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MTS Systems FlexTest IIm Manual

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  • Page 1 sales@artisantg.com artisantg.com (217) 352-9330 | Click HERE Find the MTS 497.05 at our website:...
  • Page 2 Models FlexTest IIm, FlexTest GT, and FlexTest SE Controller Hardware Service Information: - Hardware Descriptions - Specifications - Installation - Cabling 100-147-133 E Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
  • Page 3 Copyright information © 2008 MTS Systems Corporation. All rights reserved. Trademark information MTS, Temposonics, and TestWare are registered trademarks of MTS Systems Corporation. FlexTest, MPT, Station Builder, and Station Manager are trademarks of MTS Systems Corporation. Adobe is a registered trademark of Adobe Systems Inc.
  • Page 4 Interlocks Specifications FlexTest SE Controllers Model 493.02 Chassis Hydraulic control Interlocks Specifications FlexTest IIm Controllers Model 497.01 Analog Chassis Model 497.05 Hydraulic Control Panel Model 498.22 Chassis with Test Processor (FTIIm) Specifications MTS 793 Controller Hardware Contents Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
  • Page 5 Chapter 2 Installation 37 Installing the 493.10 Chassis (FTGT) Connecting Electrical Power Installing the Plug-in Modules VMEbus Modules Installing the Transition Panels Installing the 493.02 Chassis (FlexTest SE) Installing the Plug-in Modules VMEbus Modules Chassis Installation Options Connecting Electrical Power Installing the Handle Kit Installing 497/498 Electronics (FTIIm) Connecting the Console and Chassis Power...
  • Page 6 Chapter 3 FlexTest GT Controller Connections 73 CE EMC Compliant Cabling Typical Cabling Cable Part Numbers Model 493.40 I/O Carrier Connections Sensor Connections Model 493.21B (DUC B) Jumpers Digital Universal Conditioner (DUC BC) Switches Full-Range Digital Universal Conditioner (FRDUC) Jumpers Sensor Cables Sensor cable specifications Sensor cable part numbers...
  • Page 7 Cabling and Programming Model 407 Controllers How to Provide Program to a Model 407 Controller Connecting Interlock Signals to 407 Controllers Sending and Receiving Signals to a Model 407 Controller Connecting Interlock Signals to 458 Controllers Eurotherm Temperature Controller Connection Miscellaneous Conditioner Output Connections Cabling for External Command Inputs How to Enable and Run External Command Inputs...
  • Page 8 Chapter 4 FlexTest IIm Controller Connections 161 Workstation Connection Sensor and Valve Connections ADDA Module Connections ADDA II Connections Hydraulic Connections HPU Connections HSM Connections Interlock Connections Interlock Jumper Plugs Serial Communications Digital I/O Connections Encoder/Temposonics Connections Remote Station Controller (RSC) Connections...
  • Page 9 Chapter 5 FlexTest SE Controller Connections 197 Standalone Cabling Overview Automated Cabling Overview Multiple Controller Connections Cable Part Numbers Model 493.40 I/O Carrier Connections Sensor Connections Valve Connections Analog I/O Connections Encoder Connections Workstation Connection Service Connection Model 493.42 System I/O Connections J25 Hydraulic Power Unit Connection J28 Hydraulic Service Manifold Connector J29 Emergency Stop Connections...
  • Page 10 Appendix A Hydraulic Configurations 221 Model 493.02 Chassis Multiple Controller Interconnections Independent HSM (no HPU) Independent HSM (shared HPU) Shared HSM (with HPU) Shared HSM (no HPU) Independent HSM with HPU (FO-LO) Appendix B Model 493.07 Converter Box 227 Appendix C Chassis Maintenance 229 Appendix D Optional Station Configurations 231...
  • Page 11 MTS 793 Controller Hardware Contents Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
  • Page 12 Technical Support How to Get Technical Support Start with your The manuals supplied by MTS provide most of the information you manuals need to use and maintain your equipment. If your equipment includes MTS software, look for online help and README files that contain additional product information.
  • Page 13 Before You Contact MTS MTS can help you more efficiently if you have the following information available when you contact us for support. Know your site The site number contains your company number and identifies your number and system equipment type (material testing, simulation, and so forth). The number number is usually written on a label on your MTS equipment before the system leaves MTS.
