve droop etc It can correct a single natural frequency inherent in load units Adjust feed forward if oscillation cannot be stopped It is usually needed with force se
126. ators contain high pressure gas that is very hazardous if improperly handled or poorly maintained Read all gas cylinder labels to properly identify the type of accumulator and the type of gas used Follow all accumulator charging instructions given in the manuals When charging accumulators use only dry nitrogen Dry nitrogen can be labeled oil pumped or dry water pumped Do not use oxygen in place of nitrogen If oxygen comes in contact with hydraulic fluid e g if an accumulator bladder ruptures or leaks a highly explosive condition will exist When in doubt about any nitrogen charging procedure or about any type of accumulator consult MTS Systems Corporation refer to the Preface for information on technical assistance Protect electrical cables from spilled hydraulic fluid and excessive temperatures that can cause cable hardening and can eventually result in cable failure Clean spilled hydraulic fluid from cables as soon as possible 23 Safety Precautions Inspect all cables for cuts exposed wires or other types of possible damage prior to system operation Cable connectors must be securely plugged into their respective receptacles Inspect each cable where it enters the cable connector for signs of excessive flexing broken insulation or exposed wires Remove all system power before replacing any cable found to be defective Ensure that all cables have appropriate strain relief devices installed at th
127. ault name is the same as the Control Channels selection Channel Type Controller is the only type available It represents a servo loop controller Selecting none removes the control channel and any related control modes Channel Label Drive Type Labels the control channel as a particular type of channel e Axial e Torsional e Pressure e Generic Specifies the type of servovalve connected to the control channel e none e 252 e dual252 e 256 257 Selecting none will maintain the selections in this window but will not allocate controller resources to produce a signal Auto Tuning Control Mode Selects a control mode to control the actuator while the auto tuning feature monitors the response of the control mode being tuned If no control modes have been tuned select Undefined Normally a tuned displacement control mode should be selected Phase Amplitude PAC Enables or disables the phase and amplitude control compensation method When enabled PAC can be selected by any cyclic command used by the function generator or TestWare SX process TestStar Reference Manual 113 Edit Menu Control Channels Control channel Each control channel uses a control mode to determine the required command Each control channel controls an axis of actuator movement by providing the valve When you define a control channel you also define all the control modes available for that channel Each control
128. be defined Action Name Names the detector action The name you enter is used throughout TestStar to identify this action Action type Specifies a ramp or a hold action Controls needed for the selection are added at the bottom of the window The Disabled selection closes the action so it does not appear in the detector action selections Standard actions 126 The first four actions cannot be changed and are identified as follows Action 1 Disabled Action 2 Indicate Action 3 Hydraulic Off Action 4 Interlock TestStar Reference Manual Detector Actions A Hold Actions Hold actions are useful when you want to stop a test without causing an interlock or tuning the hydraulic pressure off ies ou j 0 mk 5 Renon Selection a x Action 5 10 Selecting the Hold action type displays this window configuration Action Definition Action Name Action Type Control Channel G tJ Control Mode Using hold actions All that is needed is to select a control channel and a control mode The type of control mode should reflect how the action will be used For example a general purpose hold action uses a length control mode When a fault is detected the actuator holds its current position If a limit detector faults because the specimen breaks this action can prevent damage to other equipment Anoth
129. below ea Toolbar Button Title the index oe Soa cate ees She oat ane ees ee ate he Pee ae ee Prerequisites Edit Detector Actions Widow Prerequisite Sample Window Random Topics Basic Explanation Action type Standard actions Detailed Explanation 1 Using the window More Information Using the Window 34 TestStar Reference Manual Don t forget the index Toolbar button Titles Prerequisites Sample window Basic explanation Detailed explanations TestStar Reference Manual How to Use This Manual When in doubt use the index It contains entries for both this Reference manual and the Installation manual Index listings for the Installation manual are preceded with the letters IN and RE for this manual Any menu or window that can be directly accessed from the toolbar has its associated button displayed with the menu or window title All TestStar windows can be accessed from a menu or the toolbar See the Configure Toolbar window for more information Each description is titled with the name of a menu selection or a name of a window Menu titles are also shown next to the page number at the bottom of the page Following the title is a brief paragraph explaining what the menu or window is used for Sometimes a window requires another function or functions to be completed
130. bration Resister Bridge Feedback gt T Negative Excitation Calibration lt More infor mation Calibrating a sensor Installation Manual 8 9 Determining a shunt cal reference Installation Manual 2 8 9 158 TestStar Reference Manual Tuning Tuning A CAUTION Every control mode must be properly tuned Using a poorly tuned control mode may cause the actuator to move so slowly it may appear not to be working make an obnoxious noise identifying unstable operation orin extreme cases slam to its mechanical limit Be sure you know the following before you tune e the Safety Precautions in the Preface of the Installation manual e the Tuning chapter in this manual e how the adjustments affect your system e how to use the error detector and limit detectors to help stop the system if it performs outside your expectations nua isnl py e that you need to retune when testing specimens with different characteristics rubber vs steel Prer equisites You must define a control channel and its control modes with the Edit Control Channels window before you can use this window Control channels The number of control channels is set when the TestStar software is installed Each control channel can have up to 10 control modes The Tuning window opens with controls for the active control mode shown below the control mode selection Selecting a control mode displays the appropriate controls at the bottom
131. cimen can also be an extra testing specimen designated for tuning The advantage of a dummy specimen is that it can simulate how your testing system reacts to real specimen You can establish a more precise level of tuning with a dummy specimen Note Ifyou have a dummy specimen you can use the normal tuning procedure If you do not have a dummy specimen or if a dummy specimen is not practical review the following recommendations if you must use a real specimen Start your PIDF controls at minimum settings Do not use a square waveform for a massive specimen or a specimen sensitive to vibrations Adjust rate to minimize any oscillation overshoot or ringing in the waveform Be very conservative by beginning with a triangle waveform to establish initial control Then use a waveform that resembles the test waveform to provide a precise level of control A specimen is required to tune force and strain control modes Initial force tuning may be accomplished with the actuator up against the force sensor The actuator acts as a specimen reacting against the force sensor 1 Adjust the load unit crosshead so the actuator can reach the force sensor 2 Carefully adjust the actuator using a tuned length control mode so it contacts the force sensor 3 You can now switch to force control and proceed with initial tuning 277 Tuning About Tuning Monitoring Waveforms What to monitor DO NOT monitor the ent
132. control channel stants Drive LUCP Display Sets up the underpeak detector for each control Toolbar Meters Selects a load path channel j y stiffness set Defines up to 6 hold or pints hic haec ramp actions in addition to the 4 standard actions Creates a row of buttons that opens parameters Defines what is displayed on the load unit control panel 5 mk m ro a Q q baie 5 Defines a scope to display signals in a graphical form Defines up to 4 digital displays Each display can monitor a signal in one of four display modes TestStar windows TestStar Reference Manual 49 Introduction Using TestStar Configuration Files Using TestStar Configuration Files Configuration file 50 Predefined settings allow you to completely set up the TestStar controls for a specific test and save those settings as a configuration file A TestStar configuration file contains information about every selection you made in every TestStar window Each type of test you use should have a different configuration file The configuration file not only saves every TestStar parameter setting it also includes the size and screen location of every TestStar window The configuration file is one the most useful tools in TestStar It allows you to completely set up TestStar for a specific test then save all the settings you made You can later recall those settings when you
133. d paths gt az ge ou j 0 gt lt TestStar Reference Manual 313 Debug Options Using the window Be sure you know where you save your debug log files For example assume you created a directory called Log in the TS directory of the C drive and you save your debug log files in that directory 1 Use the list icon for the Drive field to select the drive where your configuration files are located In this case the C drive should already be displayed 2 Double click the desired directory in the Directory list this causes its files to be displayed in the Files list and it also displays any additional directories In this case TS should be displayed double click the Log directory you created 3 Select the TestStar configuration file you want to open from the File list The selection will be displayed in the Open filename field Otherwise enter a new file name and a new log file will be created 4 Press the OK pushbutton to open the file asl TO eD er lt 314 TestStar Reference Manual Bypassing the Login Appendix E Bypassing the Login If you want you can configure any TestStar program to open without logging in This is required if you want to open TestStar by double clicking a configuration file A CAUTION Bypassing the login lets anyone use TestStar If you are concerned about unauthorized access to your configuration files DO NOT bypass the TestStar logi
134. d to reposition the actuator and continue the adjustment While running a test on a properly tuned system you observe either of the following A sinusoidal test waveform is distorted at its maximum and minimum points peak and valley values change This will normally be more observable during a test that has either a low frequency or a low amplitude test waveform Dither amplitude is insufficient See Adjusting dither amplitude You hear a really annoying sound that irritates your nerves as much as a fingernail continuously scraping a blackboard Dither amplitude is excessive See Adjusting dither frequency TestStar Reference Manual Adjust Drive Adjusting dither To adjust dither amplitude perform the following no specimen is amplitude needed 1 Set up the Function Generator for a very slow ramp in length control 2 Set up an oscilloscope to monitor the system response 3 Run the Function Generator If the system response indicates a smooth ramp adjusting the dither amplitude is unnecessary If the system response indicates a jagged ramp the actuator sticks before moving adjust the dither amplitude 4 Increase the dither amplitude until the system response becomes smooth Adjusting dither Dither frequency is adjusted in conjunction with the dither amplitude frequency The following is an adjustment guideline no specimen is needed nus isn py 1 Set up the Function Generator for a very slow
135. detect a y peak or valley If set too low Signal noise will incorrectly be recognized as a valid change If set too high A small but valid change will not be recognized TestStar Reference Manual 179 Adjust Drive i Adjust Menu Adjust Drive Prerequisite Hydraulic systems 180 Electro mechanical systems The drive adjustments optimize the interface between the digital controller and a specific drive type TestStar supports hydraulic and electro mechanical drive configurations Each configuration can have several kinds of drives associated with it You must define a control channel with the Edit Control Channel window before you can use a drive window The Adjust Drive window that is displayed depends on the Drive Type selection in the Edit Control Channel window During the software installation the system configuration choice defines your system as a hydraulic or an electro mechanical system This identifies the type of equipment in your system and adjusts the TestStar windows accordingly Hydraulic systems use servovalves to control the actuator The following complement of valves have different drive windows 252 Valve represents the MTS Series 252 Servovalve Dual 252 Valve represent two MTS Series 252 Servovalves mounted to the actuator manifold 256 257 Valve represents the MTS Series 256 and Series 257 Servovalves Although these valves differ the
136. draulic fluid spilled on any type of flooring results in a dangerous slippery surface Keep bystanders at a safe distance from all equipment Never allow bystanders to touch specimens or equipment while the test is running Do not wear neckties shop aprons loose clothing or long hair that could get caught in equipment and create a potentially injurious situation TestStar Reference Manual Safety Precautions Safety Guidelines to Follow While Operating the Equipment Know proper system operation Know results of using system controls Know crosshead lift and lock controls Know when to turn on hydraulics Know system control electronics Know system hydraulic configuration Check system cabling Make a trial run TestStar Reference Manual Do not make mechanical or electrical adjustments to system components unless you know exactly how the adjustment will affect system operation Consult your MTS representative when in doubt about any adjustment procedure Do not make any unnecessary adjustments during operation of the system To avoid erratic or unexpected system response do not make any adjustments while the system is operating unless specifically instructed to do so Unlock the crosshead only with high hydraulic pressure applied Do not adjust the lift controls when the crosshead is locked Turn off hydraulic power except for those times that it is necessary for specimen setup or to run the test Do no
137. ds 16 Current output 190 Customer defined actions 124 Cycle counter 220 continuous cycling 220 defining 226 how it works 221 preset count 221 D Data display max min data 141 324 span mean data 140 timed data 138 139 Debug 311 Debug file 313 Defaults configuration file 241 Defining calculated signals 93 calculation constants 122 control channels 110 control mod 120 control mode 118 121 control modes 116 detector actions 124 input signals 85 load path stiffness sets 319 LUCP display 131 meters 136 output signals 99 scope 142 toolbar 133 Detector actions 124 Detectors display error action 194 display limits 194 display underpeak action 194 display window 193 Digital controller error codes B 303 Digital scope 280 Display detector actions 193 input signals 190 load unit control panel 131 load unit control panel Defining LUCP display 131 menu 189 meters 136 196 scope 142 screen 64 Dither adjusting amplitude 182 adjusting frequency 183 amplitude 181 184 frequency 252 servovalve 181 256 257 servovalve 184 Drive types 115 TestStar Reference Manual E Edit User window 235 Electro mechanical systems 180 E mail 26 Emergency Stop switch 62 EPO switch 62 Error codes 311 digital 303 firmware 295 Error Detector how it works 175 Error detector actions 176 causes 55 using the window 176 Error signal 279 External command source defining ramp amplitude 219 function generator 218 External senso
138. e The auto tuning control mode lists all of the control modes defined in TestStar Not all of the control modes are valid selections A valid control mode for auto tuning must be able to run 100 full scale A valid auto tuning control mode is usually a displacement or angular control mode Auto tuning uses one control mode to control the servo loop while tuning another control mode For example tuning a force control mode needs a tuned displacement control mode as the auto tuning control mode This allows the system to reliably control the actuator using displacement while monitoring the force sensor Monitoring the force sensor data allows the auto tuning feature to calculate tuning values appropriate for the control mode The default selection Undefined should be used TestStar automatically updates the undefined selection to the first auto tuned control mode The patented PAC phase amp amplitude control method compensates for amplitude error and phase lag Amplitude error refers to the tendency of amplitudes measured by the sensors to be less than the desired amplitudes Phase lag refers to the tendency of the feedback signal to trail the command signal at higher frequencies 115 Edit Menu Control Modes Control Modes Control mode types PIDF Channel Limited Channel Cascade Prerequisite 116 Each control channel requires at least one control mode Each control mode uses at least one input signal Kno
139. e 3 Select the force sensor to be adjusted 4 Using a Readout channel connected to an oscilloscope monitor the selected sensor signal 5 Run the function generator command 6 Adjust the Acceleration Compensation control until the signal being monitored is minimized The signal will look like noise The adjustment If the Acceleration Compensation control doesn t seem to make any isn t working difference or it makes the noise worse press the Polarity button and change the polarity of the adjustment If it still doesn t work the mass attached to the force transducer may be too small and acceleration compensation may not be needed TestStar Reference Manual 155 Input Signals Set Zero Scroll Range Window Use the Set Scroll Range window to establish a range of zero adjustment The default values are 100 min and 100 max full scale Using the window Adjust Menu 156 Range Maximum Minimum 100 00 lt Value lt 100 00 100 00 100 00 Cancel The window displays the full scale value of the selected control mode range You can change the maximum or minimum setting of the Offset Zero control to a value less than full scale The Max and Min parameters can be set to different levels To change a scroll range value type the new value in the entry field You cannot set the maximum range to a value less than the current Offset Zero setting or the
140. e Vol Volts MT mm Acceleration N cm Percent Energy Unit Area N mm vi Vv Dansall bait Viol TestStar Reference Manual 255 Defining a Unit Assignment Set Step 4 Save the unit assignment set A If you want type a description of your unit assignment set in the Description entry field B Select Save or Save as in the File menu Type a file name in the entry field and press the Save button If you are creating a new Save Unit Assignment Set s 2 file the Set Name lt none gt 3 is shown Select Save in ea the File menu Unit Set Names D 7 CGSSET a N If you are editing an ENGSET existing file the name of ENGSETSM T the file is shown Select SISET Save as in the File menu SISETSM S so the original file isn t is 22 replaced nN Save Cancel Help A lt lt a Step5 Assign a unit set as the default set Select Global default in the File menu Select the file you want to be as the default unit assignment set Any TestStar configuration Y g Assign Default Unit Assignment Set can have another unit assignment set assigned your file name You can also change the Unit Set Names unit assigned to any CGSSET A individual parameter of a ENGSET TestStar configuration ENGSETSM SISET SISETSM y Assign Cancel Help Step6 Close the Unit Assignment Set Editor 256 TestStar Refe
141. e assume you want to cycle a specimen 100 times and acquire data such as the maximum and minimum values once every 10 cycles Perform the following 1 Turn the Preset Counter On 2 Enter 10 in the Preset Count entry field 3 Run the function generator 4 When the function generator stops record the required data The Current Count automatically resets to 0 5 Repeat steps 3 and 4 until the total count equals 100 Cycles count from one end level to the next end level of the same value The amplitude and mean level settings define two end levels of a cycle A cycle consists of two waveshape segments The waveshape order begins the waveform from the mean level to an end level When the waveform cycle ends it continues from the end level to the mean level 1 segment _ _ end 7 k a k level ka 1 7 i Amplitude jJ i TANS ea S end J i lt 1 cycle gt lt cycle gt D level waveform return to order mean 221 EF a ie e p 0 5 ap Oo a gt a g o eD D 0 a Home Menu Option Window Home Menu Option Window Use this window to define the Function Generator Home button The Home Menu Option window defines a ramp for the Function Generator Home button The Home option returns the actuator to a specific position at the end of a test typically the starting position or zero reference
142. e Aux indicator on the LUCP Interlock turns off the hydraulic pressure generates an interlock signal clamps the servovalve lights the Controller LUC indicator and displays a message in the Fault Status window Customer defined these actions can be defined to ramp or hold the control channel output These actions may also be identified with a customer defined name or as Action 5 10 Note Customer defined actions are created with the Edit Detector Actions window An interlock monitors a specific condition The purpose of an interlock is to prevent hydraulic pressure from being applied or starting a test before certain conditions are satisfied Once a test begins an interlock can stop the test and remove hydraulic pressure if a specific condition occurs An active interlock turns off the hydraulic pressure generates an interlock signal clamps the servovalve and displays a message in the Fault Status window Some tests are designed to cause the specimen to fail An interlock is used to stop the test and protect the equipment One of your initial detector settings may be inadequate for the test The interlock may stop the test and you can readjust it and continue the test You observe a problem and press an Emergency Stop switch A component fails and causes an interlock 53 5 ro a Q j 0 5 Using the Fault Status Window Clearing a Detector All detector fau
143. e Rate 1 00000 Limit 100 000 Calculation Constant Section Pi Value 3 1400 none Radius Value 12 5 mm Modulus Value 10 MPa Action Display Section Disabled Type Disabled Indicate Type Indicate Hydraulics Off Type Hydraulics Off Interlock Type Interlock Return to Zero Type Ramp TestStar Reference Manual Mars TestSi Control Sys Some selections add controls to the bottom of the window Edit Input Signals Signal Selection a amp Signal Definition Signal Name Signal Type Dimension Display Units Signal Label Slot 1 14 Calci AC Conditioner DC Conditioner External Calculation td Edit Detector Actions Action Selection ______ B 5 Action 1 10 Action Definition Action Name Action Type Edit Load Path Stiffness Set Load Path Stiffness Set Selection default set Description No Load Path Stiffness Correction x Edit LUCP Display Pane Selection B E TestStar Panel 1 Available Items Input Signal Header Control Channel Header Blank 1 Blank 2 Blank 3 Blank 4 Blank 5 input signal names control channel names Selected Items ea Ee E Enabled Pane Display Signal
144. e Refresh button to update the list of load unit stiffness sets if a new one is created while TestStar is running or an existing set is modified TestStar only checks the list of stiffness sets when it is started 130 TestStar Reference Manual LUCP Display Use this window to define the appearance of the display on the load unit control panel The first seven items are available for each LUCP window LUCP Display ies a j 0 5 Pane Selection 6B B Available Items Selected Items Input Signal Header Control Channel Header Blank 1 Blank 2 Blank 3 Blank 4 Blank 5 input signal names control channel names m nabled Pane Display CONTROL FUNCTION Pane Selection Selects one of the display panes available for the load unit control panel Available Items Lists the items that can be displayed in the load unit control panel display All input signals and control channels are available for display along with a selection of standard items Selected Items Lists the item in order as they would appear in the load unit control panel display Moves highlighted items from the Available Items column to the Selected Items column lt Moves highlighted items from the Selected Items column back to the Available Items column Enabled Pane Display Check this box to display this pane on the load unit control panel The
145. e a large instantaneous error and the actuator will respond accordingly Do not make any program changes unless you know exactly how the change will affect operation 17 Preface Safety Precautions 18 An unexpected actuator stroke or excessive actuator force can result from over programming The composite command to the servo control loop is the algebraic sum of the Function Generator window s Mean Level and Amplitude inputs either can program 100 of the system s force producing capability For example in most systems a 10 volt signal produces full system response if the input to the controller is a 10 volt sine wave and Amplitude is adjusted to the maximum setting any mean level offset introduced by the Amplitude control causes the command to exceed the capabilities of the system When determining program commands make sure to avoid over programming Many systems contain hydraulic accumulators that store enough energy to temporarily operate the actuator at full force capacity when the hydraulic pressure is shut off For this reason the usual interlock devices will not prevent hazardous actuator stroking The failure or shutoff of electrical power to the testing system while hydraulic pressure is applied will cause considerable unpredictable actuator reaction due to stored energy in the accumulators and irregular pump shutdown Under these conditions the actuator will generally stroke at maximum force and maximum velocit