  • Page 14 • Amount of system memory • Amount of free space on the hard drive in which the application resides • Current status of hard-drive fragmentation • Connection status to a corporate network Know relevant For software application problems, have the following information software information available: •...
  • Page 15 Be prepared to Prepare yourself for troubleshooting while on the phone: troubleshoot • Call from a telephone when you are close to the system so that you can try implementing suggestions made over the phone. • Have the original operating and application software media available.
  • Page 16 Preface Before You Begin Safety first! Before you attempt to use your MTS product or system, read and understand the Safety manual and any other safety information provided with your system. Improper installation, operation, or maintenance of MTS equipment in your test facility can result in hazardous conditions that can cause severe personal injury or death and damage to your equipment and specimen.
  • Page 17 Conventions Conventions Documentation Conventions The following paragraphs describe some of the conventions that are used in your MTS manuals. Hazard conventions As necessary, hazard notices may be embedded in this manual. These notices contain safety information that is specific to the task to be performed.
  • Page 18 Conventions Special terms The first occurrence of special terms is shown in italics. Illustrations Illustrations appear in this manual to clarify text. It is important for you to be aware that these illustrations are examples only and do not necessarily represent your actual system configuration, test application, or software.
  • Page 19 Conventions Preface Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
  • Page 20 MTS 793 Controllers. It includes setup information for the Model 493.04 PC Per Station option. This chapter describes the hardware components and specifications of FlexTest GT, FlexTest SE, and FlexTest IIm Controllers. Contents FlexTest GT Controllers Model 493.10 Chassis...
  • Page 21 FlexTest GT Controllers FlexTest GT Controllers MTS FlexTest GT Controllers are fully digital Proportional, Integral, Derivative, Feedforward (PIDF) servocontrollers which use an identical chassis configuration. They provide complete control of up to eight channels distributed among up to eight stations. Optional station configurations are available (see “Hydraulic Configurations”...
  • Page 22 FlexTest GT Controllers Front panel The Model 493.10 Chassis front panel has twelve slots; ten VMEbus slots and two slots (A and B) which are reserved. Rear panel The rear panel of the chassis has twelve transition bus slots. Two of these rear panel slots (slots A and B) can not be used with powered MTS transition modules.
  • Page 23 FlexTest GT Controllers Cable conduit The chassis has a conduit that allows cables to be routed from the front VMEbus modules to the rear transition modules and out of the chassis. Power supply Two power supplies are used. One provides +5 V DC and ±15 V DC for the plug-in modules;...
  • Page 24 FlexTest GT Controllers System wide interlock The emergency stop circuit consists of a loop that only runs through the rear panel transition boards of the chassis. Any board that generates an interlock by breaking this system wide loop causes the hydraulic power unit to be shut down.
  • Page 25 FlexTest GT Controllers FlexTest GT Specifications (part 2 of 2) ARAMETER PECIFICATION Power supply #1 maximum draw is 400 W total +5 V DC 40 A ±15 V DC 7 .5 A Power supply #2 maximum draw is 400 W total ±12 V DC +24 V DC 10 A...
  • Page 26 FlexTest SE Controllers FlexTest SE Controllers The MTS Model 493.02 FlexTest SE Controller is a fully digital Proportional, Integral, Derivative, Feedforward (PIDF) servocontroller. It provides complete control of one servohydraulic channel or station in an MTS test system. FlexTest SE Controller The FlexTest SE may be operated in the standalone mode from its front panel controls, or in the automated mode with MTS Model 793.00 System Software running on a connected PC.
  • Page 27 FlexTest SE Controllers FlexTest SE standalone A function generator (with a built-in cycle counter) in the controller provides basic sine, square, triangle, and ramp command waveforms. function generation For tests requiring complex waveforms, the controller provides an external command input to receive externally generated commands. The function generator waveform can be output to another MTS FlexTest SE Controller (or any external device) for synchronization.
  • Page 28 FlexTest SE Controllers Model 493.02 Chassis Except for two front panel BNC connectors, all cabling is accessed through the controller’s rear panel. It is not necessary to remove the rear panel chassis cover to access jumpers or switches. The chassis can be rack mounted or used in a table-top configuration.
  • Page 29 FlexTest SE Controllers Specifications FlexTest SE Specifications ARAMETER PECIFICATION Environmental For indoor use only Temperature 5ºC – 40ºC (41ºF – 104ºF) Relative humidity 10% – 85%, noncondensing Altitude For use at altitudes up to 2000 m (6500 ft) Power input power factor corrected universal input 100 –...