146. e cable and near the connector plug Do not use the connector plug as a strain relief Thoroughly inspect hoses for blisters cuts or other damage prior to system operation Any weakening of the wire wrapping or reinforcing should be considered cause for hose replacement While the system is operating inspect all hoses and cables to ensure that there is no excessive thrashing bending or chafing that could cause cable or hose damage Preface Flush the hydraulic system immediately after any of the system s piping i e hoses hard lines servovalve hydraulic power supply components etc has been replaced or its configuration has changed Special safety considerations are necessary when operating a system that contains fire resistant hydraulic fluid These fluids are usually toxic and can present a lethal situation if fluid is accidentally swallowed or if a sufficient amount of fluid is absorbed through the skin Avoid breathing the vapor or mist from these fluids do not eat or smoke while working with these fluids and practice absolute personal cleanliness when working with these fluids Do not mix fire resistant fluids with petroleum based fluids Also do not add fire resistant fluids to systems incompatible with these types of fluids doing so will destroy seals and severely damage the equipment 24 TestStar Reference Manual Safety Precautions Hazard Conventions Used in This Manual A WARNING A CAUTION NOTE
147. e controls for the selected input signal Prer equisites You must define an input signal with the Edit Input Signals window before you can use this window EEP S N v o TE ELE o This window shows all Signal Selection ossible features gt 4 x signal name x a The Sensor Zero Limits 2 N S Shunt Calibration and Upper Limit 0 000000 units Action baa Acceleration lt gt z zZ Compensation features are P i bower timi 0 000000 units Aion present only for input z signals that need them z Sensor Zero Shunt Calibration e Unlock Lock e Shunt Cal Offset o 000000 Sensor lt gt Output 0 000000 units Acceleration Compensation 1 lt Polarity Compensation Normal Polarity gt gt veneg A v TestStar Reference Manual 149 Adjust Menu Input Signals CONTROL FUNCTION Signal Selection Selects the input signal you want to adjust Each input signal can have a different set of parameters Limits Upper Limit Lower Limit Action Establishes the settings of the limit detector for the selected sensor If the sensor signal exceeds a limit the selected action occurs The upper and lower limits define an acceptable range for the sensor output during a tes
148. e sensor feedback of the selected control mode 6 Start the program command and adjust the outer loop P control to produce about 10 over shoot 7 Increase the Outer Loop D control slowly until the over shoot disappears TestStar Reference Manual Tuning Set Scroll Range Window Setting the scroll range for the tuning controls can ensure the controls are not adjusted beyond a desired range Reducing the scroll range also increases the resolution of the control adjustment The Set Scroll Range window reduces the range of the selected x control in the Tune Range windows 0 lt Value lt 3 40282e 38 Maxi 10 0000 The value 3 40282e 38 is aximum the maximum value Minimum 0 000000 supported by the computer nua isnl py Using the window The window displays the current setting for the control all controls are initially set to 10 You can change the minimum or maximum setting to any value above zero To change the scroll range value type the new value in the entry field P 5 Lp 5 P J 5 0 gt gt gt 0 10 6 0 20 The P control is set to 5 with Changing the scroll range Changing the scroll range the scroll range set at 10 o 6 changes the reference to 20 also changes the of the control setting 5 reference of the control setting 5 Do not
149. e servo loop before you attempt to adjust the tuning controls The following is a tuning guideline Note Go to Chapter 9 to determine an appropriate tuning strategy for your system and specimen 1 Install a dummy specimen If a displacement control mode is to be tuned a specimen is not required 2 Select the control mode you want to tune 3 Set up the Function Generator or select a TestWare SX test procedure for your test command 4 Set up the TestStar scope or an oscilloscope to view the sensor feedback of the selected control mode 5 Start the test command and adjust the tuning controls for the ideal response 162 TestStar Reference Manual Auto Tuning Prerequisite Pressing the Auto tune button in the Adjust Tuning window displays the Auto Tuning window End levels How it works TestStar Reference Manual Tuning The auto tuning feature automatically tunes control modes for a moderate level of tuning The auto tuning feature is only available for PIDF control modes using the segment generator SG command source Auto Tuning Control Mode 1 End Level 1 0 00000 units End Level 2 0 00000 units Run Auto Tuning Cancel The end levels represent the limits of the signal that exercises the actuator Set the end levels to the upper and lower amplitude values that are expected for the control mode during the test While the auto tuning cont
150. e system near the point of oscillation or instability Inaccurate tuning reduces the response This makes the system mushy and the actuator may not even reach the peak the program command calls for As a specimen changes characteristics during testing the response of the system also changes This can cause unstable system operation In this case you may not want the most precise tuning For the greatest control accuracy use a compensation feature that can be found in several MTS software products Amplitude mean control in the Function Generator Spectrum Amplitude Control SAC with the file playback process in the TestWare SX application Phase Amplitude Control PAC used in conjunction with the 790 00 TestStar software the 790 31 Dynamic Characterization application and the 790 14 Advanced Function Generation processes FIT compensation frequency based iterative technique used in conjunction with the TestWare SX application and the 790 14 Advanced Function Generation processes The following can be dangerous if you do not know how it will affect your system The following items apply to expert operators who are experienced at precision tuning You may need to retune the system response when the characteristics of the specimen change during a test You may also want to tune the system with the test program command after the initial tuning is accomplished TestStar Reference Manual About Tuning
151. e the selection are added at the bottom of this window None Indicates that an input signal is not assigned or no module is plugged into the slot location of the Signal Selection AC Conditioner Use this selection to define a sensor connected to an ac or dc conditioner DC Conditioner TestStar checks the type of module plugged into the slot location and lists it as the only selection See AC amp DC Conditioner Signal Type on page 90 External Use this selection to define a sensor signal from an external conditioner This selection is available for slot locations 7 14 only See External Signal Types on page 91 Calculation Use this selection to define an input signal that has a mathematical equation applied to a signal This selection is only available for a Calculated Signal Selection See Calculation Signal Types on page 93 The calculation feature may be used without an input signal see Calculation Constants on page 122 88 TestStar Reference Manual Input Signals ies ou j 0 5 CONTROL FUNCTION Dimension Assigns the type of units for this signal Select an appropriate dimension for the signal Only sensors that match the dimension are available Display Units Selects the specific units you want to assign to the sensor signal The selected dimension determines what units are available Signal Label Specifies a number to distinguish input signals of the same dimension TestStar uses this label inte
152. e you are to run a compressive test to 8 kN with a 10 kN force sensor Set the end levels to 2 and 8 kN Press the Start Auto tuning button You are prompted to install a specimen into the load unit The actuator must be left in contact with the specimen and the actuator positioning control APC turned off Pressing OK displays the Auto tuning in Progress window and starts tuning the process It takes about 1 2 minutes for auto tuning to finish Note Ifthe actuator doesn t move for more than two minutes press the Stop Auto tuning button It is possible that the valve balance may need adjustment If you encounter an interlock while running the auto tune feature you may need to change either the limit of the interlock detector sensor or the range of the sensor being tuned I lt Running Auto Tuning Auto Tuning is being performed Please Wait Stop Auto Tuning TestStar Reference Manual Auto tuning Step3 Save the settings A When tuning is complete the Accept New Gains window appears Press the Accept Gains button to use the tuning values Otherwise select cancel to dismiss the window without using the tuning values A CAUTION Non linear specimens can produce invalid gains Non linear specimens should be rough tuned manually instead of using the auto tune featrure B Use the File menu to select Save This adds the tuning values to the current TestStar configuration file
153. each meter with the Edit Meters window before you can display the meters This menu selects how the meters are arranged vertically horizontally or in a box This menu and the buttons below it start stop and reset all of the meters Use this window to monitor test related signals The meter works like a Controls Alignment digital meter The mode can be 0a e Timed Timed e Peak Valley Slot 2 The parameters are e Span Mean determined by the Max Min Undefined selected mode Types of meters Each type of meter defines what information is displayed for a given input signal This waveform shows the 100 type of data that can be displayed Peak Maximum The peak valley and span mean modes update data each cycle The max min maximum 0 and minimum data mode Valley monitors the entire Span waveform Mean The timed data mode Minimum displays a signal value every second tititttitiiy 100 Timed Data 196 TestStar Reference Manual Tool bar Control menu Alignment menu TestStar Reference Manual Display Meters Starts displaying data on all data meters l Stops udating the data meters Clears the data meters so new Jets values can be acquired Displays the Edit Meters window Controls Alig Display Metezg
154. each selection you make in the window a message is sent to the TestStar digital controller Since a zero rate is invalid the controller returns the error message 1101 MTSERR ZERO RATE The computer translates the message and displays the dialog box The debug feature allows knowledgeable programmers access to the sequence of message strings to and from the digital controller If you encounter an error code and wish to know what it means see Appendix A and B Appendix A identifies firmware error codes codes 1 999 and Appendix B identifies digital controller error codes codes 1001 1200 311 gt az ge ou j 0 gt lt Debug Options x Debug Options Window Use the Debug Options E Debug Options window to record TestStar i Disable Window Updates activity J Message Log Window J Message Log File Select File OK CONTROL FUNCTION Disable Window Updates Disables the display located on the load unit control panel The LUC remains functional except for the display Message Log Window Displays a window that shows the activity between your computer and the digital controller Message Log File Creates a file C TS mess log of the activity between your computer and the digital controller Select File Displays the Select Output Log File window Use this window to create a log file use a LOG extension or to overwrite an existing file gt lt
155. ecimen starts to contact the grip the force increases When force reaches 2 kN and you continue to adjust the control nothing happens The displacement value that caused the force limit is maintained and will not increase After the specimen is gripped and you adjust the Actuator Positioning Control for tension the lower limit value ensures the tension does not go beyond 1 kN A CLC channel limited channel control mode receives a program command from the Actuator Positioning Control on the load unit control panel A typical CLC control mode uses length as the master channel and force as the limiting channel Note The easiest way to tune a CLC mode is to use the proportional gain P values from any tuned PIDF control mode of the same signal type for the master P and limiting P values The following is a tuning guideline assuming the Master feedback is displacement and the Limiting channel is force Adjust the Master P control for adequate actuator response when adjusting the Actuator Positioning Control Monitor the force output and adjust the limiting channel control to minimize any delay to stop actuator movement when it reaches the specified limit TestStar Reference Manual Tune CASC Window Prerequisite Cascade control mode adjustments tune the response of both servo loops Use the CASC control mode for specimen testing that requires a high degree of stability such as dynamic load applications
156. eck the range of the input signal TestStar Reference Manual Auto tuning Auto Tuning the First Control Mode If you have no tuned control modes start with a displacement control mode Even though the displacement control mode is not tuned yet it is the most reliable control mode for this purpose Once the control mode has been tuned automatically it can be used for testing and as a auto tuning control mode However if you notice during your test that end levels aren t being reached you may want to fine tune the control mode Use the manual tuning procedure at the end of this chapter to achieve a higher level of tuning higher level of response For example tuning the first control mode requires feedback from displacement or rotation This type of control mode can be governed to produce stable operation Step 1 Getting things ready This step defines the full scale range of the control mode Auto tuning with an undefined auto tuning control mode requires a full scale range The full scale range allows the actuator to be exercised across its full range of movement A Be sure that no specimen is installed and that the actuator can move through its full range of movement You may need to move the crosshead or other fixtures that may be in the actuator s path B Use the Adjust menu to select Input Signals This displays the Adjust Input Signals window C Select a displacement or angular input signal and select the
157. ection is indicated by reverse video Examples Press F2 to move the selection up In the window shown on the previous page this would select the sensor called Load Cell If you press F2 a second time you select the LUC mode control F4 Changes the display between pane 1 and pane 2 Gf pane 2 is defined See LUCP Display on page 131 to define the panes 5 ro a cS Q j 0 5 TestStar Reference Manual 65 jo el O ge Ho q p Using the Load Unit Control Panel Control Channel Modules A control channel module is added to the main module for each actuator in the test system Each axis of control i HSM off requires one control Control channel module E a Actuator N O Positioning ontrol HSM Control These switches control the hydraulic pressure of the hydraulic service switches Off turns off the HSM manifold Note that these switches affect pressure only at the test station being served by one manifold The HPS must be on first Low turns on low hydraulic pressure typically 2 MPa 300 psi High applies high hydraulic pressure typically 21 MPa 3000 psi Actuator Position Pressing the APC switch enables the Actuator Control Positioning control knob and the selected LUC control mode With hydraulic power on HPS and HSM switches not set to Off adjusting the control causes the actuator to exte
158. ector is also shown Detector Faults Generated input signal name upper limit detector input signal name lower limit detector control channel name error detector control channel name underpeak detector More than one detector action may occur Sometimes the first detector fault causes other faults to occur Refer to Chapter 1 for instructions on how to reset interlocks or correct faults Setting limits Upper and lower limits on page 151 Display Detector Actions on page 193 Setting the error detector Error Detectors on page 174 Setting the underpeak detector Underpeak Detectors on page 177 Changing detector actions Display Detector Actions on page 193 125 ies a j 0 mk 5 Edit Menu Detector Actions Al Edit Detector Actions Window Use this window to define up to 6 customer defined detector actions Customer defined actions stop the test program and holds the output of any control mode A ramp and hold operation is also available The detector actions are available to all TestStar detectors Error detectors Underpeak detectors Limit detectors Action Selection Action 1 10 Action Definition Action Name Action Type Disabled Ramp Hold CONTROL FUNCTION Action Selection Selects an action to define Actions 1 4 are predefined and cannot be changed Only actions 5 10 can
159. efines the control channels Defines the control modes for each control channel Calculation Constants Detector Actions Defines constant values that can be referenced in calculated inputs Defines up to 6 hold or ramp actions in addition to the 4 standard actions Creates a row of buttons that opens TestStar windows Defines a scope to display signals in a graphical form Load Path Stiffness LUCP Display ON Undefined Sets the upper and lower i limits for each input signal gt along with zero and range adjustments Adjust Tunes each control mode Input Signals Specifies the type of compensation applied to the command Tuning Compensators Error Detectors Underpeak Detectors Drive Sets up the error detectors for each control channel Sets up the underpeak detector for each control Selects a load path channel stiffness set P Adjusts the servovalve parameters Defines what is displayed on the load unit control panel Defines up to 4 digital displays Each display can monitor a signal in one of four display modes Chapter 1 Introduction A WARNING Read the Safety Precautions in the Preface of this manual before you use the equipment The Safety Precautions portion describes hazards that apply to test systems and offers suggestions for avoiding hazards MTS test systems are powered by high pressure hydraulic fluid High pressure hydraulic fluid
160. eived error from external obj 60 dio selector out of range 61 dly received selector for wrong class 62 dly selector not implemented a TestStar Reference Manual 297 Firmware Error Codes ERROR No TYPE DESCRIPTION 63 dly internal error unpacking parameters 64 dly parameter out of range 65 dly couldn t find class from object id 66 dly specified event is not defined 67 hio internal error unpacking parameters 68 hio invalid source for command 69 hio invalid key command for HIO 70 hio sel not implemented 71 hio received selector for wrong class 72 hio received invalid channel number 73 hio can t change connection to event 74 hio can t find class for oid 75 hio proportional valve range error 76 hio input parameter value error 77 hio approval Timeout 78 hio rcv override on command 79 hio rcv override off command 80 hio rcv low command 81 hio rcv high command 82 hio rcv off command 83 hst received selector for wrong class 84 hst selector not implemented 85 hst null msg received 86 hst message too long 87 ibc received selector for wrong class 88 ibc selector not implemented 89 ibc internal error unpacking parameters 90 ibc parameter out of range ha 91 ibc timeout addressing register 92 ibc invalid address for desired function 93 idp received selector for wrong class 298 TestStar Reference Manual Firmware Error Codes
161. en All of these components act together as the load path The load path stiffness editor defines a set of stiffness values for the displacement sensors and saves it in a data base A stiffness set consists of stiffness values for an LVDT accelerometer and in some cases an ATD Any unique combination of the components of the load path should have a stiffness set defined for them For example assume you have a system that uses compression platens with extension rods to accommodate a temperature chamber for one type of test For another type of test you use the compression platens without the extension rods You should create a stiffness set for both types of tests TestStar Reference Manual 129 Edit Menu Load Path Stiffness Edit Load Path Stiffness Window Use a load path stiffness Load Path Stiffness Set Selection set to remove any lt lt no correction gt gt influence the load path hardware components have on the specimen displacement data Description No Load Path Stiffness Correction Using the window Use the list icon to select a predefined load path stiffness set The description of the load unit stiffness set is also shown A load path stiffness set should be created for any combination for load path components For example assume you change your test to one that requires a different set of grips You should have a load path stiffness set for both configurations of the load path Use th
162. ence between the min and max readings Multiply the difference by 10 the range between the auto tuning end levels must exceed that difference There is not enough response from the feedback channel This message appears when a command produces no detectable actuator response Check the following The feedback sensor may not be connected properly Hydraulic pressure may be off If a control mode requires a specimen to be installed be sure the specimen is installed The selected feedback may be much noisier than the feedback for the auto tuning control mode The polarity of the feedback doesn t match the polarity of the valve If a positive change in the valve opening results in a negative reaction in the feedback of the selected control mode then the polarity of the sensor must be changed Use the sensor calibration program to change the sensor polarity The system could not allocate or start a TestStar resource This message appears if TestStar can t run a required resource This usually means that another TestStar application is running An application that acquires data or commands the servo loop can cause the error message Auto tuning Canceled This message appears when you press the Stop Auto tuning button during the auto tuning procedure Controller next mode error interlock This message appears in the Fault Status window It indicates a saturated feedback signal from the auto tune control mode Ch
163. enerator or TestWare SX program is started A command to reset the clock is available for those who program trunc x Truncates the value of x x Brackets identify a variable array 94 TestStar Reference Manual Examples A CAUTION Area Axial Stress Average Strain True Strain Corrected Axial Strain TestStar Reference Manual Input Signals Here are some examples of formulas that create a calibrated input Define all constants with the Calculation Constants feature see Calculation Constants on page 122 for additional information ies ou j 0 5 If you do not use the Calculation Constants feature the constant will assume the units of the SI metric unit assignment set you will not have control of the units This example calculates the area of a cross section of a specimen Area could be represented as a calculation constant or a constant value instead of a calculation Pi power radius 2 Where Pi is a calculation constant radius is a calculation constant that represents half the diameter of the specimen s cross section This example divides the force input signal by the area of the specimen Load Area Where Load is the name of a force sensor input signal Area is a calculation constant or the calculation above a specific value may also be used in place of the name This example adds three input signals and divides them to produce an average sign
164. ent accuracy Precise tuning ensures the program command requirements are applied to the specimen This is your goal TestStar Reference Manual About Tuning If you ve never Until you are experienced at tuning you probably don t know what each tuning control does The only way to find out what they do is to tuned before adjust them and see what happens In other words experiment with the controls However before you begin adjusting the controls with reckless abandon please review the following guidelines Set up the upper and lower limits for the LVDT and force sensor Tune the displacement control mode first no specimen is needed While the tuning program is running note the shape of the waveform you choose to monitor Note the value of the tuning control you intend to adjust so you can return it to that value if necessary Make a small adjustment with a control and note how the waveform changes If the waveform doesn t appear to change make a bigger adjustment Use the auto tuning feature to establish your initial tuning values What if I adjust If you make an inappropriate adjustment the system will go unstable something wrong or shut down An unstable system produces an obnoxious sound A system shutdown displays the Fault Status window If an adjustment causes the system to go unstable readjust the control until the noise stops If an adjustment causes the system to shut down readjust t
165. er control channels TestStar Reference Manual Underpeak Detectors Underpeak Detectors Prerequisites Use this window to define an acceptable minimum operating range for a control channel An underpeak detector monitors an input signal during cyclic tests only You must define an input signal and a control channel with the Edit menu before you can use the Underpeak Detectors window Control Channel Selection LJ E Underpeak Detector Values nua Isnfpy Input Signal Each control channel can Action have an underpeak Maximum detector Minimum Sensitivity CONTROL FUNCTION Control Channel Selects a control channel Each control channel can have one underpeak detector Action Selects the action that the Underpeak detector takes when the detector triggers Input Signal Selects an input signal for the detector The units of the input signal are automatically set for the maximum and minimum values Maximum Sets values of the underpeak Minimum and Maximum parameters within Minimum the range of the selected input signal Sensitivity Determines when the maximum or minimum value is detected The sensitivity setting is the amount the signal must change to detect a maximum or minimum value TestStar Reference Manual 177 Underpeak Detectors How it works Adjust Menu The
166. er example assume you want to stop the test to change test parameters when force reaches a specific level In this case a hold action in force control would allow you to stop the test change parameters including the detector that stopped the test and resume the test For Biaxial you need to perform these steps 1 Select your control channel 2 Select your control mode 3 Perform the Step 2 for each control channel TestStar Reference Manual 127 Edit Menu Detector Actions A Ramp Actions Selecting the Ramp action type displays this window configuration Ramp actions are useful when you want to move the actuator using any control mode and stop a test without causing an interlock or tuning the hydraulic pressure off il Action Selection 4J iy Action 5 10 z Action Definition Action Name Action Type I lt Ramp Time Sec Control Channel A v axial torsional pressure generic Control Mode x Endlevel units CONTROL FUNCTION Ramp Time Sets the amount of time in seconds for the ramp The selected control mode ramps from the current level to the specified end level in the specified time Control Channel Selects a control channel defined with the Edit Control Channels window Control Mode Selects a control mode defined with the Edit Control Channels window End
167. eristics PARAMETER SETTING PARAMETER SETTING Command Home Ramp Control Mode length Control Mode length Units cm End Level 0 cm Waveshape sine Time 1 sec Waveshape Order Normal Frequency 1 Hz Initial Ramp Rate 1 cm sec Mean Level 1 cm Preset Count Off Amplitude 4 cm continuous cycling Pressing the Stop button 1 cm causes the waveform to homing time end at the mean level 0 reference gt home mean level poses oNscssco hace dans hess ramp initial ramp Home pushbutton stoppin Sem pping pressed Stop pushbutton pressed EF 5 ie e j 0 5 ap 5 t a TestStar Reference Manual 217 Command Menu Options Window Using an external The function generator can be used in conjunction with an external command source Before you can use an external command source command source the following must be true The external command source must defined See Chapter 10 in the Installation manual for complete instructions to define an external command source A temporary sensor must be defined for the external command input channel See Chapter 10 in the Installation manual The external command control mode must be defined See PIDF Control Mode in Chapter 3 The external command control mode must be selected with the Command Menu Options window The following characteristics apply when an external command source is used with the func
168. erlock input signal name lower limit detector causes other interlocks to control channel name error detector control channel name underpeak detector occur hardware interlocks Check the load unit control Eeeh I lock panel Interlock indicators eoe e E Controller One or more of these ie P ecnanica indicators may be lit Auxiliary jo lt O jm ge Ho p 56 TestStar Reference Manual Using the Fault Status Window Step 2 Determine the cause of the interlock Review the following to determine how each interlock occurs FAULTS AND INTERLOCKS EXPLANATION AD Overrun The analog to digital converters are overwhelmed by a high level of conversion activity Review your test strategy Auxiliary Interlock An auxiliary interlock does not remove hydraulic pressure instead it inhibits a test from starting This is usually caused when the crosshead is unlocked or by an external device connected to the rear panel connector J43 The Hydraulics Off detector action also can light this indicator Lock the crosshead or correct the cause of the detector action Controller Interlock This is caused by a plug in module or a software detector limits error or underpeak Check the Fault indicators on all plug in modules Check the Error indicators of the machine control modules A lit indicator indicates the module be replaced The Power indicator should be lit
169. ervovalve command cannot exceed the range set for the limiting channel A CLC control mode can be used only with the Actuator Positioning Control on the load unit control panel Upper x Limit XE Upper Limit If force feedback upper limit gt And displacement error is positive Error Then use upper limit error Limit Pj 10 0 gt Force Feedback Lower amp Limit Pod Displacement Command Error Displacement Master P Feedback Lower Limit If force feedback lt lower limit gt And displacement error is negative Error Then use lower limit error Otherwise use displacement error 10 oe Servovalve gt a Command Proportional Gain TestStar Reference Manual 165 nus isnfpy Adjust Menu Tuning CLC example Using the controls 166 Assume you have a 3 cm displacement sensor LVDT an 11 kN force sensor and phasing that produces tension with a positive command A typical CLC control mode uses length as the master channel and force as the limiting channel The upper limit is set to 1 kN and the lower limit is set to 2 kN The LUC is selected for specimen insertion control The specimen is installed in one of the grips As you adjust the Actuator Positioning Control on the LUC the specimen moves towards the other grip compression in displacement control When the sp
170. evice TestStar Reference Manual Output Signals ies ou j 0 mk 5 Output signals are from input signals conditioner modules valve driver modules and optional TestWare applications that can program the output You need to know the following to define an output signal The capabilities of the external device Where the external device is connected If you have any questions about the external device check the product manual that came with the external device for assistance The first thing you need to do is to decide what kind of device you want to connect Output signals can be configured for either of two types of devices A monitor device such as a meter oscilloscope or x y recorder can display an output signal A monitor device uses a readout or analog bus type of output signal A control device such as a temperature controller uses the output signal as a command source A control device uses a programmable type of output signal Note The programmable output signal is not used with standard TestStar but is used with optional applications such as the Analog Output process in TestWare SX You also need to know the range of the voltage that the external device can receive The TestStar output signal can be scaled within 10 volts Knowing this will help you determine how to scale the output for the external device input 99 Edit Menu Output Signals Signal connection Labels such a
171. ex for TestStar Displays the help panel for the main TestStar window Press the F1 function key or use the help menu to get help information Shown here is the OS 2 help menu Help Index Extended Help The Windows NT menu i Using Help includes two selections a Keys Help Help Topics selection and an About selection the OS 2 help system Product Information 3e ss Lists all the TestStar Displays the TestStar keyboard short cuts software version number Note Pressing the F1 key on some windows displays the main TestStar window 5 ro a Q j 0 5 TestStar Reference Manual 59 Introduction Using On line Help Calling for help You can access TestStar help whenever a TestStar window is active Press F1 to open the help for the active window Some windows also include a Help menu or a Help pushbutton The following are the most common selections for on line help Review information about OS 2 for additional help information WINDOWS OS 2 KEY MENU SELECTION FUNCTION NT KEY Fil F1 Help Extended help Opens help utility with the help panel for the active window F10 Help Help index Lists all the help panels Alt C Ctrl C Options Contents Lists all the help panels according to the structure of the program Alt B Esc Options Previous Displays the previous help panel Repeatedly using this
172. feedback signal must exceed an underpeak level before it crosses the underpeak mean level If not an underpeak detection occurs 178 The underpeak detector monitors an input channel to ensure the sensor feedback achieves a specified range Underpeak is used with cyclic tests The purpose of the underpeak settings is to detect a sensor output that is changing from the normal operating range For example underpeak detection is used to stop the test at the onset of failure in a fatigue test or to detect inadequate servo loop control peaks not being reached Two underpeak levels are set A minimum and a maximum level establish a range the channel output must achieve each cycle Underpeak levels are set to stop the test when a specimen fails or excessive deformation causes a failure according to material testing standards Only one channel can be selected for underpeak detection If an underpeak level is not reached the digital controller performs the selected action Set the interlock action after the test starts The detector may trip when the test program ramps to a testing amplitude under peak maximum detected under peak fe Qe eee n eee eee l vaLGe under peak amp mean level minimum under peak f Je value a zero minimum reference under peak missed TestStar Reference Manual Underpeak Detectors Maximum Both min
173. folder B Double click the Unit Assignment Set Editor icon You may need to log into the Unit Assignment Set Editor program Enter your user name and password in the MTS Login window nw MTS TSII TestStar Utility d 7 a ni Administrator Unit Assignment Set Editor Function Config es Generator Cy WY i Sensor Diagnostics Calibration TestStar Reference Manual Defining a Unit Assignment Set Step 2 Assign a unit to a dimension You may use the File menu to open one of the five predefined unit assignment sets You may use one of these sets to modify or assign as the default set see step 4 File Help First one select a dimension Description Then __Clear_ m select a unit E T vv gt Nn Dimensions Units 2 A ojo Time kN Frequency Ibf S qe Temperature MT Temp Tolorance os Tima x Nn aa rri Step 3 Repeat step 2 for each dimension you expect to use Ss Dimensions Units These are dimensions we H ill in the examples of een wi use p Force mil initial software settings Time Fasan You can select your own Aj inin gt set of preferences Stress mim Velocity Segment Count En A Unitless rad Ar
174. following controls See Appendix B in the Installation manual Polarity selects the polarity of the signal driving the servovalve DO NOT change the setting unless performing the servo loop phase check Valve Balance selects how the valve balance controls operate Select Separate to adjust each control individually Select Combined to adjust both controls simultaneously Valve Balance B and Valve Balance controls appear only when the dual 252 Drive Type is selected in the Edit Control Channels window TestStar Reference Manual 181 Adjust Menu Adjust Drive Adjusting valve balance Dither 182 To adjust the valve balance perform the following using the controls on the load unit control panel with no specimen installed 1 Auto zero force 2 Set up for a Force Pod control mode 3 Monitor the force sensor output on the display 4 Turn On the Actuator Positioning Control If the actuator holds its position valve balance is not needed If the actuator moves adjust the valve balance Note Perform a mechanical adjustment if the electrical valve balance cannot be achieved Go to the appropriate servovalve product manual for the mechanical valve balance procedure When a mechanical valve balance is complete perform this procedure again 5 Adjust the Valve Balance control to stop the actuator movement Make the adjustment before the actuator reaches its maximum displacement otherwise you will nee
175. full scale range 2 cm to optimize the maximum AA 0 cm sensor output for a test 2 cm 6 cm 2 cm Another example assume your test requires a 1 5 cm displacement A 6 cm or 3 cm range functions properly but a 2cm range provides the best resolution 154 TestStar Reference Manual Input Signals Acceleration The acceleration compensation feature can only be used for input signals that have the acceleration compensation option p n 481172 compensation xx installed This feature is enabled during the software installation procedure see Chapter 4 in the Installation manual Acceleration compensation minimizes unwanted feedback from vibration caused by the acceleration of any fixture and specimen mass attached to the force transducer This feature is applied to force input signals Acceleration compensation is common in the following Moving load cells The force transducer is mounted to the end of an actuator Load units that operate at high frequency with massive grips Note Adjust the acceleration compensation after the system has been tuned Also set up a Readout channel to monitor the input signal see Output Signals Chapter 3 nus isn py m Adjustment procedure Be sure no specimen is connected to the system N Set up the function generator for a command using a displacement control mode at a frequency approximately 80 100 of the maximum frequency the application will us
176. function closes the help window and returns you to the active window 60 The help window The help window includes a help panel within it The menu bar provides several functions for the help utility see the User s Manual for detailed information about the help system Function Generator Help a Services Options Help window menu bar TestStar Function Generator via Help Panel gt Use the Function Generator to generate a wave form to command the servo control loop Highlighed link PE Use the Define menu to create the servo loop command set up the counter and establish the home function Ends the test and causes the program command to return to FH Other links the mean level TestStar Reference Manual Using the Load Unit Control Panel Using the Load Unit Control Panel The load unit control panel LUC or Pod is located Emergency Stop near or mounted onto the 4 load unit The panel consists of a main module and up to 4 control channel modules The main module of the load unit control panel contains the controls and indicators that are common to all control channels Main One control channel Module module is added to the main module for each actuator in the test system 5 Interlocks Bae oe Stop x ontroller bate Auxiliary O m jo HPS a 5 HSM Control Control Channel Module Positioni
177. gineers if they service your equipment The optional TestStar A to Z manual p n 150371 xxx is an encyclopedia of testing It describes testing terminology concepts and topics from Actuators to Zeroing sensors You may also have other manuals for components included with your system that are not manufactured by MTS such as a printer manual or video monitor manual 10 TestStar Reference Manual Safety Precautions Safety Precautions A WARNING Overview TestStar Reference Manual Improper system installation operation or maintenance can result in hazardous conditions that can cause severe personal injury or death and damage to equipment or a specimen Read these Safety Precautions before you use the equipment It is very important that you remain aware of hazards that apply to your test system These Safety Precautions describe hazards that apply to your test system and offer suggestions for avoiding hazards This chapter contains general operating safety techniques and precautions for operators of materials test systems Because each test system is configured for a unique application and operates within a unique environment it is important to review these guidelines while considering your test system to ensure that the specific operating environment and operating procedures do not result in hazardous situations Although complete elimination of hazards may not be possible use the following guidelines to iden
178. h fixture to establish the mechanical zero of the sensor Use sensor zero if the sensor output is not zero 191 Display Input Signals Ranges Each sensor can be calibrated for more than one range A range re defines the input channel to represent a portion of the sensor s physical capacity You can create a range for any portion of a sensor s capacity Sree SN 5mm lt 10mm lt lt Ranges represent a portion of the sensor s capacity For example assume a displacement sensor has a full scale capacity of 10 cm A 5 mm range can operate across the full scale range of the sensor 5 mm A 2 5 mm range of the same sensor can operate across half the capacity of the sensor this redefines full scale to be 2 5 mm Note Be sure you select a range large enough to accommodate the maximum sensor output expected during a test 6 cm 2 cm Select a full scale range to wil A 2 cm optimize the maximum 0 cm sensor output for a test 2 cm 6 cm 2 cm Display Menu Another example assume your test requires a 1 5 cm displacement A 6 cm or 3 cm range functions properly but a 2 cm range provides the best resolution 192 TestStar Reference Manual IN Display Detector Actions Prerequisite Select the Limits radio button to display this window Any of the ten actions can be assigned to any detector actions 1 4 are shown for the Upper Limit actions
179. he control to the last level where the system was running OK The reason for the shutdown is listed in the Fault Status window usually it s caused by a detector Reset the system and continue tuning see Using the Fault Status Window in Chapter 1 Saving the tuning The tuning values are saved as part of the TestStar configuration file param eters See Using Configuration Files in Chapter 1 for more information TestStar Reference Manual 261 Tuning About Tuning 262 When to tune Checklist Tuning is needed whenever any of the following events occurs A change in the compliance or size of the test specimen For example you were testing steel and change to rubber The servo hydraulic configuration has changed For example a servovalve is replaced or changed to a different capacity The system is sluggish slow to react or not reaching the desired peaks However this is not always a tuning problem it could be insufficient velocity capability such as that resulting from a low capacity servovalve If a control channel or sensor is recalibrated The system is unstable indicated by a humming or screeching sound When you observe poorly controlled accuracy When you create a new control mode all control modes should be tuned Or if the sensor for a control mode is changed The end levels or frequencies are significantly different from those observed earlier in the test For example you notice
180. he default name is the same as the Signal Selection name Signal Type None Analog Bus Readout Programmable Specifies the type of signal you want to define Your selection displays appropriate controls at the bottom of the window Disables the output Use this selection to monitor analog signals during calibration and setup procedures This selection is available only on Output 1 and Output 2 Use this selection to monitor any sensor or valve signal This type of output can be scaled This selection customizes the output for use with optional applications Your MTS TestWare application manual will tell you if you need a programmable output TestStar Reference Manual 101 Edit Menu Output Signals Signal selection All six output signals are also available at rear panel connectors J41A and J41B See the Installation manual Chapter 3 for cable and signal information 102 The output signals DAC 1 though DAC 6 correspond with the rear panel connectors J71 through J76 Readout From DAC 1 Or From DAC 2 J71 Jie Output 1 Output 2 From DAC 3 O From DAC 4 J73 J74 Output 3 Output 4 From DAC 5 gt O From DAC 6 J75 J76 Output 5 Output 6 TestStar Reference Manual Analog Bus A Device is one of the plug in modules an ac dc conditioner or a valve driver Each device has a unique set of signals you can monitor Using the output TestStar Reference Manual Output
181. he peaks and valleys should be balanced Before adjusting Reset be sure the feedback signal is repeatable G e the same peaks and valleys are achieved For example assume the test command is centered on zero and the meter displays 3 mm and 5 mm You want to adjust the reset Q control to achieve 4 mm If the command is not centered on zero monitor the difference between peaks and valleys of the sensor feedback to the upper and lower levels of the test command Any difference should be the same Monitor the amplitude of the settled portion of the error signal The settled portion of the error signal should be the same level rm oe 4 Adjust Reset hi Ideal Waveform Monitor the amplitude of the settled portion of the error signal The settled portion of the error signal should be balanced Balance difference Zero F around zero Step 4 Tune each control mode and save your work 290 TestStar Reference Manual Tuning Procedure Repeat steps 1 3 for each control mode Then use the TestStar File menu to save the Tune settings as part of a configuration file TestStar Reference Manual 291 Tuning Tuning Procedure 292 TestStar Reference Manual Test Control Sys Appendix Contents Appendix A Firmware Error Codes 295 Lists the definitions of the error code numbers that can be returned when a firmware error occurs Appendix B Digital Controller Error Codes 303 Lists the definitions of
182. hould have its own configuration file This allows you to recall previous parameter settings so that you don t have each type of test to enter them again Although one normally associates user name with people s names consider making user names the same as test names if your workstation runs different tests This allows TestStar to automatically match the correct configuration file with a specific test Each user name a system administrator can assign a default configuration file for each oO user name This file along with a unit assignment set are automatically has a default loaded when you log onto the system See the Installation Manual for configuration file the procedure You can always change the configuration file after you logged into TestStar If your system has both experienced operators and trainees consider setting up separate files for the trainees Doing so can neutralize the possibility of their corrupting existing carefully adjusted files 5 ro a Q j 0 5 TestStar Reference Manual 51 Using the Fault Status Window Using the Fault Status Window The Fault Status window appears whenever a detector action or a hardware interlock becomes active See Clearing a Detector or Clearing an Interlock for procedures to remove the fault from the Fault Status window Use this window to fd A input signal name upper limit detector identify active detector in
183. i S CONTROL FUNCTION Shunt Cal Value Shows the value returned from the shunt calibration operation Shunt Cal Reference Shows the reference value determined during the sensor calibration The value represents the positive or negative selection in the Adjust Sensors window Checking shunt Compare the Shunt Cal Value with the Shunt Cal Reference value to cal determine if the sensor requires recalibration Ifthe difference is less than 20 mV the calibration is OK If the difference is between 20 mV and 150 mV you should adjust the excitation value in the Sensor Calibration program Add or subtract the shunt cal difference to from the excitation value If other ranges of the sensor use the same excitation value also change the excitation value for those ranges If the difference is more than 150 mV you should recalibrate the sensor with the Sensor Calibration program TestStar Reference Manual 157 Adjust Menu Input Signals How it works Pressing the Shunt Cal button shunts a precision resistor across one arm of the sensor bridge to create an imbalance that affects the sensor output The imbalance produces a reference value to verify the calibration accuracy of the sensor and the integrity of the cable Positive a Calibration The precision resistor A shunts across one arm to i gt check positive shunt calibration or across a different arm to check Shunt Sensor negative shunt cali
184. ically to check the accuracy of a dc sensor and associated conditioning circuit Selecting Pos or Neg checks the appropriate calibration nua isnl py Note You cannot check shunt calibration of a sensor being used with the active control mode when hydraulic pressure is on See the Shunt Cal window for information any difference between the reference value and cal check value You also use shunt calibration to check accuracy when you move a sensor and sensor cartridge to a different dc conditioner or if you change the sensor cable the cable resistance may be different Shunt calibration does not compensate for changes in the sensor sensitivity over time TestStar Reference Manual 153 Adjust Menu Input Signals Ranges Each sensor can be calibrated for more than one range A range re defines the input channel to represent a portion of the sensor s physical capacity You can create a range for any portion of a sensor s capacity Ranges represent a portion of the sensor s capacity For example assume a displacement sensor has a full scale capacity of 10 cm A 5 cm range can operate across the full scale range of the sensor 5 cm A 2 5 cm range of the same sensor can operate across half the capacity of the sensor this redefines full scale to be 2 5 cm Note Be sure you select a range large enough to accommodate the maximum sensor output expected during a test 6 cm y 2cm 7 Select a
185. ifold PIDF P Proportional Gain Control Integral Gain Control D Derivative Gain Control F Feed Forward Gain Control Pod or LUC The Load Unit Control panel mounted to the load unit Stroke or Length Displacement TestStar Reference Manual vononposuy 45 jo lt O jm ge Ho Introducing the TestStar Software Introducing the TestStar Software The OS 2 desk top is shown here The Windows NT desk top shows all the icons in a single Program Group TestStar programs oe TestStar Function Generator 46 TestStar software requires the Windows NT version 3 51 or newer or OS 2 version 3 0 or newer operating system You should have some knowledge of the operating system to successfully use TestStar fa MTS TSII Icon View TestStar Utility Function Config Generator AT MTS TSII i System Unit Assignment Administration Set Editor a vE Sensor Diagnostics _ Load Path Calibration Stiffness Editor The TestStar software consists of a number of programs The TestStar application is the main program that sets up a test and controls the digital controller Double clicking this icon starts TestStar by opening the Login window where you must enter a user name and password The Function Generator program creates and runs a test command It can produce simple monoto
186. igns values and selections to the parameters in each TestStar window Each user name opens a TestStar configuration file Each TestStar configuration file is designed for a specific test If you use configuration files correctly you will have a configuration file for each test you run You need to know the names of the configuration files and what they were designed for You can always select a different TestStar configuration file after you log onto TestStar Note TestStar configuration files can be located in any computer directory see the Save As window in the File menu of the main TestStar window If you do not change the default settings when you save a configuration the file should be located in the DB directory within the TestStar directory Use the following form to type the configuration entry field where filename is the name of your file and TCC is the extension C TS2 config filenmame TCC The unit assignment set contains a selection of preferred units for each dimension If you have not created a set of preferred units select one of the predefined sets The preferred set of units is used as the initial selections for the TestStar parameter values The unit assignment for any parameter can be changed after you log onto TestStar For example you may prefer a set of units that automatically selects millimeters instead of inches for all length parameter values By using a preferred set of units you will not need to selec
187. ility can occur at some frequencies Amplitude error refers to the tendency of amplitudes measured by the sensors to be less than the desired amplitudes Phase lag refers to the tendency of the feedback signal to trail the command signal When Peak Valley is the selected compensator the convergence rate applies to the signal amplitude and mean When PAC is the selected compensator the convergence rate applies to both amplitude and phase Amplitude Te mmand an Error lt est command and desired feedback lt Initial feedback Test Command Convergence Feedback The amplitude error and phase lag are determined when the feedback is compared to the test command When the convergence rate is properly adjusted the feedback signal converges to the command rapidly without instability If the max limit is set too low convergence may not be possible 172 TestStar Reference Manual Limit adjustment Assume the limit is set at 2 If the test command must be boosted 6 mm to achieve the desired 2 5 mm amplitude the command is clipped at 5mm The limit should be increased to 3 Changing the adjustment range TestStar Reference Manual Adjust Compensators The Limit setting establishes how much amplitude compensation is available through PAC The limit value represents a multiplier of the command A setting of zero results in a command of zero For example assume a command with an amplitude of
188. imum Action x r oe he Aniud Control Mode Selection alve Balance A 0 000000 V ither Amplitude 0 100000 Vpp E fea x lt T gt Ko gt i Error Detector Values Maximum units The Drive window you will see depends i 5 x j Dri on your Drive Type selection in the Edit AGIUSEBENS Controls Channel window Minimum units Control Channel Selection a Dl a j x Control Channel 1 Valve Adjustments Valve Balance 0 000000 V AC Gain 1 00000 5 7 5 Adjust Underpeak Detecto ies a iat Control Channel Selection _ Dither Amplitude 0 100000 Vpp Rate Gain 0 000000 a v RE 1 K gt Underpeak Detector Values Dither Frequency 625 000 Hz Inner Loop Gain 1 00000 Inpu t Signal g lt gt k l gt Action x Spool Zero 0 000000 V Inner LoopPhase 0 000000 deg K g Maximum units lt DI EK gt 3 lt Setup a Minimum units lt gt Sensitivity units Chapter 4 Adjust Menu Contents TestStar Reference
189. imum and maximum values must be entered to define a Minimum range The range represents maximum peak and minimum valley values the input channel must achieve each cycle Maximum underpeak is the most positive least negative value and Minimum underpeak is the most negative least positive value Actions An action determines what happens when an underpeak has been detected Refer to Chapter 1 for instructions on how to reset actions The following are the actions you can use Disabled turns the error detector off Indicate displays a message in the Fault Status window that the detector has been triggered Hydraulics Off turns off the hydraulic pressure at the service manifold displays a message in the Fault Status window and lights the Aux indicator on the LUCP nua isnl py Interlock turns off the hydraulic pressure generates an interlock signal clamps the servovalve and displays a message in the Fault Status window You must correct the reason for the interlock and use the Reset button located on the load unit control panel to clear the interlock Customer defined these actions can be defined to ramp or hold the control channel output These actions may also be identified with a customer defined name or as Action 5 10 Note Customer defined actions are created with the Edit Detector Actions window Sensitivi Sensitivity is the amount of change the signal must change to
190. in use Use extreme caution when handling or supporting the specimen so that fingers and hands are never exposed to potential crush points during specimen installation Use tongs to handle the specimen To move the crosshead on load units not equipped with hydraulic lifts support the crosshead using a lifting device capable of supporting the crosshead weight plus the weight of any fixtures and grips Remove any slack from the crane cable or chain before unlocking the crosshead A hazardous situation exists when air becomes trapped inside the lift cylinders on load units equipped with hydraulic lifts Trapped air can cause erratic movement of the crosshead when the lift controls are operated After installation or if the crosshead does not move smoothly bleed the lift cylinders as directed in the load unit product manual Stay clear of the lower platen and the crosshead when operating the lift controls TestStar Reference Manual 19 Safety Precautions Checking the Hardware Setup Check for hard ware configuration changes Preface When you have multiple force sensors 20 Always determine the necessary hardware configuration required for the test to be performed Make all necessary changes to the configuration before applying electrical power or hydraulic pressure Due to the comprehensive nature of the system s testing capabilities different types of tests may require changes in the hardware configuratio
191. indow 239 Creating a New User 240 You need to know the following to use the System Administrator How do you want to use user names What are the file names of the TestStar configurations What to do if you cannot log onto TestStar A user name can represent people or test configurations Consider how you expect to use the TestStar system so you can determine how to use user names For example assume you have several people using TestStar that run specific tests In this case you may want to assign user names that represent the individuals Assign the following A user name to identify the individual A unique password for each individual Continued 231 N lt N 7 S gt a 5 j 0 N 7 a p ji 0 5 What isa username A configuration file that the individual is most likely to use other continued configurations can be opened once TestStar is started The TestStar programs that the individual needs to use such as the Function Generator or TestWare SX for tests For example assume you have several competent people using TestStar to run many different types of tests In this case you may want to assign user names that represent specific tests Assign the following S jo a g N _ am E g lt eD Nn a N A user name to identify the specific test A password one password for all user names is easier to remember assuming all operato
192. ing like the sample shown here Know where the potential load unit pinch and crush points are and take appropriate safety precautions Refer to the discussion on crush point hazards Emergency Stop x System interlock devices should always be used and properly adjusted as described in this manual Test all interlock devices for proper operation immediately before a test Never rely on interlock devices to protect you These devices are designed to minimize the chances of accidental damage to test specimens or to equipment TestStar Reference Manual Safety Precautions Do not bypass the Do not use any interlock reset to bypass the interlock chain while interlock chain attempting to start the hydraulic power supply Doing this could cause the hydraulic pressure to be applied regardless of the interlock condition Do not disturb sensors Do not bump wiggle adjust disconnect or otherwise disturb a sensor e g an extensometer when hydraulic pressure is applied and the system is operating under control from that sensor Ensure secure cable Do not change any cable connections with electrical power or connections hydraulic pressure applied Changing cable connections with the system operating can result in an open control loop condition An open control loop condition can cause rapid unexpected system response resulting in severe personal injury or death or damage to equipment Also ensure all cables are connected if you make
193. inistration window and returns you to the TestStar window Define Menu Configures the window for to edit users or applications Add Adds a new user or application to the list shown Displays the New User or New Application window where you can define a new user or application Delete Removes the selected user or application from the list Select an item from the list Pressing the Delete button displays a dialog box that asks you to acknowledge your action Edit Changes the information that defines a user or application Displays the Edit User or Edit Application window for the selected item TestStar Reference Manual 233 System Administration Window Users Users are names representing individuals and their access to TestStar applications A user ID and a password define each user Optional information can include the individual s full name When you log onto TestStar you must enter a user name and a password You can use upper or lower case characters for the user name and password S jo D g N S E TO lt eD Nn a N Applications When you install an application you can assign which users can have access to the application Applications are programs such as the Function Generator TestWare SX or the sensor calibration program Adding and editing The Add and Edit buttons work the same for users and applications __System Administration File Define Help Users
194. iplex switching processor module odp output device used for DAC s and valve drivers rom remote object manager keeps track of labels such as input signals control channels etc rtc real time clock rtr router distributes messages within the transputer network Sgc segment generator command gt az ge 5 aa j 0 gt lt TestStar Reference Manual 295 Firmware Error Codes gt lt ge eD er lt 296 ERROR NO TYPE DESCRIPTION 1 act internal error unpacking parameters 2 act selector not implemented 3 act received selector for wrong class 4 act received invalid destination oid 5 act received invalid action type 6 act received parameter out of range 7 aio received selector for wrong class 8 aio selector not implemented 9 aio internal error unpacking parameters 10 aio parameter out of range 11 aio cannot alter running system 12 aio channel cannot be selected 13 aio excitation over range reset to max 14 aio excitation under range reset to min 15 aio error writing data to mux object 16 aio invalid address for desired function 17 aio undefined register setting detected 18 buf received selector for wrong class 19 buf selector not implemented 20 buf internal error unpacking parameters 21 buf parameter out of range 22 buf no data is available in the buffer 23 buf no buffers are available 24 buf channel
195. ique calculated input signal A calculated input signal applies the equation to each sample of the input signal ies ou j 0 mk 5 Note Calculated input signals require processing time from the digital controller This reduces the maximum servo loop update rate and the maximum test frequency range available to you A calculation signal type can also be used as a calculated constant Csee Calculation Constants on page 122 Signal Selection G Calculated 1 8 Signal Definition Signal Name Signal Type Dimension Display Units Signal Label Calculation Maximum Minimum Type formula here Using a flawed calculated input in a control mode can cause unexpected actuator movement that can injure someone or damage equipment Be sure your calculation contains no errors or unworkable algebraic expressions 93 Edit Menu Input Signals Functions Use the operators and with the following math functions FUNCTION DESCRIPTION arccos x Returns the arc cosine of x x is in radians Domain 12868 0 12868 0 Range 1 0 1 0 arcsin x Returns the arc sine of x x is in radians Domain 12868 0 12868 0 Range 1 0 1 0 arctan x Returns the arc tangent of x x is in radians Domain 6434 0 6434 0 Range avgly x Returns the last x samples of input
196. ire waveform Instead zoom in on the area of interest 278 When you tune the servo loop you need to monitor the results of your adjustments There are two ways to monitor a waveform during tuning An oscilloscope is preferred The TestStar scope is adequate if you don t have an oscilloscope Note Set up your scope to monitor the area of the waveform that shows characteristics useful for tuning You can monitor the sensor feedback or the error signal of the contro mode The accuracy of the waveform represents how well it reaches the amplitude of the command or how repeatable the end levels are The peaks and valleys of triangle and haversine waveforms should be consistent Use the area of the square wave after the ringing settles to monitor the end levels These are the areas of interest for these waveforms 4 If the amplitude of the feedback cannot be achieved without going unstable and the end levels are repeatable simply increase the command to achieve the desired end levels TestStar Reference Manual Monitoring the error signal The error signal from a square wave should show the feedback ringing centered on the zero reference A static accuracy difference in the error signal can be corrected with reset The square wave shape of the error signal represents the phase lag of the feedback signal The error signal from a haversine should be a small amplitude sine waveform that looks like a rou
197. its Cancel Help Using the window The window displays the full scale value of the selected control mode range You can change the maximum and or minimum setting of the Mean control to a value less than full scale Set the Max and Min limits to different levels You cannot set the maximum range to a value less than the current Mean setting or the minimum range more than the current Mean setting To change a scroll range value type the new value in the entry field For example assume the Mean o cm Mean 0 cm control mode range is 5 3 cm With the Max and Min values set With the Max and Min values set to 3 cm and 3 cm the zero to 3 cm and 1 5 cm the zero reference is centered reference is offset Changing the range re Mean 2 cm C Mean 2 cm scales the control setting m z The Max and Min values are 3 Changing the Max setting to cm and 3 cm and the Mean 2 cm causes the Mean control control is 2 cm to reach the maximum range TestStar Reference Manual 211 EF a ie e p 0 5 ap Oo 5 a Function Generator Window Set Amplitude Scroll Range Setting the scroll range of the Amplitude adjustment ensure the control is within a safe range Reducing the scroll range also increases the resolution of the control
198. k the Load Path Stiffness Editor icon You may need to log into the Load Path Stiffness Editor Enter your user name and password in the MTS Login window K The Load Path Stiffness MTS TSII Editor is located in Utility folder of the MTS TSII folder m Utility Ilcon View a TestStar Utilities Load Path Stiffness Editor File Help psignment itor Current Set 1000Hz Compression ps Load Path Stiffness Editor This is for a compression 2 platen setup on the a 1000Hz Elastomer Test machine Displacement A Acceleration 1 Angle Strain Define Stiffness gt lt gel eD lt 320 TestStar Reference Manual Load Path Stiffness Editor Step3 Create a new stiffness set Perform the following to initiate a new load path stiffness set A B Use this window to enter the stiffness values Select New in the File menu Type a description for the stiffness set in the entry area of the Load Path Stiffness Editor window Highlight each input signals that will have a correction value only sensors that can measure displacement are listed Press the Define Stiffness pushbutton to display the Define Stiffness window A Define Stiffness Z e Linear Input 1 I Angular Stiffness Cancel Select an input signal in the Define Stiffness window If you
199. l defined for readout Set up a Readout channel to monitor the sensor signal of the input channel used for the control mode you intend to tune Or you could monitor the error signal You can tune using either signal To monitor the error signal set up a readout channel to use the analog bus Set up the oscilloscope to monitor the feedback of the input signal or the error waveform Connect the oscilloscope to the appropriate Readout connector on the rear panel of the digital controller J71 J76 oo oo aaa o o TTS iii a BNC connectors J71 J76 correspond with the output signals 1 6 280 TestStar Reference Manual Auto tuning Prerequisite How it works Is auto tuning good enough TestStar Reference Manual Auto tuning The auto tuning feature automatically tunes control modes for a low to moderate level of tuning The auto tuning feature is only available for PIDF control modes using the segment generator SG command source Auto tuning uses an auto tuning control mode to control the actuator while the selected control mode is being tuned except when the auto tuning control mode is undefined The first control mode to be auto tuned should normally be a displacement or angular control mode which doesn t require a specimen When the auto tuning control mode is undefined auto
200. lation This way the constant can be changed with this window instead of changing each formula that uses a specific constant x Edit Calculati Constants o Constant Selection B Constant 1 16 Constant Definition Constant Name Dimension Display Units X Current Value units Referenced In List of calculated input signals a that use this constant Calculation a CONTROL FUNCTION Constant Selection Selects a constant to define You can define up to 16 constants Constant Name Names the constant Type a name you wish to call the constant Use this name in the formula that defines a calculated input signal The default name is the same as the Constant Selection Dimension Assigns the type of units for this constant Select a dimension that is appropriate for the constant Display Units Selects the specific units you wish to assign to the constant The selected dimension determines what units are available Current Value Specifies the value of the constant Referenced in Calculations Lists all the calculated input signals that use this constant This helps you determine the impact of changing the value of the constant 122 TestStar Reference Manual Calculation Constants Examples The following constants are referenced in the Calculated Input Signal description y zZ
201. lay perform its task um Clears the display Starts displaying data on the scope File menu Prints the current Scope display Display Scope Print Printer Setup f Displays the Printer Properties window for you printer see your system software E I Opens the Display Options window where you select colors _ for the scope components Colors Select Font 0 l 0 54 i Displays the Font window B lt Any system font can be applied to the display So Control menu nua Avyjdsiq NISS Stop Starts displaying data on the scope ji T T aaa Clears the scope display so A Run new data can be displayed oxo aX 0 25 5 0 50 0 00 1 0000 2 0000 TestStar Reference Manual 199 Display Menu Display Scope Set Scroll Range Window x Use this window to Range establish the adjustment 100 00 lt Value lt 100 00 range for one of the axis Maximum 100 00 Minimum 100 00 Note The default values are 100 min and 100 max full scale for a signal a
202. lect Font Window 76 Print Preview Window 77 TestStar Reference Manual Chapter3 Edit Menu 83 TestStar Reference Manual Input Signals 85 Edit Input Signals Window 88 AC amp DC Conditioner Signal Type 90 External Signal Types 91 Calculation Signal Types 93 Assign Sensor Window 96 Define External Sensor Window 97 Output Signals 99 Edit Output Signals Window 101 Analog Bus 103 Readout 105 Programmable Output 109 Control Channels 110 Edit Control Channels Window 112 Control Modes 116 Edit Control Modes Window 117 PIDF Control Mode 118 Channel Limited Channel Control Mode 120 Cascade Control Mode 121 Calculation Constants 122 Detector Actions 124 Edit Detector Actions Window 126 Hold Actions 127 Ramp Actions 128 Load Path Stiffness 129 Edit Load Path Stiffness Window 130 LUCP Display 131 Toolbar 133 Configure Toolbar Window 134 Meters 136 Meter Definition Window 137 Timed Data 138 s a ge C3 5 5 e N Nn S o S n So je Q iS Peak Valley Data 139 Span Mean Data 140 Max Min Data 141 Scope 142 Chapter 4 Adjust Menu 147 Input Signals 148 Adjust Input Signals Window 149 Set Zero Scroll Range Window 156 Shunt Cal Window 157 Tuning 159 Tune PIDF Window 161 Auto Tuning 163 Tune CLC Window 164 Tune CASC Window 167 Set Scroll Range Window 169 Adjust Compensators 170 Error Detectors 174 Underpeak Detectors 177 Adjust Drive 180 Adjusting 252
203. led you may choose to use a broken specimen Uses a triangle waveform for the initial tuning Do not use a square waveform for tuning A square wave can cause the extensometer to move or fall off the specimen which can cause the system to go unstable The expected range for the proportional gain setting may be much greater than that for of length or force If gain is too low the system may be unstable at low frequencies with large static offsets Or it may be uncontrollable Tune for each type of specimen TestStar Reference Manual 267 Tuning About Tuning CLC control mode The CLC channel limited channel control mode is used to install specimens into the grips of a load unit This control mode uses two feedback channels one to move the actuator master and one to limit the movement limiting Upper Upper Limit If force feedback upper limit E gt And displacement error is positive Limit Error Then use upper limit error This CLC control mode can only be used with the Force cm 10 0 Actuator Positioning Feedback 2 Control on the load unit control panel Lower K Lower Limit If force feedback lt lower limit gt And displacement error is negative Limit Error Then use lower limit error Pod Displacement Otherwise use displacement error Command Error Displacement Master P Master Fol
204. lename field 4 Press the OK button to open the file TestStar Reference Manual 73 5 S oO oO lt lt Save Window Use this window to save a TestStar configuration file The default path for this window is B Save Window x File Name Directories A c ts2 config C TS2 config Cancel Al joc a Some systems have the 4 default TS2 directory located on the D drive Ne recommend a List Files of Type Drive a configuration file for each Network type of test you run TestStar tcec s c DISK1_VOL1 a etwor CONTROL FUNCTION File Name Displays TCC in the entry field Type the name you want to call the configuration file here Files Lists the configuration files in the current directory Selecting a file name displays it in the File Name entry field List Files of Type Selects the type of files displayed in the File list By default lt All Files gt is selected Select file type TCC to display only the files with the TCC extension in the Files list Directories Lists the available directories for the selected drive Double clicking a different directory displays the files of the directory in the Files list and any other directories in the Directories list Drive Displays the current drive All root directories of the drive are listed in the Directories list Network P
205. libration program Calibration Info Pressing the Calibration Info button opens this window 96 This window displays basic information about the selected sensor The information is recorded when the sensor is calibrated 4 sensor name Calibration Date MM DD YY Model Number Serial Number TestStar Reference Manual Define External Sensor Window Prerequisite Use this window to define an external signal from another control system without defining an external signal with the sensor calibration program Input Signals An external sensor is a sensor signal that is conditioned by another control system ies ou j 0 5 As an external sensor the signal does not use a Model 490 21 DC Conditioner or a Model 490 22 AC Conditioner As an external command source the signal is from a remote program device such as a function generator or profiler Note See the Installation manual Chapter 10 for detailed information about connecting and defining external sensors You must be defining or editing an external input signal to reach this window The external signal must be within 10 volts Sensor Name Sensor Range 1 00000 Offset 0 000000 m Inverted CONTROL FUNCTION Sensor Name Names the external signal Call it anything you want Sensor Range Defines the range of the input signal Enter a va
206. ltiPurpose TestWare etc Know the version of each software application involved TestStar Reference Manual How to Obtain Technical Assistance Other software being used What other software was running when the problem was encountered This could include such things as screen savers keyboard enhancers and print spoolers Know the name and version of each software program involved While on the phone Prepare yourself for troubleshooting while on the phone Try to call from a telephone close to the system so that you can conduct some active testing over the phone Have the original operating and application software disks available If you are not familiar with all aspects of the operation of the equipment have the necessary people available to assist you Prepare yourself in case a call back is required Remember to ask for the work order number Record the name of the person who helped you Make sure you are able to write down any specific instructions to be followed such as data recording or performance monitoring TestStar Reference Manual 29 Preface How to Obtain Technical Assistance 30 TestStar Reference Manual m TestS tar IT rol Syst Chapter 1 Introduction Opens a previously saved configuration file that includes the settings for all the TestStar windows Saves the current configuration of all the TestStar window settings g File Selects the font
207. lts must be cleared with the Reset switch on the load unit control panel Determine the For example assume an excessive limit is detected The selected action holds the output so the detector can t automatically clear itself cause of the fault If pressing Reset doesn t clear the fault there are two ways to clear this detector Fault Status Window Detector Faults Generated Slot 1 lower limit detector The Hold Output action is a customer defined action that holds m F Slot 1 the actuator at its current output Limits Upper Limit 5 000000 cm Action lt gt Hold Output Lower Limit 5 000000 cm Action lt gt Hold Output x Sensor Zero Unlock Shunt Calibration a A RI E that the current output 5 200000 cm exceeds the lower limit Auto Zero D w Q oO 11 jo ean O jm ge Ho One select an APC mode in the main TestStar window and use the Actuator Positioning Control on the load unit control panel to adjust the current output with in the upper and lower limits Then press the Reset switch Two open the Adjust Input Signals window and change the lower limit value Then press the Reset switch to clear the fault 54 TestStar Reference Manual Using the
208. lue that defines 10 volts The units are assigned in the Edit Input Signals window Offset Specifies an electrical offset in volts that is applied to the external sensor signal Inverted Reverses the polarity of the input signal TestStar Reference Manual 97 Edit Menu Input Signals 98 Range Offset For example assume the external sensor is measuring length If the full scale output of the sensor represents 75 mm then enter 75 as the Range and select mm for the Range Units This is a 100 range Another example assume you are using the same sensor as above and your test will operate within 10 mm and the external conditioner can select different ranges You may enter a value smaller than the full scale output but larger the expected output In this case you could enter a value that matches the range of the external conditioner A calibrated sensor output from an external conditioner may change due to cable length resistance or environmental factors 1 Set up the external conditioner to provide a null output 2 Monitor the external conditioner null signal with the Sensor Output value in the Adjust Input Signals window or the Display Input Signals window 3 The Sensor Output value should also be null If not record the difference 4 If necessary enter the signal difference using the opposite polarity into the Offset entry field TestStar Reference Manual Output Signals About the external d
209. m highlights the item menu item name menu item Menu menuitem gt Three types of menu items are used selected item Menu items with an ellipsis mark indicates that the menu selection displays another window Menu items with an arrow indicate the menu selection displays another menu All other menu items perform an action and may display a dialog box Some menu or window items may be dimmed grayed out This indicates either of the following The item is not available in the application Menu A prerequisite action has not been performed yet menu item Using a mouse Select the menu name and drag the mouse to highlight a selection Using the keyboard Menus and menu items identify their keyboard access with an underlined letter Press the Alt and the underlined letter keys to display the menu then press only the underlined letter of a menu item to activate the selection The up or down arrow keys can also select a menu item when a menu is displayed Press enter to activate the selection 5 ro a Q j 0 5 TestStar Reference Manual 39 Introduction How to Use This Manual Radio button Check box 40 A radio button is a small oval next to a selection A function name accompanies the group of selections you can enable You can enable only one of the choices A filled in oval indicates the enabled selection Using the mouse
210. m response from the servo loop system It also places a large acceleration on the test system and specimen A square waveform is most useful for tuning length displacement Do not use a square waveform when tuning a control mode that uses an extensometer The large accelerations can cause the extensometer to move or fall off the specimen which can cause the system to go unstable Monitor the feedback or error signal to evaluate the system stability A triangle waveform requires the actuator to move at a constant rate This requires the servovalve to move quickly between two discrete openings A triangle waveform is useful for all levels of tuning Continued TestStar Reference Manual Waveform continued Sine Frequency Amplitude TestStar Reference Manual About Tuning Use a triangle waveform if a square waveform creates excessive velocities or acceleration for the type of specimen being tested Monitor the error signal to evaluate the system stability A sine waveform requires the servovalve to move at a variety of rates A sine waveform is a poor waveform to evaluate system stability Monitor the error signal to evaluate the system stability A low frequency waveform is adequate for most testing Tests at higher frequencies cause a frequency shift that cannot be completely corrected with the PIDF adjustments Do your initial tuning at a low frequency then fine tune at the highe
211. mation is shown A vertical scroll bar indicates that a selection field contains more information than can be shown at one time Use a vertical scroll bar to scroll up and down through a list of selections or text The slider box controls the portion of information that is shown The arrow icons step the portion of information up or down one selection Horizontal scroll entry field above the scroll bar to LA ae show a value Use a horizontal scroll bar like an adjustment to increase or decrease a value Ifthe name of a horizontal scroll bar is in a pushbutton the adjustment range of the horizontal scroll bar can be changed Using a mouse Drag the slider box until the desired selection or value is displayed Use the arrow icons to step through the selections or increment the value For vertical scroll bars click above or below the slider box to page up or down through the selections Using the keyboard For vertical scroll bars use the Home and End keys to jump to the top or bottom of the list Use the Page Up and Page down keys to page through the selections Use the up and down arrow keys to step through the list one item at a time 41 5 ro a Q j 0 5 Introduction How to Use This Manual 42 Button Entry field A button performs an action or displays a window The most common buttons are the following Pressing an OK pushbutton accepts any changes y
212. mbination requires that any test laboratory setup provide adequate protection for bystanders as well as for system operators Be sure to study the manuals to gain sufficient knowledge of system operation and service and modification procedures Refer to the TestStar Installation Manual for information about emergency stop connections on the digital controller rear panel A competent engineer should be responsible for system installation or modification The engineer must consider how changes to an existing facility or system might affect safety and reliability TestStar Reference Manual 21 Safety Precautions Supervising the System The engineer responsible for any installation modification or alteration to a test system should consider the following precautions Protect all system hoses and cables from sharp or abrasive objects that could cause hose or cable failure Route hoses and cables away from areas that expose them to possible damage To avoid thrashing and subsequent deterioration hydraulic pressure hoses should be anchored to the ground or tied to a corresponding return line within two feet of the flow outlet end As an alternative hoses can be run in trenches or other protected areas Design enough fittings into a system to allow for the accommodation of dimensional errors without placing severe strains on the fittings or tube ends Be sure to use appropriately rated fittings from a reputable manufacturer
213. minimum range more than the current Offset Zero setting For example assume the control mode range is defined as 3 cm Offset Zero 0 gt 3 cm 0 cm 3 cm With the Max and Min values set to 100 and 100 the zero reference is centered Offset Zero 0 gt 1 5cm 0cm 3 cm Changing the Min setting to 50 re scales the adjustment range to 1 5 to 3 cm The zero reference is also offset Changing the range re scales the control setting Offset Zero 50 lt gt 3 cm 1 5cm 3 cm The Max and Min values are set to 100 and 100 and the Offset Zero control is set to 50 Offset Zero 50 gt 3 cm 1 5 cm Changing the Max setting to 50 causes the Offset Zero control to reach the maximum range TestStar Reference Manual Input Signals Shunt Cal Window A shunt calibration reference value is determined when the sensor is calibrated for use with a specific range The reference value is usually set for approximately 80 full scale Shunt calibration is used only with dc sensors Both positive and negative shunt calibrations are supported This window displays the results of the shunt Shunt Cal Value 9 87600 Volts A calibration operation Shunt Cal Reference 8 69961 Volts T a
214. mode force control control mode may be different Units N Initial ramp rate 1 x The information in this window appears in the Definition area of the Function Generator Waveshape Triangle window Ampl ramp time 1 lt I lt Waveshape order J Inverted Step 4 Define the counter A Select Counter in the Define menu B Turn the Preset Count Off to cycle continuously Count Menu Option Preset count On This window sets up a continuous cycle Preset count Current count 0 Total count 0 OK Cancel Heip i pur S o S eD S 0 S gt a 226 TestStar Reference Manual Designing a Test Program Step5 Define the home ramp A Select Home in the Define menu B Complete the Home Menu Option window to define the Home button ramp Home Menu Option The control mode shown may have a different name than the one you may use Control mode force control End level A typical home ramp returns the actuator to Its Time starting position Step 6 Parameterize the program command Set the Mean Amplitude and Frequency controls as shown to parameterize the waveform 4 Function Generator El Define Help Csee ma C
215. mode uses two feedback sources displacement usually controls the inner loop and force usually controls the outer loop Using the controls 168 Command Outer Loop A cascaded control mode uses any two sensor feedback signals The outer loop has proportional gain P and rate D adjustments The inner loop has proportional gain P and reset 1 adjustments Program P Inner Loop D Command gt DS Inner Loop 4 P E Valve I Command gt A Displacement Angular Force Feedback Feedback You should be familiar with the concept of tuning the servo control loop before you attempt to adjust the tuning controls The following is a tuning guideline Note Go to Chapter 9 to determine an appropriate tuning strategy for your system and specimen 1 Install a dummy specimen If a displacement control mode is to be tuned a specimen is not required 2 Select the control mode you want to tune 3 Select a tuned PIDF control mode that uses the same feedback as the inner loop typically length and record P and I values Enter these values for the P and I controls of the inner loop 4 Set up the Function Generator or select a TestWare SX test procedure for your test command 5 Set up the TestStar scope or an oscilloscope to view th
216. more of the existing input signals they also have no ranges associated with them External input signals cannot be zeroed because a zero condition cannot be assured when the circuit that applies the zero correction is located outside the TestStar environment All input signals associated with an AC or DC conditioner plugged into the TestStar chassis have a zero button The button is enabled and disabled dimmed or grayed out with the Adjust Input Signals Window An input signal that is defined as Calculated or External does not have a zero button available Pressing an enabled Zero button zeros the current output of the input signal This redefines the reference for zero to be the current sensor position and output Note You cannot zero a sensor being used with the active control mode when hydraulic pressure is on Also do not zero a cold system The actuator should be cycled so silting doesn t affect the zero function The following are examples why you may want to zero a sensor output nua Avyjdsiq Assume the LVDT is calibrated with the zero point at mid actuator displacement Also assume that after the specimen is installed the LVDT sensor output is not at zero In this situation you would want to zero the output After installing a grip you may zero the force channel to remove the effects of the grip tare weight on the force sensor output Before installing an extensometer use the zero pin or gage lengt
217. n sequence Bypassing the login The following procedure describes how to bypass the Login window A Select a TestStar program but do not open it B From the Program Manager File menu select New C Select Program Item in the New Program Object window and press the OK button D Add the mts mts parameters to the end of the path and file name in the Command Line entry field Repeat steps A D for any TestStar program Description Function Generator OK Here the settings file opens the Function Command Line C ATS2 FG exe mts mts Cancel Generator using the Working Directory C TS2 Browse default MTS user name and password Shortcut Key None Change Icon Run Minimised Help DO NOT change the Path and File Name or the Working Directory entries DX Run in Separate Memory Space gt az ge 5 aa j 0 gt lt TestStar Reference Manual 315 Bypassing the Login asl TO eD er x 316 TestStar Reference Manual Appendix F Load Path Stiffness Editor Load Path Stiffness Editor The Load Path Stiffness Editor creates sets of values that compensate for deflection in the load path Use the Load Path Stiffness Editor to create a stiffness set for each configuration of the load path Note The stiffness sets created by the Load Path Stiffness Editor are used by the 790 3x processes only Prerequisites TestSt
218. n to accommodate specific desired test results Examples of hardware configuration changes include Changing from one extensometer to another Changing from a high capacity force sensor to a low capacity force sensor Changing the sensor cartridge for higher or lower resolution testing Changing between servovalves on dual servovalve manifolds If the system is configured to use more than one force sensor e g typically one with a force rating equal to system capability and another with a lower force rating additional considerations may be necessary to protect the low capacity force sensor from damage Using a force sensor rated below the maximum capability of the system is basically the same as changing a sensor cartridge It does not reduce the full force capability of the hydraulic actuator It only increases the sensitivity of the electronic control and readout components TestStar Reference Manual Safety Precautions Installation and Modification Guidelines The following installation and modification guidelines recommend design practices and modified system setup considerations that should be observed to minimize system operating hazards Even when using the system for the first time and setup changes seem unlikely a thorough understanding of the following guidelines will help in understanding system operation Tests often operate for extended periods with no supervision and may attract spectators This co
219. nd or retract Actuator l Lo Positioning Control Clockwise Retract Actuatol 66 TestStar Reference Manual Using the Load Unit Control Panel Module The control channel modules are available in three different configurations based on the capabilities of the hydraulic service configu rations manifold also called HSM actuator manifold or station manifold An HSM with Off Low and High pressure capabilities include switches and indicators for these functions An HSM with Off On pressure control do not include a Low pressure switch If an HSM is not used no hydraulic switches are included LUC chassis Control channel modules added to the main module require different configurations LUC chassis configurations LUC chassis configurations for 1 2 3 and 4 channels 5 gt Qu om e gt 5 TestStar Reference Manual 67 Introduction Using the Load Unit Control Panel 68 TestStar Reference Manual E Test Control Sys E open Open filename ltscontig TCC Type of file Drive lt All Files gt z c fos2 El File Directory 2 S Cx A K aA TS2 list of files els s i c Configuration y a kI a E gt Save as filename Save file as type Drive All Fil C os2 z
220. nd the time axis has a range of 0 to the trace time Using the window The window displays the full scale value of the selected input signal You can change the maximum or minimum setting of the scroll bar to a value less than full scale The Max and Min parameters can be set to different levels To change a scroll range value type the new value in the entry field You cannot set the maximum range to a value less than the current output or the minimum range more than the current output For example assume the Y1 axis is an LVDT input signal its range is 5 mm and you expect an LVDT output between 0 mm and 3 mm Setting the scroll bar range to a minimum of 0 5 mm and a maximum of 3 5 mm changes the size of the slider box This represents the scale of the graph You could move the slider box to the top of the scroll bar and the graph would be scaled to show from 1 to 5 mm 200 TestStar Reference Manual Scope Display Options Window Use the this window to select the colors of the digital scope display Using the window Colors TestStar Reference Manual Display Scope Window Background Graph Background X Axis Color Y1 Axis Color Y2 Axis Color ok Cancel Help The Scope Display Options window shows the current settings of the scope display colors Pressing the list icon of any parameter lists the available colors
221. nded square waveform TestStar Reference Manual About Tuning The error signal shows similar characteristics as a feedback signal The error signal represents the difference between the command and sensor feedback The following show the error signal characteristics for each type of waveform A square waveform is best suited to view the overshoot and ringing characteristics that occur when tuning a system Review the following waveforms to determine the kind of characteristics that can be found in an error signal Command Feedback Static Accuracy Difference Zero Error Signal Comman Feedback Zero f Following Error y Difference Error Signal Command Feedback Actuator ra Friction Zero ta A Error Signal 279 Tuning About Tuning Using the if you don t have an oscilloscope use the TestStar scope feature for TestStar scope tuning control modes See Chapter 3 and Chapter 5 in the Reference manual to set up the scope and use it Review the following Select a continuous sweep Enter a refresh time that is longer than the trace time Adjust the scroll bars on the Y axis to zoom into the area of interest Using an An oscilloscope has a higher resolution and is faster than the TestStar oscilloscope scope See Chapter 3 in the Reference manual to set up the analog output channel Review the following Be sure you have an output channe
222. ng It provides stability at higher gain settings It can reduce noise from high gain settings It can amplify noise from noisy sensors Series 256 and 257 Servovalves always need rate applied Tuning the inner loop of a 3 stage servovalve always benefits if rate is applied Higher rate settings tend to decrease system response Too much rate can create instability at high frequencies Too little rate can make a rumbling sound The correct amount of rate is quiet Way too much rate can make aringing or screeching sound Optimum Rate Too Much Rate Way Too Much Rate TestStar Reference Manual 271 Tuning About Tuning Reset integr ation Reset introduces an integral of the error signal that gradually over I time boosts the low frequency response of the servovalve command It improves mean level accuracy It corrects feedback droop caused by the spring characteristic of the servovalve in static and very low frequency test programs It maintains the mean level in dynamic test programs Can be used to minimize the amount of time the system needs to recover from transitions Use the Max min meter to monitor the mean level Reset the meter after each adjustment Higher reset settings increase system response Too much reset can cause a slow oscillation hunting Can be used to minimize the amount of time the system needs to recover from transients A rule of thumb set the integration r
223. ng Vv TestStar Reference Manual 61 jo lt O jm ge Ho p Using the Load Unit Control Panel Main Module Controls and Indicators Emergency Stop switch Test Control switches A test can be started held or stopped either by the LUC switches or by the Function Generator pushbuttons 62 Pressing this switch removes hydraulic pressure and stops the test program The Emergency Stop Interlocks Emergency Stop indicator then turns on To restore normal operation reset the switch by twisting the knob as indicated by the arrows Press the Reset switch to clear the interlock indicator The Test Control switches correspond to the pushbuttons in the Function Generator program window excluding the Home pushbutton Refer to Chapter 6 Function Generator Window for further information on using these switches L E pa Rime Control Function Generator via Define Help __ Stop Hold Run Home Nantrnle Nafinitian TestStar Reference Manual Using the Load Unit Control Panel Interlocks interlocks cause the hydraulic pressure to be removed when specific events occur Whenever an interlock becomes active the cause of the interlock must be corrected before hydraulic pressure can be reapplied Refer to Clearing a Detector on page 54 for information on the names and causes of interlocks When the cause of an interlock i
224. ngs you are editing Displays the Save Unit Assignment Set window when you save the file for the first time New Open Save Save as Delete Global default Print Displays the Save Unit Assignment Set window where you can save the current unit set with a diiferent file name Deletes a previously defined set of units eo m gt N L ge z oO mt Nn oO rrj ou j 0 mt o Assigns a default unit set The default unit set is assigned to all users who have not selected a different set Prints the current unit set file TestStar Reference Manual 249 Unit Assignment Set Editor Window Open Unit Assignment Set Window CGSSET Use this window to select Unit Set Names a set of units ENGSET ENGSETSM SISET SISETSM Open Cancel Using the window select a unit set from the list of defined unit set names The selected set of units is shown in the entry field at the top of the window Press the Open button to assign the unit set 5 an e5 N e5 ove _ N N lt t a The unit set you open remains active until you select another unit set or exit TestStar 250 TestStar Reference Manual Unit Assignment Set Editor Window Save Unit Assignment Set Window Use the Save Unit Assignment Set
225. nic or cyclic test commands using triangle sine and square waveshapes See Chapter 6 Function Generator on page 205 TestStar Reference Manual Introducing the TestStar Software TestWare SX TWSX is an optional flexible general purpose program that combine processes that can produce a test command acquire data and can interface with external devices This application has its own manual OS 2 only This folder contains all the TestStar configuration files that you create Double clicking a configuration file icon starts TestStar by opening the Login window where you must enter a user name and password Each test you run should have a TestStar configuration file The Administrator program defines user names passwords and their access to the other TestStar applications See Chapter 7 System Administrator Administration on page 231 The Unit Assignment Set Editor allows you to define a set of preferred units for the various values used in TestStar Each dimension can have a preferred set of units assigned For example you may prefer Unit Assignment millimeters or inches for length dimensions See Chapter 8 Unit Set Editor Assignment Set Editor on page 245 R The Sensor Calibration program creates or imports sensor calibration data This program keeps a data base of you calibrated sensors You can install calibration data for sensors calibrated at MTS Systems See ag Sensor Chapters 6 9 in the
226. nput signal that is defined as an external signal type Note See Chapter 10 in the Installation manual if you are using an external command source or an external feedback signal TestStar Reference Manual 119 Edit Menu Control Modes Channel Limited Channel Control Mode A CLC control mode uses one input channel to control the servo loop feedback while using a second input channel limiting channel to restrict the command source The limiting channel uses a limit range to ensure the feedback signal cannot produce a command that exceeds the range set for the limiting channel Me trol Modes o Control Channel Selection Selecting the Channel Limited Channel Mode Type displays this window Control Mode Selection configuration 4 LyJ j Control Mode Definition 4 e Mode Name Mode Type X Mode Label x CLC Mode Definition Command Source Pod x Feedback x Limit Channel x CONTROL FUNCTION Command Source The only command source available is Pod This command source is from the Actuator Positioning Control APC on the load unit control panel Feedback Selects an input signal as the source of feedback for the control mode Limit Signal Selects an input signal as the source of feedback for the limiting channel 120 TestStar Reference Manual Control Modes Cascade Control
227. ns may also be identified with a customer defined name or as Action 5 10 Note Customer defined actions are created with the Edit Detector Actions window The Lock and Unlock radio buttons disable and enable the Auto Zero function The Lock Unlock selection applies to the Auto Zero button and the manual adjustment in this window and the Auto Zero button in the Display Input Signals window You cannot zero a sensor being used with the active control mode when hydraulic pressure is on The Offset field shows the amount of offset applied to the sensor in percentage of full scale You can zero the sensor output manually with the slider bar or automatically with the Auto Zero button Continued TestStar Reference Manual Input Signals Sensor zero The following are examples why you may want to zero a sensor continued output IVDT Assume the LVDT is calibrated with the zero point at mid actuator sensor displacement After a specimen is installed the LVDT sensor output may not be zero In this situation you would want to zero the output Force After installing a grip you may zero the force channel to remove the sensor effects of the weight of a grip fixture on the force sensor output Extensometer Before installing an extensometer use the zero pin or gage length fixture to establish the mechanical zero of the sensor Use sensor zero if the sensor output is not zero Shunt calibration Use shunt calibration period
228. nsitivity of the valve command Rate Gain Adjusts the level of derivative gain for the inner loop The rate derivative gain affects stability at higher inner loop gain settings nua isnl py Inner Loop Gain Adjusts the level of proportional gain for the inner loop Proportional gain affects the inner loop response of the pilot valve Inner Loop Phase Matches the phase of the inner loop LVDT feedback with 10 kHz demodulator reference signal Adjust this for a maximum output for the maximum LVDT spool offset Setup Displays the following controls at the bottom of this window Phase Selects the phase of the signal driving the servovalve Inner Loop Polarity Selects the polarity of the inner loop feedback signal Integrator Enables disables the reset integrator of the inner loop Rate Amplifier Signal Selects the signal that is input to the rate circuit Select Spool Position for most applications Select Error if a higher rate response is needed TestStar Reference Manual 185 Adjust Menu Adjust Drive 186 TestStar Reference Manual ms TestS tar II rol Syst Chapter 5 Display Menu Display Input Signals Signal Zero Range 0 0
229. nsors attached to the end of an actuator also called moving load cells May be needed for systems with large actuators and massive grips It is needed when testing a soft specimen in force control May be used to minimize phase lag Do not use with square wave Needs Feed Forward Optimum Original Command ra Feed Forward Command Original Feedback 273 Tuning About Tuning About the Tuning Program Waveform Square Triangle 274 The purpose of a tuning program is to produce a command that reflects the most demanding system response expected from a test The all purpose tuning program is a low frequency low amplitude square wave command Note The function generator is very useful for quickly setting up a tuning program If you use the same tuning program on a regular basis and have the TestWare SX application software you may wish to create and save your tuning procedure Initial tuning is best done with a waveform that has abrupt changes This excites the system at frequencies likely to be unstable with excessive gain Square and triangle waveforms are preferred Final tuning can be done with the actual program command for the test Note Always monitor the sensor feedback or error signal to evaluate the control accuracy See Monitoring Waveforms A square waveform requires the servovalve to open rapidly to a large opening It is the most demanding waveform because it requires the maximu
230. nterlock the type of test you are running and how your test system is configured It is beyond the scope of this manual to provide procedures to correct all possible interlocks You will need to produce you own interlock methods and procedures for your equipment and test requirements Step 4 Clear the interlock Press the Reset switch on the load unit control panel 58 After you have corrected the first interlock press the Reset switch to clear it Sometimes the first interlock can cause other interlocks to occur Any interlock that has not been corrected will occur again lighting the appropriate indicator and displaying the interlock in the Fault Status window Note lf the interlock was caused by a power failure and you are using TestWare SX you can recover the test see the TestWare SX Application Manual Emergency Stop Interlocks Controller Hydraulic Mechanical L Auxiliary TestStar Reference Manual Using On line Help From any window one or more of the following access the help utility Press the F1 function key Select Extended Help OS 2 or Help Topics Windows NT from the Help menu See the OS 2 manual Using the Operating System for additional information about the entire help system See the Windows NT documentation for additional information about the entire help system The help menu The help menu is the same on every window that has Help Displays the ind
231. ntrol Mode is the length control mode you tuned in the previous procedure Or you can use any stable tuned segment generator SG control mode C Use the Adjust menu to select Input Signals This displays the Adjust Input Signals window Check or select a range for the input signal used for the control mode to be tuned The range determines the maximum settings for the auto tuning end levels D Use the Display menu to select Input Signals Set limits that are appropriate for the test for each sensor not being calibrated If a specimen is used set the limits so the specimen won t fail Select Hydraulics Off or Interlock for each limit action E Use the Adjust menu to select Tuning This displays the Adjust Tuning window F Select the control mode you want to auto tune 285 Tuning Auto tuning Step 2 Setting up the auto tune feature While the auto tuning feature works the Auto tuning in Progress window is shown Use the Stop Auto tuning button to stop the process at any time 286 This step sets up and runs the auto tune feature A Press the Auto tune button in the Adjust Tuning window This displays the Auto tuning window Enter two end levels that reflect the type of test you intend to apply to the specimen Note For compressive only tuning set up end levels that are non compressive Do not set limits from 0 or above The reverse is true for tensile only set ups For example assum
232. o brings up the Application Access window Username Elvis The information you enter is not case sensitive These are mandatory fields Password blue_shoes The New User window A Nie and the Edit User window casi name i are the same except for Middle initial M These are the name of the Add or optional fields i i Jir Edit button First name ui Configuration none SISET Unit Assignment Both the Configuration and the Unit Assignment can be changed after you login to TestStar If a configuration file has not been created type in none for now no path is needed It can be changed later The Configuration file name must show the full path for the file s location In addition the extension TCC is required A configuration file named none lets you open TestStar without any selections made All parameter values and selections are blank The Unit Assignment is selected from a list of predefined unit assignment sets TestStar Reference Manual 241 S jo D g N o E g lt eD Nn a N Creating a New User Step3 Select the TestStar programs the user can access Click to select the applications that the user can have access to This sample user has access to two applications but is barred from another four Press OK when done
233. of Control Channel Selection this window a s control channels 1 4 x Control Mode Selection aj Ly control modes 1 10 z v Us o TestStar Reference Manual 159 Adjust Menu Tuning Types of control modes Auto tuning More information 160 The type of control mode is set when the control mode is created in the Edit Control Channels window There are three types of control modes and they use different sets of controls PIDF Proportional integral derivative and feed forward are a group of gain adjustments to tune the servo loop response using a single feedback source Channel Limited Channel A CLC control mode uses one input channel to control the servo loop master channel while using a second input channel limiting channel to restrict the master channel The limiting channel ensures the master channel operates within a limit range The tuning controls consist of gain controls for the master and limiting channels along with adjustments to establish the limit range Cascade A CASC control mode uses two feedback sources one for an inner loop and one for an outer loop The output of the outer loop is the input to the inner loop Gain and rate controls tune the outer loop while gain and reset controls tune the inner loop Note The inner and outer loops of a cascade control mode should not be confused with the inner and outer loops found in
234. ol modes Control Modes on page 116 Setting the number of control channels Installation Manual 4 TestStar Reference Manual 111 Edit Menu Control Channels Edit Control Channels Window Prerequisite Use this window to define each control channel Each control channel requires a drive type and at least one control mode 112 TestStar can control up to four control channels A control channel commands one axis of movement Each control channel uses a Model 490 14 or 490 17 Valve Driver module to produce a servovalve signal The maximum number of control channels is chosen during the Hardware Configuration portion of the software installation procedure 9 har Control Channel Selection Control Channel 1 Control Channel Definition Channel Name Control Channel 1 Channel Type Controller Channel Label Axial Drive Type 252 Valve Auto Tuning Control Mode Undefined Phase Amplitude PAC Disabled TestStar Reference Manual CONTROL Control Channels Control Channels FUNCTION Selects the control channel you want to define The number of control channels is selected during the software installation Channel Name ies ou j 0 5 Names the control channel Type a name you wish to call the channel This name is used throughout TestStar to identify the control channel The def
235. ommand Command A A j 1 0 Integral Gain al _b 0 1 gt Derivative Sensor d Gain gt gt Feedback dt 265 Tuning About Tuning 266 Length control Force control A length control mode uses the LVDT sensor in the actuator as the controlling feedback source The length control mode only needs to be tuned once Does not need a specimen installed for initial tuning Uses a square wave when tuning an LVDT but not when tuning a displacement gage If gain is too low there may not be any actuator movement If gain is too high the actuator will move quickly and noisily Tune once then tune again if you change the grips Force control uses a force sensor also called a load cell as the controlling feedback source Tune for each type of specimen or any changes in the force train Requires a specimen to be installed Uses a triangle waveform for the initial tuning If the required results cannot be achieved change to a square waveform If gain is too low the system may be unstable at low frequencies with large static offsets Tune for each type of specimen and changes in force train TestStar Reference Manual About Tuning Strain control Strain control uses an extensometer or strain gage bonded to the specimen as the controlling feedback source Tune for each type of specimen or any changes in the force train Requires a specimen to be instal
236. on ik aj lv Control Channel 1 Valve Adjustments Valve Balance 0 000000 V AC Gain 1 00000 lt gt lt gt Dither Amplitude 0 100000 Vpp Rate Gain 0 000000 lt gt lt gt Dither Frequency 625 000 Hz nner Loop Gain 1 00000 lt gt lt gt Spool Zero 0 000000 V nner LoopPhase 0 000000 deg lt gt lt gt Polarity Integrator Normal Inverted In Out Inner Loop Phase Rate Amplifier Signal Normal J Inverted e Error Spool Position TestStar Reference Manual Adjust Drive CONTROL FUNCTION Valve Balance Electrically compensates for minor mechanical unbalance in the servovalve Dither Amplitude Adjusts the amount dither needed to overcome friction in the actuator Dither is most effective for static and low frequency tests Dither Frequency Adjusts the dither frequency The operating frequency of the system can affect the dither frequency setting The typical dither frequency is 700 to 900 Hz Spool Zero Adjusts the electronic null of spool position signal to match the mechanical null position of the servovalve pilot spool AC Gain Calibrates the maximum valve LVDT feedback signal for 10 volts This adjustment can affect the PIDF settings and the noise se
237. ontrols Definition Channel Axial Mean 0 N Control Mode force control lt gt WaveShape triangle Amplitude 2500 N Preset Count 0 lt gt e r Status 1 H gekeer Current Count 0 s Total Count 0 Amplitude Mean Control Status Stopped Le a 5 ie gt e 5 ap Oo 5 a aa TestStar Reference Manual 227 Designing a Test Program Step 7 Run the program command Before you run the test command install a specimen You should also have a TestStar configuration defined for this test command limits detectors etc A Press the Run button to start the program command While the test is running you can press the Hold button to suspend the test Press the Run button to resume the program command Otherwise perform any tasks you need to do In this case you would tune the force control mode B Press the Stop button to end the command At this point you could change the command definition and run the new program command C Press the Home button to return the actuator to the Home position i g o eD ies D 0 F 228 TestStar Reference Manual TestS tar IT trol Syste Chapter 7 System Administration File Define Users list of defined users Delete j New User Username Password La
238. or is to warn you that a specimen is beginning to fail or to shut down the test before the specimen breaks which can cause equipment damage If an error exceeds the level you set the digital controller performs the action you choose disabled indicate hydraulics off interlock customer defined An effective error detector requires the servo control loop to be properly tuned For static or low frequency tests the error detector is typically set to a low level nus isn py At high frequencies the error detector is used to detect loss of closed loop control Set the error detector to a high level Error Error lt _ Feedback Test Command Test Command Feedback At higher frequencies the error level is At lower frequencies the error level is large The phase lag of the feedback usually small The feedback tracks the creates a larger error command more closely Use the minimum error to indicate an approaching failure Use the maximum error to perform an appropriate action TestStar Reference Manual 175 Adjust Menu Error Detectors Actions Using the window 176 An action determines what happens when the associated limit level is crossed Select the action you want to occur when an error is detected You can assign an action for each error The following are the actions you can use Disabled turns the error detector off Indicate displays a message in the Fault
239. orking around crush points These paragraphs apply to most testing and production systems Keep clear of any mechanical linkage that moves within a closed area If the linkage should move when the system starts or due to mechanical failure very high forces can be present that could pinch cut or crush anything in the path of linkage movement Preface Never allow any part of your body to enter the path of machine movement or to touch moving machinery linkages hoses cables specimens etc These present serious crush points or pinch points Crush Point A crush point exists between the platen and crosshead reas on load units where the actuator piston rod and specimen move Another potential crush point exists where the lower end of the actuator piston rod extends below the platen and the bottom of the load unit load frame 16 TestStar Reference Manual Safety Precautions Avoiding Hazardous Actuator Movement A CAUTION TestStar Reference Manual The high forces and rapid motions that are usually present in testing systems can produce destructive forces from unexpected or uncontrolled actuator response Several things can cause unexpected actuator movement The possible combinations of system hardware and software settings make it impossible to predict conditions that produce unexpected actuator movement Some conditions can cause an actuator to slam to its mechanical limit smashing anything in it
240. oth mouse buttons to display the Window list and double click the name of the window For Windows NT double click the desktop to display the Task List and double click the name of the window The Maximize Icon changes the window to fill the entire screen Press the Maximize Icon again to return the window to its scaled size Windows have several controls in them and each one can be used when it is selected or has focus A control that has focus is identified by highlighting it reverse video for text an outline around a graphic a different color or the appearance of a button being pushed When an object is selected it looks different For example selecting a menu in the menu bar makes the name of the menu look like a button being pressed and the list of menu items is shown Move the mouse until the on screen pointer is over a control Press the left mouse button to select the control You can now use the selected control Use the Tab key to move between controls Each time you press the Tab key the selected control moves to the next control The sequence of controls assume a starting point in the upper left corner and progresses from left to right and top to bottom Use the Tab and shift keys to move the selection moves between control groups TestStar Reference Manual How to Use This Manual Menu bar Selecting a menu with the mouse highlights the menu name and displays the menu items Selecting a menu ite
241. ou have made in a window Pressing OK in a dialog box acknowledges the statement of the dialog box Pressing a Cancel pushbutton returns you to the previous screen without accepting any changes you may have made Cancel Pressing a Help pushbutton displays a text window that describes the controls and functions of the window containing the Help pushbutton Using the mouse Select the button by clicking on it Using the keyboard Press the letter that corresponds with the underlined letter of the button or use the Tab key to select the pushbutton then press the Enter key An entry field is a box where you can type information To change an existing entry highlight the entry and press delete or type a new value function name you type in here units A cursor blinks in an active entry field Using the mouse Select the entry field by clicking on it then type the entry Use the OK pushbutton to accept the information you have entered Using the keyboard Use the Tab key to select the entry field type a value or name into the field then press the Enter key TestStar Reference Manual List button Step switches TestStar Reference Manual How to Use This Manual A list button displays a list of selections The current selection is shown in the box with the list icon The box may include a Current Selection List Item S 1 lt Selected Item scroll bar List Item List Item
242. our system e how to use the error detector and limit detectors to help stop the system if it performs outside your expectations e that you need to retune when testing specimens with different characteristics rubber vs steel 259 Tuning About Tuning About Tuning Tuning minimizes the system error and phase lag in the selected control mode Inaccurate tuning Precise tuning 260 Tuning affects the control accuracy and stability of the servo control loop Proper tuning improves the performance of the system like setting an automobile s timing The purpose for tuning is to optimize the system to be able to accurately deliver demanding system test programs while maintaining acceptable levels of stability Each control mode uses a different sensor feedback signal for servo loop control Each control mode needs to be tuned Each sensor usually has several ranges Only ranges used for control need to be tuned Tuning DOES NOT affect measurement accuracy Time Lag phase shift Fj Program Command gt Feedback higher Proportional gain Feedback lower Proportional gain Inaccurate tuning causes a greater error and phase lag between the program command and the sensor feedback A large error may indicatethat the full potential of the program command is not being applied to the specimen It indicates reduced control accuracy and repeatability It does not indicate reduced measurem
243. ow The function generator defines a program command to control the TestStar Reference Manual hydraulic actuator Before you run a waveform you should complete any necessary functions in the TestStar Adjust menu Use the Define menu to create a waveform Use Mean Amplitude and Frequency controls to parameterize the waveform Use the Stop Hold Run Home buttons to control the waveform See Designing a Test Program on page 224 for detailed instructions 207 EF 5 ie e j 0 5 ap Oo 5 a i g o eD ies D 0 a Function Generator Window Mean level For example assume you want to run a 2 cm sine waveform between 1 5 and 3 5 cm Adjust the Mean level control for 2 5 cm The mean level changes when the current cycle reaches an end level 208 The Mean level control introduces an offset that references the command to a level other than zero The mean level value uses the units selected in the command definition Adjust the Mean level control within full scale of the selected control mode 3 5 Mean Level 2 5 1 eT You can adjust the mean level while the program is running Changing the mean level while the current output is here D New L ean Mean T HF E me FS causes the transition to the new mean level to begin here You can change the range of the control by pressing the
244. ples 107 Reset switch 63 Return to zero 223 Run Resume switch 62 Run Resume switch 62 S Safety 327 Index guidelines while operating equipmen 15 precautions 11 Scope 142 198 axis adjustment range 200 control menu 199 display 198 display colors 201 file menu 199 printing display 199 scaling an axis 198 200 selecting colors 201 set scroll range 200 tuning notes 280 Sensor assign window 96 calculated 93 conditioners 90 define temporary 97 full scale 154 192 internal 90 limit actions 53 152 195 limits 151 range 154 192 sensor cartridge 87 temporary 97 types 85 zero 152 Sensor Zero using 154 Sensor zero using 152 Sensors zero 191 Servo loop things that slow it down 310 update rate 309 Servomotors 180 Servovalve adjusting dither 182 adjusting valve balance 182 adjustment procedure 276 connection 110 dither 184 Series 252 control 181 Series 256 257 controls 184 types 115 Servovalves 180 Set Scroll Range window amplitude 212 auto zero 156 frequency 213 mean 211 scope 200 328 tuning controls 169 SG command 265 Shunt calibration 153 checking 157 how it works 158 information window 157 value 157 Software introduction 46 version 59 78 Span Mean data 140 Specimen installation 19 Stiffness 129 317 Stop switch 62 Stop switch 62 Stopping the test 62 63 Stopping the test 62 Stopping the test 63 Supervising the System 22 Switches Actuator Positioning Control 66 Emergency Stop
245. ption Window Count Menu Option Window Preset count e On Use this window to configure the counter to cycle continuously or to stop the function generator after a preset number of cycles Current count Preset count Total count CONTROL FUNCTION Preset Count Turning the Preset Count Off causes continuous cycling Turning the Preset Count On sets the counter to the value entered in the Preset Count entry field A preset count of 0 causes the waveform to execute a half cycle a single segment Current Count Displays the current count When the current count equals the preset count the waveform stops Type O to clear the current count Total Count Displays the total count Use the total counter to keep a cumulative count Type 0 to clear the total count 220 TestStar Reference Manual Preset count How it works Two components are added to a cyclic waveform The waveshape order starts the waveform and return to mean ends the waveform TestStar Reference Manual Count Menu Option Window After enabling the Preset Count type the number of cycles you want Each cycle of the waveshape updates the Current Count and Total Count displays When the current count equals the preset count the function generator stops You may want to use the counter to stop the waveform periodically to record data or to change the servo loop command For exampl
246. put signal name lower limit detector actions and interlocks control channel name error detector control channel name underpeak detector hardware interlocks Detector Faults Generated The source of a detector action is identified by the name of the input signal or control channel along with the type of detector Interlocks are identified with the type of interlock More than one detector action or interlock may occur Sometimes the first detector fault causes other faults to occur If an interlock i ti an interlock is active one 3 Interlocks Emergency Stop Eo con Reser p C5 Hydraulic CO Mechanical Oooo 1 Auxiliary You must use the Reset switch on the load unit control panel to clear an interlock or detector fault If a fault is detected after being reset it is displayed again 52 TestStar Reference Manual Detector actions Interlocks TestStar Reference Manual Using the Fault Status Window Detectors monitor specific test conditions The purpose for detectors is to perform an action when a detector condition is satisfied The following are the actions you can use Disabled turns the detector off Indicate displays a message in the Fault Status window that the detector has been triggered Hydraulics Off turns off the hydraulic pressure at the service manifold displays a message in the Fault Status window and lights th
247. r This is a required parameter Password A password is linked to each Username Each individual must enter a password when logging on to TestStar after entering a Username This is a required parameter Last name These are optional parameters You can label a Username with the Middle initial individual s proper name These are provided in the event you forget who First name is assigned to a given Username Configuration Selects the TestStar configuration file that opens when you log on Enter the complete path and filename in the entry field or enter none if you don t know the path you can edit it latter This is a required parameter Unit Assignment Selects a set of default units that are used for the initial settings of the various TestStar and TestWare parameters This is a required parameter TestStar Reference Manual 235 S jo D g N o E g lt eD Nn a N System Administration Window How it works Configuration file 236 Unit assignment When you log onto TestStar you enter your user name and password TestStar recognizes only the names and passwords entered with the New User window or the Edit User window A configuration file and the unit assignment set open with TestStar with all the settings that were established during a previous session After you add or edit a user select which applications the user name can access A TestStar configuration file ass
248. r define temporary 97 defining 92 how it works 92 offsetting input 98 F Fault status display 56 Fault Status window 52 Fax number 26 Feedback safety precaution 17 File extension configuration file TCC 50 debug log LOG 313 Firmware error codes 295 Following 295 Force sensor acceleration compensation 155 Frequency adjustment 206 227 how it works 210 scroll range 213 Full scale 154 Function Generator 205 Function generator amplitude how it works 209 TestStar Reference Manual ramping 219 set scroll range 212 amplitude mean control 219 command 214 controls 206 counter 220 continuous cycling 220 how it counts 221 preset count 221 designing a test 224 external command 218 frequency 210 frequency adjustment range 213 home ramp 222 controls 222 how it works 222 223 how it works 216 mean control range 211 mean level 208 opening 225 phase amplitude control 219 prerequisites 205 programming 207 224 return to zero 223 status 210 test requirements 224 using the window 207 waveform components 216 window 206 Function Generator Top 62 G General safety guidelines 12 H Hazard conventions 25 Help 26 calling for 60 calling for re 1 60 introduction 59 menu 59 window 60 HELPline 27 Hold actions 127 Hold switch 62 Hold swith 62 325 Index Home ramp 222 How information is arranged 34 How to contact MTS 26 troubleshoot 27 How to use this manual 34 HPS control switches
249. r a max min meter to determine the maximum and minimum sensor values While running the test note the upper and lower values Valid limits can be more than the upper value and less than the lower value Note We recommend that you establish limits for at least one input signal to prevent damage to the test equipment if the servo control loop is broken such as a cable becomes unplugged or the specimen breaks The best input signal for this purpose is from the LVDT sensor 151 nus isn py Adjust Menu Input Signals Actions Sensor zero 152 An action determines what happens when the associated limit level is crossed Refer to Chapter 1 for instructions on how to reset action The following are the actions you can use Disabled turns the limit detector off Indicate displays a message in the Fault Status window that the detector has been triggered Hydraulics Off turns off the hydraulic pressure at the service manifold displays a message in the Fault Status window and lights the Aux indicator on the LUCP Interlock turns off the hydraulic pressure generates an interlock signal clamps the servovalve and displays a message in the Fault Status window You must correct the reason for the interlock and use the Reset button located on the load unit control panel to clear the interlock Customer defined these actions can be defined to ramp or hold the control channel output These actio
250. r in parentheses A telated topic can be found in chapter 1 Sometimes it is helpful to describe how a feature works to understand what it does This kind of information helps you sound more intelligent when someone asks you what you are doing Random topics are usually found at the beginning of a main topic such as an overview of a menu selection or the beginning of a chapter This kind of topic may pose questions or offer suggestion so you can determine why you want to use a feature These topics can also provide information to help you choose from the available selections Information that is common for all selections may also be described TestStar Reference Manual How to Use This Manual Window Controls This sample window System Menu Title Bar Maximize shows the types of Icon Icon controls you will see in the TestStar windows E The following Menu EEE B describes the controls Bar File Edit Menu List shown Control Channel menu item 1 Icon B menu item Current Selection x TI Step menuitem gt Switches selected item List Item A ly Selected Item ars function ____ List Item Radio i Buttons S Selected List Item K J Not Selected J Not Selected control name value units Check function z G Boxes N Selected you type in here Selected Entry J
251. rWhen gain is set to 1 then 1 unit 1 volt To change the scale of the ain desired output output use the formula gam Sensor output Where Gain is the value you enter into the Gain entry field Desired output is expressed in volts within 10 volts Sensor is expressed in engineering units Therefore changing the gain to 3 33 changes the displacement sensor output of 3 cm into a 10 volt readout signal TestStar Reference Manual Displacement gain example Force gain example TestStar Reference Manual Assume you Create a test program that requires a 0 to 1 cm haversine command With the Gain set to 1 the output produces a 0 to 1 volt signal Changing the gain to 3 33 magnifies the output to produce a 0 to 3 33 volt signal Output Signals 3 cm 2 cm 1 cm 0 AAVV Assume you create a test program that requires a 0 to 11 kN haversine With the Gain set to 1 the output tries to produce a 0 to 11 volt signal However the maximum output is 10 volts and the output clips 1 volt Changing the gain to 0 909 produces a 0 to 10 volt signal 3 33 volts 1 volt 0 Gain 1 Gain 3 33 11kN 0 VY 10 volts 4 i f i 0 107 ies a j 0 mk 5 Edit Menu Output Signals 108 Offset example Offset and gain example Assume you create a test program that ramps to 11 kN and holds the force at that level With the offset set to 0
252. rairie Minnesota 55344 2290 In the United States all 50 states HELPLine 800 328 2255 Outside U S Contact your local service center 29 0521 Technical support questions 612 937 4766 General questions 612 937 4515 E mail Info mts com Internet Home Page http www mts com TestStar Reference Manual How to Obtain Technical Assistance What to Expect When You Call Before you call TestStar Reference Manual Your call will be registered by a HELPLine agent The agent will ask for you site number If you do not have an MTS site number or do not know your site number you should contact your MTS sales engineer The HELPLine agent may also ask to verify the following information Your company s name Your company s address Your name and the telephone number where you can normally be reached If you have called before regarding this problem we can recall your file You ll need to tell us the following The MTS work order number The name of the person who helped you Be prepared to respond to questions when interfacing with MTS technical support personnel We may ask you to perform certain tasks so we can locate the source of the problem Prepare the following information before you call HELPLine support to prepare for the troubleshooting process Know your site number and system number Describe the problem you are experiencing How long has the problem been occurring Can
253. rence Manual MTS Test Control Sys EF 0 1 gt Feed Forward Gain P dt A gt Proportional E Gain Servovalve Command X Bii CJ i z gt Integral Gain P gt mJ o1 E gt Derivative P i gt Gain Feedback at High ye 7 aa Gain P pigh Low Chapter 9 Tuning Contents A CAUTION TestStar Reference Manual This chapter describes tuning the servo loop Tuning adjusts the servo loop to optimize the relationship between the sensors the test command and the servovalve About Tuning 260 About Control Modes 265 About the Tuning Controls 270 About the Tuning Program 274 About the Servovalve 276 About Specimens 277 Monitoring Waveforms 278 Auto tuning 281 Auto Tuning the First Control Mode 283 Auto Tuning Additional Control Modes 285 Tuning Procedure 288 Every control mode must be properly tuned Using a poorly tuned control mode may cause the actuator to move so slowly it may appear not to be working make an obnoxious noise unstable operation or in extreme cases slam to its mechanical limit Be sure you know the following before you tune e the Safety Precautions in the Preface of the Installation manual e the contents of this chapter e how the adjustments affect y
254. ressing the Network button displays the Connect Network Drive window Windows NT only where you can define new network drives and paths 74 TestStar Reference Manual Using the window TestStar Reference Manual Save Window Be sure you know where you want to save your configuration files The default path for this window is C TS2 config Note We recommend that you have a configuration file for each type test you perform Each user can have a configuration file automatically open when they log into TestStar and they can change it once they are logged in You can t save a configuration file while another TestStar or TestWare application is running 1 Use the list icon for the Drive field to select the drive where you save configuration files In this case the C drive should be displayed 2 Double click the desired directory in the Directory list this causes all its files to be displayed in the Files list and it also displays any additional directories In this case the Config directory in the TS2 directory should be displayed 3 Type a file name in the Save as filename entry field the TCC extension is automatically added 4 Press the OK button to save the file 75 Select Font Window BE Select Font Window This is a standard OS 2 window The Windows NT window looks similar It allows you to customize the text of the TestStar windows Use this window to select FA Font
255. rnally to identify the input signal internally Using the window 1 Select a slot location or calculated input in the Signal Selection TestStar Reference Manual area This selection determines the Signal Type selections 2 Enter a Signal Name if you want otherwise the Signal Selection text is used 3 Select a Signal Type Most of the time a single selection is available the exception is when a module is installed in one of the slots 7 14 These locations can support ac dc conditioners and external inputs 4 Select a dimension The default selection is Length 5 Select your preference for Display Units The units selection is shown anywhere the signal is used within TestStar or any TestWare application 6 TestStar chooses a Signal Label You may change it if you need to match input signals and configurations with other TestStar systems 89 Edit Menu Input Signals AC amp DC Conditioner Signal Type When you select an AC Conditioner or DC Conditioner signal type you will see this window configuration Use the Assign Sensor button to select a calibrated sensor Use the list icon to select a Range from the list of calibrated ranges Assign Sensor When you press the Assign Sensor button this window opens 90 Edit Input Signals Signal Selection a Slot 1 14 Signal Definition Signal Name Signal Type Dimension Display Units
256. rocess causes the rear panel connector to output a specific voltage to control an external device 109 Edit Menu Control Channels Control Channels Servovalve connection The convention for multiple control channels is Channel 1 J14 Channel 2 J13 Channel 3 J12 Channel 4 J11 110 A control channel commands an axis of movement or some other operation such as pressure or temperature TestStar supports up to four control channels Each valve driver module represents a control channel You need to know the following to define a control channel Where is the servovalve connected to TestStar What kind of drive signal is needed to control the servovalve What type of compensator if any is needed for this channel After you define the control channels you will need to tune each control mode The maximum number of control channels is established during the TestStar software installation Each control channel has a valve driver module plugged into the digital controller Module locations 11 14 correspond with rear panel connectors J11 J14 Connectors J11 J14 can be used for input signals or control channels 0 OG 0 0 0000000 For multiple channel systems you need to identify each actuator and determine the control channel rear panel connector that is associated with it Knowing the nature of the control
257. roducing a physical event and the measured response from a sensor PAC is available only for sinusoidal command waveforms It expects the feedback to be balanced about a mean level some Reset 1 adjustment may be necessary PAC compensation is available only on channels that have PAC enabled in the Edit Control Channels window Its computational requirements may limit the sampling rate on multi channel systems TestStar Reference Manual 171 Adjust Menu Adjust Compensators Convergence rate The convergence rate controls how quickly the feedback signal is matched with the command signal Convergence will occur eventually Gif rate is not set to zero this adjustment determines how fast it occurs A typical peak valley range for the convergence rate is 0 2 to 0 8 The default setting of 0 5 should work fine for most applications The range for PAC varies according to the frequency of the command At low frequencies a range of 1 20 can be appropriate while at high frequencies 500 1000 Hz the range can reach as high as 200 The default is set at 1 Set up a meter to monitor the span mean of the feedback If span of the command is not being reached fast enough increase the convergence rate If the span seems to hunt for the proper span the span varies above and below the command span decrease the convergence rate If the rate is too low convergence occurs very slowly If the rate is too high instab
258. rol mode moves the actuator the input signal for the control mode that is being tuned is monitored so the actuator doesn t cause a command that exceeds the end levels Auto tuning uses an auto tuning control mode to control the actuator while the selected control mode is being tuned The auto tuning control mode is selected in the Edit Control Channels window The first control mode to be tuned should normally be a displacement or angular control mode Auto tuning begins by moving the actuator using the auto tuning control mode While the actuator is moving the feedback for the control mode being tuned is monitored to determine the response of the control mode Once the feedback is evaluated tuning parameters are calculated The tuning values are displayed in the Accepting New Gains window Note See Auto tuning on page 281 for procedures to use this feature 163 gt amp N zZ 5 Adjust Menu Tuning Tune CLC Window Prerequisite Channel Limited Channel CLC tuning controls establish the response of the servo control loop for specimen installation and removal using the load unit control panel Also use this window to establish an operating range for the limiting channel You must define a CLC control mode for the control channel with the Edit Control Channels window before you can use this window v iu a amp Control Channel Selection a amp CLC Mode Tuning
259. rs are competent A configuration file that the test requires The appropriate TestStar programs that the operator needs to access for the test such as the Function Generator TestWare SX Sensor Calibration etc J If you can t log ON Itcan happen You may have forgotten your user name or password or your user name could have been deleted TestStar includes a default user name and password so you can start TestStar the first time The default user name is MTS and its password is also MTS Unless your site has no security concerns the MTS user name should be deleted after you have created additional users Any unauthorized person attempting to gain access to the system would surely try this entry first A CAUTION Deleting the MTS user name without creating another user name will require the TestStar software to be reinstalled Be sure you create a user name that has full access to the TestStar programs 232 TestStar Reference Manual System Administration Window System Administration Window pete eee Administration window to He Daire ki add users and which Users or Applications applications they can access Nn lt N 7 S gt lon 5 j 0 N 7 a ji 0 5 The Define menu configures the window to edit users or applications ee pp list of users or applications Add Delete CONTROL FUNCTION File Menu Exits the System Adm
260. s Output 1 6 Readout 1 6 and DAC 1 6 all correspond with each other More information 100 All signals that can be monitored are output through rear panel connectors Knowing where the external device is connected to the digital controller helps you determine a DAC number to assign to the signal Both J41A and J41B include all six of the _____ J71 J76 output signals 100000000 oTo Cabling Installation Manual 3 Programmable outputs Any application that uses one describes its use TestStar Reference Manual Edit Output Signals Window Use this window to define output signals Controls are added to the bottom of the window according to the Signal Type you select Six digital to analog DAC converters are available for output signals and they correspond with the rear panel Readout connectors J71 J76 Output Signals ies ou j 0 5 Signal Selection Output 1 6 11 lt E A Signal Definition Signal Name Signal Type ik analog readout programmable CONTROL FUNCTION Signal Selection Selects one of the 6 possible output signals for definition Signal Name Names the output signal The name you enter is used throughout TestStar to identify this output signal Enter any name you wish T
261. s corrected press the Reset switch to turn the interlock indicator off An interlock indicator lights when a problem is Interlocks Z Pal Stop detected The System Hydraulic Status window also pops Mechanical i Auxiliary up to display the interlock HPS Control The HPS control switches control the hydraulic pressure of the hydraulic power supply The HPS may supply hydraulic pressure to more than one load unit Control Off turns off the HPS 5 gt Qu om Q gt 5 Low turns on low hydraulic pressure typically 2 MPa 300 psi High applies high hydraulic pressure typically 21 MPa 3000 psi 63 TestStar Reference Manual Introduction Using the Load Unit Control Panel Display screen This sample display S hows The current control mode is length The SG stands for segment generator which is normally the function generator e When system control is turned over to the LUC or Pod it will be in force mode 64 The display screen shows key information that assists with installing and removing the specimen The illustration below shows the normal screen supplied with each standard system Note You can create your own display screen using the Edit LUCP Display window Go to Chapter 3 for more information TestStar Control lt Title Line Current Mode LUCP Mode Controllers Length A SG Force A
262. s path Some conditions can cause an actuator to react so slowly to a command it may appear not to be working And some conditions can cause the actuator to dance in an unstable fashion while making an obnoxious noise Following are safety precautions for you to take If the control mode feedback signal is interrupted during operation e g if a sensor or servovalve cable is disconnected or breaks the digital controller senses an error and causes the actuator to attempt to correct the error by stroking at maximum force and maximum velocity until it reaches an internal limit or external mechanical obstruction e g tools specimens hands The full force of the actuator will be applied to that limit or obstruction A selectable operating range does not reduce the force capability it only increases the sensitivity of the electronic components To avoid a control mode feedback signal loss protect sensor cables from damage and never connect or disconnect any cable with electric of hydraulic pressure applied If the feedback signal is lost remove hydraulic pressure immediately An open control loop also results if the cable from the digital controller to the servovalve is disconnected or broken while hydraulic pressure is applied The composite command signal for the servo control loop may consist of several program inputs If one of these inputs is suddenly changed while hydraulic pressure is applied the servo control loop will sens
263. select a strain signal select the appropriate Linear Angular dimension for the stiffness units 1 lt Select the stiffness units then enter the stiffness value Repeat steps E and F for each input signal selected in step C Press OK in the Define Stiffness window Step 4 Close the Load Path Stiffness Editor Select Save As in the File menu Type a name for the stiffness set in the entry field and Press OK Then close the program by double clicking the system menu icon upper left corner of the window TestStar Reference Manual xIpueddy 321 Load Path Stiffness Editor al ge eD er lt 322 TestStar Reference Manual Index A B Abbreviations 45 Acceleration com pensation 155 Actions correcting 54 defining 124 edit window 126 fault status 125 hold 127 ramp and hold 128 standard 124 126 Actuator Positioning Control 66 Adjust 256 257 Valve window 184 Adjust drive 180 Adjust menu error detectors 174 underpeak 177 Adjusting controls inadequate adjustment 270 Administrator see system administration 240 Amplitude adjustment 206 227 compensation methods 171 219 control amp mean control 170 convergence rate 172 how it works 209 ramp rate 215 ramp time 219 scroll range 212 Amplitude ramp time 218 Auto tuning 115 Auto zero 191 adjustment range 156 using 152 Auto tuning 160 163 Auto tuning control mode 283
264. sine wave in length control 2 Set up an oscilloscope to monitor the system response Be sure you have an output channel defined 3 Run the Function Generator If the system response indicates a smooth waveform adjusting the dither frequency is not needed If the system response indicates a jagged waveform or if the dither amplitude can be detected on a scope adjust the dither frequency 4 Adjust the dither frequency until the system response becomes smooth If dither frequency is adjusted too low the dither amplitude can be detected Ifthe dither frequency is adjusted too high the effects of dither are negated the system response indicates a jagged waveform TestStar Reference Manual 183 Adjust Menu Adjust Drive Adjusting 256 and 257 Valves This window adjusts the Valve Driver module for use with a Series 256 or 257 Servovalve 184 The MTS Series 256 and 257 Servovalves include an inner loop The additional controls for this type of servovalve set up and tune the inner control loop Note The valve balance dither amplitude and dither frequency controls are the same for the 252 valves They may be adjusted periodically or to fine tune a system The procedures are located on the preceding pages The other controls are set when the TestStar system is installed Go to Appendix B in the Installation manual to setup the servovalve x Adjust Drive Control Channel Selecti
265. st command to determine if the command signal is actually being properly applied to the specimen Compensators can provide specific types of correction to ensure the command is properly applied to the specimen Note The convergence rate Adjust Compensators window determine how fast the compensator works This compensator detects any amplitude roll off and any difference in the mean level Amplitude roll off refers to the tendency of amplitudes measured by the sensors to be less than the desired amplitudes This can also cause a mean level difference Enabling the peak valley compensation causes the program to adjust the servovalve command signal until the programmed amplitude is achieved and the mean level is maintained It takes a few cycles to start amplitude mean control and a few cycles to end it PAC only works with sine waves This compensator detects any amplitude roll off and any phase lag Amplitude roll off refers to the tendency of amplitudes measured by the sensors to be less than the desired amplitudes Phase lag refers to the lag between the command producing a physical event and the measured response from a sensor Enabling PAC causes the program to adjust the servovalve command signal until the programmed amplitude is achieved and the phase lag is removed 219 EZF a ie e p 0 5 ap Oo a gt a g o eD D 0 a Count Menu O
266. st frequency in your test program Common values are 1 2 Hz Servo adjustments that do not improve performance at high frequencies generally indicate that the servovalve is running at 100 capacity or the HPS is running at 100 capacity This characteristic can easily be seen when tuning with a haversine waveform The feedback waveform appears to be more like a triangle waveform when running at 100 capacity A system tuned at a low amplitude may become unstable at high amplitudes Tuning should be accomplished over a variety of amplitudes Use a moderate amplitude 5 to 10 full scale for initial tuning Be sure the maximum velocity of the tuning command is 10 to 50 of the maximum velocity of the system Increase the amplitude for fine tuning You may find it helpful to check tuning over a variety of amplitudes by creating a test that cycles once at each of the target amplitudes The test should acquire timed data at a rate of 1 kHz so you can evaluate the results for each amplitude 275 Tuning About Tuning About the Servovalve Most of the servovalve adjustments are performed during the system installation and don t require periodic adjustment However the valve balance procedure may need periodic adjustment See Appendix B in the Installation manual for the complete set of servovalve adjustments Adjusting valve To adjust the valve balance perform the following using the controls balance
267. st name Middle initial First name Edit User user name Configuration Unit Assignme Username Password Last name Middle initial First name Configuration Unit Assignment CGSSET Cancel i Help Application Access name of user OK Cancel Help System Administration Users Reatentions Applications System Administration alol File Define Applications B list of applications installed Delete New Application Program title Program file name Edit Application application name Program title Program file name Cancel User Access name of application ok Help Chapter 7 System Administration Contents What you need to know What is a user name for people TestStar Reference Manual When you log into TestStar you must enter a user name and a password The System Administration program defines user names and their passwords the program also allows access to TestStar and its programs System Administration Window 233 New Edit User Window 235 Application Access Window 237 New Edit Application Window 238 User Access W
268. stStar main window 49 Unit Assignment Set Editor 248 User Access 239 Z Zero 191 TestStar Reference Manual 331 Index 332 TestStar Reference Manual
269. t The range of adjustment is within full scale of the selected input signal Selects the action you want to occur when a limit is detected Each limit can be assigned a different action Sensor Zero Offset Auto Zero Introduces an offset to zero the sensor s output The offset is shown as a percentage of the sensor s output Select Unlock or Lock to enable or disable the sensor zero feature in this window and the Display Sensor window This is not available for calibrated and external input signals Opens the Set Scroll Range window to scale the adjustment range of the scroll bar Automatically zeros the sensor output Shunt Calibration Performs a positive or negative shunt calibration check and displays the result in a Shunt Cal window This is available only for internal dc type sensors Sensor Displays the current sensor output and allows you to change the range of the sensor This is not available for calculated input signals Acceleration Compensation Polarity gt gt Adjusts the amount of acceleration compensation that is applied to the input signal This is available only for input signals that have an acceleration compensation circuit Displays a polarity group where you assign the polarity of the acceleration compensation signal 150 TestStar Reference Manual Upper and lower limits If the sensor output exceeds a limit and if the selected action is Hydraulics Off the test
270. t and later restored while TestStar is running You must define an input signal and a control channel with the Edit menu before you can use the Error Detectors window Use the error detectors to detect changes in the specimen characteristics during a test SJ Adjust Error Detec z Control Channel Selection E Error Actions Maximum Action 1 lt ik Minimum Action 11 lt Control Mode Selection E E Error Detector Values KI gt Minimum units ik CONTROL FUNCTION Control Channel Selects a control channel Each control channel has two error detectors that can have different values assigned to each control mode Actions Selects the actions for the selected control channel The actions apply to all control modes Control Mode Selects a control mode Each control mode has 2 error detectors Error Values Sets a maximum and minimum value for the selected control mode The units are set by the input signal defining the control mode 174 TestStar Reference Manual Error Detectors How it works The error detector monitors the difference between the test command and a feedback signal The amount of error indicates how closely the system tracks the test command As a specimen changes approaching failure the amount of error will likely increase The purpose of an error detect
271. t Mean Scroll Range 211 Set Amplitude Scroll Range 212 Set Frequency Scroll Range 213 Function Generator Window 206 Command Menu Options Window 214 Count Menu Option Window 220 Home Menu Option Window 222 Designing a Test Program 224 You must have the following defined before you can use the function generator input signals control channels control modes You should also have a TestStar configuration file set up for a test before you actually run the function generator 205 EF 5 ie e j 0 5 ap 5 t a Function Generator Window Function Generator Window Prer equisite You must define the input signals control channels and control modes to use this window You should also set up the sensors with the Adjust Input Signals window before running the function generator Function Generator Define Help generate a wave form Controls Definition to command the servo Channel name control loop Mean 0 units ee Control Mode name lt gt WaveShape sine square triangle Amplitude 0 units Preset Count 0 lt gt Status 0 05 H gepe j Current Count 0 2 Total Count 0 J Enable Compensator Status Stopped i _ g o eD is D 0 a 206 TestStar Reference Manual Function Generator Window
272. t Set Editor Window The Unit Assignment Set Editor window creates different sets of units A set of units is used as the default units for the parameters of the various TestStar windows Fi Unit Assignment Set Etor ATE jan File Help D Set Name lt none gt iF Assign a unit for each Description dimension to create a unit la o set z S Dimensions Units J A A N Force ft z Time in Frequency m a Temperature micron v Ww T Talaranaa il CONTROL FUNCTION File Lists the file management selections Set Name Shows the name of the unit set that is currently open Description Displays a description of the unit set You can type in this area A description typically describes the set name Clear Removes the description currently being displayed Dimensions Displays a list of the dimensions used by TestStar Units Displays the appropriate types of units that are compatible with the selected dimension 248 TestStar Reference Manual Unit Assignment Set Editor Window Resets the current unit assignments to the first unit listed in each dimension clears any description and displays lt none gt as the Set Name Opens a previously defined set of units Use New to create a new set of unit preferences for the dimensions Saves the current Unit Assignment Set Editor setti
273. t Signals Drive Type 252 Valve A Valve Driver Uses HEI Valve Type 252 Valve y Control Channels Valve Balance A 0 00000 Constanis Dither Amplitude 0 10000 a Dither Frequency 625 000 Actions Underpeak Detectors Input Signal Undefined Error Actions Maximum Error Action Disabled Minimum Error Action Disabled stroke control Mode Control Mode 1 Mode Type PIDF Command Segment Generator Feedback stroke Gain P 1 0000 I 0 00000 D 0 00000 F 0 00000 Error Detectors Minimum Error 127 000 Maximum Error 127 000 Pod control Mode Control Mode 4 Mode Type Channel Limited Channel Command Pod Feedback stroke Limit Feedback load Gain Master P 1 0000 Limit P 1 0000 Upper Limit 88964 4 N Lower Limit 88964 4 N TestStar Reference Manual 79 Print Preview Window Display System Information Input Signals Output Signals Control Channels v Constants Actions Display System Information Input Signals Output Signals Control Channels Constants 7v Actions 5 S oO oO lt lt 80 cascade control Mode Control Mode 7 Mode Type CASC Command Segment Generator Outer Loop Feedback stroke Inner Loop Feedback load Gain Outer Loop P 1 0000 Outer Loop D 0 00000 Inner Loop P 0 00000 Inner Loop I 0 00000 Error Detectors Minimum Error 127 000 Maximum Error 127 000 Compensators Peak Valley Convergenc
274. t have hydraulic power on when making changes to the system configuration Have a thorough knowledge of the control electronics before turning on hydraulic power Always follow the recommended operational procedures to turn on hydraulic power failure to do so can cause the actuator to move rapidly and unexpectedly Some test sites have multiple test stations served by one hydraulic power supply Understand how these units are interconnected before turning on hydraulic power Check the cabling to the system sensors and servovalve If the feedback or servovalve signal is lost for any reason such as the connector coming loose or not connected or the cable is damaged the resulting signal loss will cause the actuator piston to move at maximum force and maximum velocity until it reaches a mechanical limit Anything in its path including you could be crushed Before operating the system for the first time make a trial run through the desired test by locating the window controls involved without actually performing the adjustment or turning on hydraulic power 15 Safety Precautions Load Units and Other Crush Point Hazards It is especially important to stay clear of any potential crush points when the system is operating Know where the crush points are in your system and protect yourself and others from those crush points with appropriate safety devices The following paragraphs describe crush points and precautions to take while w
275. t resembles the test command waveform In theory you can duplicate the test command perfectly In practice you will find that you cannot get a perfect waveform You will need to determine what an acceptable waveform looks like Adjust the gain P control to achieve a waveform between the optimum and high setting This establishes a starting point Vk Gain Too Low Optimum Gain Gain Too High Adjust the rate D control to remove overshoot Then adjust the gain P control to introduce more ringing Continue these adjustments to achieve the highest gain setting while maintaining a stable waveform Review the following waveform table High ye Rate D o Low Gain P High You may need to reduce the rate setting to introduce a feed forward adjustment Make small adjustments and observe the results Continued TestStar Reference Manual 289 Tuning Tuning Procedure Step 2 continued Step 3 Adjust reset peak valley meter square wave error signal triangle wave error signal Ifa stable waveform cannot be achieved with the rate adjustment use the feed forward F adjustment If your system goes unstable and you can t correct it quickly stop the test command reduce the adjustment settings and try again To adjust reset I you may want to set up a peak valley meter or you could monitor the error waveform with the oscilloscope Monitor the peaks and valleys of the sensor signal T
276. t units for every TestStar parameter only those you want to change TestStar Reference Manual System Administration Window Application Access Window This window shows the user name and lists all the user name iS lt Nn ak 5 gt on z jam ji o Nn 2y a pi 0 applications Function Generator s Load Path Stiffness Use this window to select Sensor Calibration the applications the user System Administrator can access TestStar TestWare SX Unit Assignment Set Editor Using the window select highlight each application title you want the user to have access then press the OK button TestStar Reference Manual 237 S jo D g N am E TO lt eD Nn a N System Administration Window New Edit Application Window The New Application and Edit Application windows are the same Completing this window displays the User Access window How it works Using the window 238 New Application Program title Program file name Add Cancel When you install a TestWare application using the Setup program the application is automatically put in the appropriate directory In most cases this is TS directory The purpose for this window is to let the System Administrator program know that a new application has been added and which user names can access the application The
277. ted Each data base includes all the ranges that were calibrated for the sensor Each sensor can have up to six ranges Go to the Installation manual for the following procedures Chapter 6 Calibrating an LVDT Chapter 7 Calibrating a force sensor Chapter 8 Calibrating an extensometer Chapter 9 Printing backing up and retrieving calibration data Chapter 10 Defining external sensors TestStar Reference Manual Sensor cartridges More information TestStar Reference Manual Input Signals The 490 21 DC Conditioner has a front panel connector for a sensor cartridge Each sensor cartridge provides a place to install up to five shunt calibration resistors and three bridge completion resistors for a sensor Each dc type sensor should have a sensor cartridge for the dc conditioner The shunt cal resistors are used to check the calibration accuracy of the sensor conditioner combination The sensor cartridge must be installed when performing a shunt calibration operation Otherwise it is not required for normal operation The bridge completion resistors allow the use of quarter and half bridge strain gage sensors The sensor cartridge must be installed when using this type of sensor it is required for normal operation Cabling Installation Manual 3 Calibrating sensors Installation Manual 6 7 8 Selecting a range Edit Input Signals Window on page 88 Adjust Input Signals Window on page 149 Display Input Signals on page 190
278. that the specimen characteristics change during the test Use this checklist when you tune a system You need to determine the following 1 What type of control mode do you wish to tune Read About Control Modes d What controls should you use Read About the Controls What kind of a tuning program should you use Read Creating a Tuning Program Do you have a dummy specimen Read About Specimens 1 Where to connect the oscilloscope and what signal to monitor Read Monitoring a Waveform L Disable any compensation functions such as amplitude control or phase control See the Function Generator chapter or the appropriate TestWare application manual TestStar Reference Manual About Tuning What to do first The following are tasks that should be completed before you tune It is not necessary to perform every task each time you tune The condition of your system dictates which of the following tasks you must perform For example a new system or a system under complete recalibration requires all of the following to be completed If you are performing periodic or fine tuning review the following and determine which tasks you need to complete Disable any compensation functions such as amplitude control or phase control These functions should be used after the system is properly tuned Connect an oscilloscope to your system or use the TestStar scope You need to monitor the sensor signal or error signal for
279. the output tries to produce a 0 to 11 volt signal However the maximum output is 10 11kN 10 volts volts and the output clips 1 5 volts volt Changing the offset to 6 o volts produces a 0 to 5 volt signal that represents the 6 to 11 kN portion of the Waveform pn tin ect Assume you create a test 43cm program that ramps to 1 5 cm and cycles between 1 5 and 2 pasd reren cm 1 506M 4 rsson ee eee Assume you want to view the 0 5 cm haversine as a 5 volt readout signal When gain is set to 1 then 0 5 cm equals 0 5 volt 1 cm 1 volt Setting the offset to 5 volts and the gain to 10 produces a 0 to 5 volt signal that represents the 1 5 to 2 cm haversine Offset 10 volts TestStar Reference Manual Programmable Output This selection allows optional applications to customize the output TestStar Reference Manual Output Signals ies ou j 0 5 Signal Selection 1 lt e F Signal Definition Signal Name Signal Type ik Programmable Label 11 lt When you select a programmable output the rear panel connector is reserved for use by an optional TestWare application Your MTS TestWare application manual will tell you if you need a programmable output For example the 790 10 TestWare SX application has an analog output process that uses a programmable output This p
280. the error code numbers that can be returned when a digital controller error occurs Appendix C Servo Loop Update Rate 309 Shows the current update rate and the maximum rate can be established Appendix D Debug Options 311 Records the messages between the computer and digital controller Appendix E Bypassing the Login 315 Describes how to bypass the login sequence for any TestStar program Appendix F Load Path Stiffness Editor 317 Describes how to establish load path stiffness sets asl TO eD er lt 294 TestStar Reference Manual Firmware Error Codes Appendix A Firmware Error Codes Following is a list of definitions of the numbers that are returned when a firmware error occurs The type refers to the firmware object issuing the error Type acronyms The following help describe the different types of firmware errors TYPE DESCRIPTION act detector action events aio the analog input output module buf data acquisition buffer on ptocessor module cis calculated input stream calculated input error cmd command instructions pasted on from the hst to other parts of the digital controller dio digital input output on the prcessor module dly delay hio hydraulic input output module hst host interface messages to from the WSCI board ibc instrumentation bus controller module idp ilk interlocks processor module luc load unit control panel mux mult
281. tify hazards so that appropriate training operating procedures and safety equipment can be set up Common sense and a thorough knowledge of a specific system s operation and capabilities usually suggest the appropriate approach to system operation safety Therefore proper safety practices should begin with operator training Operators should have had prior schooling and training on similar systems MTS has training classes that cover servo hydraulic operating theory system operating procedures and system maintenance techniques In addition you should gain an understanding of system functions by studying the various instructions and manuals supplied with the test system 11 Safety Precautions General Safety Guidelines Know safety placards read the manuals Know emergency stops Preface Know potential crush points Know system interlocks 12 The following safety guidelines are applicable to most test systems As you read each item listed below consider how it applies to your system This can help to produce safer operating practices If you have any questions contact an MTS representative Locate read and follow all instructions on equipment safety placards Placard location is typically described in the installation section of the hydro mechanical product manuals Know where all of the system Emergency Stop buttons are located so that you can stop the system quickly Emergency Stop buttons have strip
282. tion generator The Waveshape selection is disabled because the external command source provides that function The Frequency adjustment is disabled The Amplitude adjustment is scaled for percentage of full scale The Amplitude ramp time specification is enabled When you press the Run button the function generator ramps the external command amplitude to full scale When you press the Hold button the function generator selects a non external command control mode to hold the actuator position When you press the Stop button the function generator ramps the external command amplitude to zero See Chapter 10 in the Installation manual for complete instructions to use an external command source i g o eD ies D 0 a 218 TestStar Reference Manual Amplitude Ramp Time A command begins with an amplitude of zero and gradually increases until the programmed amplitude is reached Compensators Peak Valley PAC TestStar Reference Manual Command Menu Options Window The Amplitude Ramp Time can only be used with an external command source It allows you to slowly apply the program command to the specimen when the program starts It also ramps the program amplitude down when the Stop button is pressed This feature prevents sudden actuator movement when the external command starts amplitude ramp time l Compensators compare the sensor feedback to the te
283. trol Mode 118 Channel Limited Channel Control Mode 120 Cascade Control Mode 121 Calculation Constants 122 Detector Actions 124 Edit Detector Actions Window 126 Hold Actions 127 Ramp Actions 128 Continued TestStar Reference Manual 83 Edit Menu Contents continued Load Path Stiffness 129 Edit Load Path Stiffness Window 130 LUCP Display 131 Toolbar 133 Configure Toolbar Window 134 Meters 136 Meter Definition Window 137 Timed Data 138 Peak Valley Data 139 Span Mean Data 140 Max Min Data 141 Scope 142 Defines input signals from sensors calculations and external signals Edit Adjust Display Help Input Signals am State ato Output Signals Control Channels Control Modes Calculation Constants be referenced in calculated inputs Al Defines up to 6 hold or ramp actions in addition to the 4 standard actions Defines constant values that can J Defines the signals assigned to the 6 rear panel output connectors J71 J76 A Detector Actions l Load Path Stiffness Selects a load path stiffness set Defines the control chanel LUCP Display Toolbar f p Meters i is di Defines the control modes Pernes wna is cispiayed on for each control channel J Scope paS Creates a row of buttons that open TestStar windows Defines up to 4 digital displays Each display
284. uency adjustment value Max TA OK Cancel Help Using the window The window displays the maximum frequency of the adjustment The range of the Frequency control setting is 0 01 and 300 Hz The default setting is 10 Hz To change the scroll range value type the new value in the entry field For example assume the default value is 10 Hz Changing the range value to 20 Hz increases the range of the Frequency adjustment Frequency 5 Hz Frequency 5 Hz gt gt The Frequency control is set to Changing the scroll range to 20 5 Hz with the scroll range set to Hz also changes the 5 Hz 10 Hz reference EF a 5 ie e j 0 5 ap 5 t a TestStar Reference Manual 213 i g o eD ies D 0 Fi Command Menu Options Window Command Menu Options Window Prer equisite You must define the input signals control channels and control modes to use this window Control channel x Use this window to define the servo loop command Control mode Units x Initial ramp rate z Ampl ramp time x Waveshape sine square triangle Compensation peak valley PAC Waveshape order C Inverted 214 TestStar Reference Manual Command Menu Options Window CONTROL FUNCTION
285. ult units Frequency Temperature TestStar Reference Manual Standard unit sets The unit Assignment Set Editor includes 5 unit sets These can be edited to create additional unit sets CGSSET is a set of units that contain centimeters grams and seconds ENGSET is a is a set of units that contain U S customary units that contain small U S customary units SISET is a set of units that contain International System units SISETSM is a set of units that contain small International System units TestStar The following list shows the dimensions used by TestStar The units j 0 ee gt Nn N bic ae oO 5 WN Oo ee er a j o ee o dim ensions assigned to each dimension are those for the SISET unit set DIMENSION UmiTs 7 DIMENSION UNITS 7 Acceleration mm Sec 2 Angle deg Stiffness kN mm Angle Rate deg Sec Strain mm mm Area Sq mm Strain Rate mm mm Sec Compliance Sq mm kN Stress kN Sq mm Damping kN Sec mm Temperature deg_C Energy kN mm Temperature deg_C Sec Rate EPV Energy per kN mm Temperature deg_C Unit Volume Cu mm Tolerance Force kN Time Sec Force Rate kN Sec Torque kN mm Frequency Hz Torque Rate kN mm Sec Length mm Unitless none Length Rate mm Sec Volts V Percent Velocity mm Sec Segment Count segments Volume Cu mm TestStar Reference Manual 247 Unit Assignment Set Editor Window Unit Assignmen
286. units Action lt j gt x Lower Limit 0 000000 _ units Action Control Channel Selection lt ea g a v control channels 1 4 Se Sensor Zero Shunt Calibration Control Mode Selection Unlock D Lock Shunt cal z 4 x control modes 1 Offset 0 000000 Sensor lt gt Output 0 000000 units Si Appropriate tuning controls are added to the bottom of the window according to the type of control mode PIDF CLC or CASC ks J Adjust Compensators Control Channel Selection R Control Channel 1 z File Edit Convergence Rate 1 00000 HPS Pressi Input Sign off on a E z Control crann Tuning mod Compensator Selection Compensators wy PeakiValley g APC Sta Error Detectors 1 Undefined 5 Compensator Adjustments Underpeak Detectors 100 000 Drive Iv lt i gt Control Channel Selection _________ 4 m z Adjust Error Actions Control Channel Selection Maximum Action a z J Control Channel 1 Min
287. window to Unit Set Names store a set of default units CGSSET ENGSET ENGSETSM SISET SISETSM Save Cancel Using the window Type the name of the unit set in the entry field at the top of the window Press the Save button to save the set of units j 0 ee gt Nn N bic ae oO 5 ee n tr a j o ee o TestStar Reference Manual 251 Unit Assignment Set Editor Window Delete Unit Assignment Set Window Use the Delete Unit Assignment Set window to Unit Set Names remove a set of default units ENGSET ENGSETSM SISET SISETSM Delete Cancel Using the window Select a unit set from the list of defined unit set names The selected set of units is shown in the entry field at the top of the window Press the Delete button to remove the unit set 5 an e5 N e5 ove _ N N lt t a A CAUTION Do not remove all of your unit sets At least one unit set must be available for use 252 TestStar Reference Manual Unit Assignment Set Editor Window Assign Default Unit Assignment Set Window Use the Assign Default CGSSET Unit Assignment Set Unit Set Names window to assign a set of units as the default set of units for users who have not selected their own defaults ENGSET ENGSETSM SISET SISETSM
288. wing the nature of your test program and the type of control channel helps you determine what kinds of control modes and their types are needed Up to ten control modes can be defined for each control channel For example an axial control channel has control mode that controls length The equivalent control mode for a torsional control channel is rotation A control mode links the feedback from a sensor input signal with a program command to control the servovalve TestStar uses the following control modes Represents four gain adjustments proportional integral derivative and feed forward This is the most widely used control mode for a closed loop system See PIDF Control Mode on page 118 CLC represents a control mode that uses a master input signal to control the actuator while a second input signal limits the master control This control mode is primarily used for specimen installation See Channel Limited Channel Control Mode on page 120 CASC represents a cascade control mode that uses two control loops The output of the outer control is the input to the inner control loop This control mode is primarily used for dynamic testing with force control See Cascade Control Mode on page 121 You must define the input signals and the control channels before defining any control modes TestStar Reference Manual Edit Control Modes Window Use this window to define the control modes for each control channel
289. witch 63 test control switches 62 Logging in 48 232 315 TestStar Reference Manual Login bypassing 315 LUC Positioning Hint 66 M Overview interlock 63 P Maintenance 23 Manual how information is arranged 34 how to use 9 34 other manuals 10 Max Min data 141 Mean amp amplitude control 219 adjustment 206 227 how it works 208 scroll range 211 Message log 311 Meters alignment menu 197 control menu 197 defining 137 display 196 max min data 141 span mean data 140 timed data 138 139 types 136 196 Modifications 21 Mouse 37 MTS technical assistance 26 0 Obtaining technical assistance 26 Oscilloscope 280 Output signals analog bus 103 sensor signals 104 valve signals 104 connecting 100 connections 102 defining 101 external devices 99 programmable 109 readout 105 offset examples 108 scaling examples 107 Overview tuning 260 TestStar Reference Manual PAC 171 219 PAC adjustments 170 Password 241 Peak Valley compensation adjustments 170 Performance rate 309 Phase amplitude compensation convergence rate 172 limit adjustment 173 PID control mode 161 Pod Display 64 Preferences configuration file 231 unit assignment set 256 units 254 Printing configuration file format 78 scope display 199 Programmable output 109 R Ramp actions 128 Range 98 192 full scale 154 192 internal sensor 154 192 selecting 154 192 Readout connectors 102 signal gain 106 offset 108 scaling exam
290. xed limit 170 TestStar Reference Manual Adjust Compensators Compensator S Compensators compare the sensor feedback to the test command to determine if the command signal is producing the required physical effect on the specimen Compensators can provide specific types of correction to ensure the command is properly applied to the specimen The compensator adjustments are like additional tuning adjustments The compensators are selected and used in the TestStar Function Generator the TestWare SX cyclic command process and the optional mixed mode sine process Note Be sure to disable any compensation when tuning Peak Valley This compensator detects any amplitude roll off and any difference in the mean level Amplitude roll off is the difference between the amplitude of the command and the amplitude measured by the sensors This can also cause a mean level difference Peak Valley compensation is available only for cyclic commands this includes sine triangle and square waveforms nus isn py Peak Valley compensation is available on all channels It uses very little of the system resources and doesn t slow down the sampling rate servo loop update rate PAC This phase and amplitude compensator detects any amplitude roll off and any phase lag Amplitude roll off is the difference between the amplitude of the command and the amplitude measured by the sensors Phase lag refers to the time lag between the command p
291. y in either direction or if a specimen is attached apply full tensile or compressive force e positive or negative acceleration Ensure that electrical power connections are not interrupted during test system operation Do not use any interlock reset to bypass the interlock chain and attempt to start the hydraulic power supply Doing this will cause the hydraulic power supply to start and hydraulic pressure will be applied regardless of the interlock condition The error detector may be adjusted to trip whenever a large error is present preventing the continued application of hydraulic pressure TestStar Reference Manual Safety Precautions Guidelines For Installing Specimens Because you are very close to or in contact with the system force train during specimen installation this procedure can be the most hazardous part of system operation Because it is usually necessary to have hydraulic power turned on follow all of the instructions in this manual in addition to the following Clear the work area especially near system crush points Ensure that the servo control loop is properly phased and stable refer to the TestStar Installation Manual for procedures Be particularly alert for phase or control reversal if the system setup has been modified since the previous operation If operating the system in force or strain control adjust the gain control to a value known by experience to be stable for the particular specimen
292. y use the same adjustments Electro mechanical systems use servo motors to control the actuator instead of hydraulics Electro mechanical systems replace the term hydraulic with motor throughout the TestStar windows TestStar Reference Manual This window adjusts the Valve Driver module for use with a Series 252 Servovalve Valve Adjustments Valve Balance A 0 000000 V Dither Amplitude 0 100000 Vpp lt gt Ik gt Valve Balance B 0 000000 V Dither Frequency 625 000 Hz lt 1 E gt gt Polarity Valve Balance Normal Inverted Separate Combined ee CONTROL FUNCTION Adjust Drive m Adjusting 252 and Dual 252 Valves x adjust D o Control Channel Selection m x Control Channel 1 1 lt Valve Balance A Valve Balance B Electrically compensates for minor mechanical unbalance in the servovalve Dither Amplitude Adjusts the amount dither needed to overcome friction in the servovalve Dither is most effective for static and low frequency tests Dither Frequency Adjusts the dither frequency The operating frequency of the system can affect the dither frequency setting The typical dither frequency for a Model 252 Servovalve is 500 700 Hz 625 Hz is nominal Setup Displays the
293. ype of test you use the compression platens without the extension rods You should create a stiffness set for both types of tests TestStar Reference Manual Load Path Stiffness Editor Using the Load Path Stiffness Editor This procedure describes how to use the Load Path Stiffness Editor to create a stiffness set 1 Determine stiffness values 319 Open the Load Path Stiffness Editor 320 Create a new stiffness set 321 Close the Load Path Stiffness Editor 321 S S Step 1 Determine stiffness values The load path stiffness value is expressed as force unit displacement units The acquired data can be used with a spread sheet application to calculate the stiffness value or slope of the data TestStar Reference Manual The following is a guideline to determine the stiffness value for an axis Note Be sure to have the load path configured with components needed for the test Create a test command program that produces a slow ramp one minute over the range of the force sensor Acquire force and displacement data Use a stiff specimen such as steel Calculate the stiffness from the force and displacement data slope Force N N mm Displacement mm 319 gt az ge ou j 0 gt lt Load Path Stiffness Editor Step 2 Open the Load Path Stiffness Editor A Double click the MTS TSII icon on the OS 2 desktop OS 2 only Then double click the Utility folder B Double clic
294. ys the Printer Properties Printer Setup window for you printer F e Slot 1 See OS 2 for more information Print to File AC Conditioner l Update Display f ngenar Calibration P Select Font 10 0082m M Creates an ASCII file of the 10 0000 mm 4 current TestStar configuration lt 10 0000 mm 20000 Unlock Lower Limit ZerovOffset 0 S Output Signal Display Section Updates the display information if you made any changes after Output 1 opening this window Type Readout Device Slot 1 4 7 gt Displays the Font window Any system font can be applied to the display Use the Display menu to select the parameters you want to display Enable each item you want to view a check mark indicates the item can be viewed These settings also affect the information that is printed or saved to a file Note Anytime the configuration file is changed the Configuration File listing shows configuration modified 77 Print Preview Window Configuration format Display v System Information Input Signals Output Signals Conirol Channels Constants Actions Display System Information 7v Input Signals Output Signals Control Channels Constants Actions 5 S oO oO lt lt 78 The following shows a generic outline of the types of information that is shown in the Print Preview window saved to

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