  • Page 30 FlexTest IIm Controllers FlexTest IIm Controllers The MTS FlexTest IIm Controller is a fully digital Proportional, Integral, Derivative, Feedforward (PIDF) servocontroller. FlexTest IIm The FlexTest IIm configuration provides complete control of up to Controllers sixteen channels distributed among up to four stations in an MTS test system.
  • Page 31 One AC Conditioned input – Two DC conditioned inputs Console The FlexTest IIm Controller is available in a full-bay (vertical) console, a table-top console, or a roll-around console. Note The larger (full-bay) consoles can also accommodate rack-mount scopes, x-y recorders, and so forth.
  • Page 32 FlexTest IIm Controllers Model 497.01 Analog Chassis The plug-in modules installed in the 497.01 Analog Chassis provide four main functions: • Interlock control—An interlock control plug-in module provides programmable interlock signal mapping between the test processor and the modules installed in this analog chassis.
  • Page 33 FlexTest IIm Controllers Model 497.05 Hydraulic Control Panel The hydraulic control panel provides the following functions. • Control of up to four independent hydraulic service manifolds • Hydraulic power supply control • Interlock shutdown and latched indicators to show interlock status •...
  • Page 34 FlexTest IIm Controllers Model 498.22 Chassis with Test Processor (FTIIm) The 498.22 test processor chassis is a VMEbus chassis that houses up to twelve plug-in modules (including processor modules, ADDA modules, digital I/O modules, and so forth). It also accommodates various rear- panel transition modules (for connections to other hardware chassis and external equipment).
  • Page 35 FlexTest IIm Controllers Specifications Model 497.01 Specifications ARAMETER PECIFICATION Environmental For indoor use only Temperature 5ºC – 40ºC (41ºF – 104ºF) Relative humidity 10% – 85%, relative, noncondensing Power requirements +15 V at 6 A; -15 V at 6 A; +5 V at 6 A...
  • Page 36 FlexTest IIm Controllers Model 497.05 Specifications (part 2 of 2) ARAMETER PECIFICATION Interlock logic level Inputs 0 = 0 V DC 1 = 3.2 to 24 V DC Dimensions Height 8.9 cm (3.5 in) Width 48.3 cm (19 in) Depth 54.6 cm (21.5 in)
  • Page 37 FlexTest IIm Controllers Model 498.22 Chassis Specifications (part 2 of 2) ARAMETER PECIFICATION LED Classification Class 1 Environmental For indoor use only Temperature 5ºC – 40ºC (41ºF – 104ºF) ambient Relative humidity 0% – 85%,relative, noncondensing Maximum altitude 2000 m (6562 ft)
  • Page 38 Installing the 493.10 Chassis (FTGT) Chapter 2 Installation This chapter describes how to install the Controller chassis and connect it to system components. Contents Installing the 493.10 Chassis (FTGT) Installing the 493.02 Chassis (FlexTest SE) Installing 497/498 Electronics (FTIIm) Installing the 493.10 Chassis (FTGT) The chassis can be installed in an equipment rack console or in a standalone configuration.
  • Page 39 Installing the 493.10 Chassis (FTGT) Console installation The rack-mounted chassis can be installed in any Model 490.8x console. Install the console with the 493.10 Rack Mounting kit (056-139-502 for FlexTest GT). The Rack Mounting kit provides the hardware (L-shaped brackets) to support the chassis and mounting screws to secure the chassis to the console rack.
  • Page 40 Installing the 493.10 Chassis (FTGT) Standalone Console Configuration Configuration Chassis ground cable (PN 037-766-102) System ground cable connected to the vertical (PN 039-709-2xx) conductive rail. connected to other components. Signal common cable (PN 037-766-101) connected to the power panel. Chassis System ground cable ground is connected (PN 005-402-3xx) connected...
  • Page 41 Installing the 493.10 Chassis (FTGT) • The power supply is protected with an external circuit breaker in the On/Off switch that trips at a 10 amp overload. An internal fuse in the power supply is not user accessible or repairable. •...
  • Page 42 Installing the 493.10 Chassis (FTGT) Installing the Plug-in Modules This section describes how to install the plug-in modules into the chassis. The modules plug into a backplane connector and are secured to the chassis with a screw at the top and at the bottom of the module faceplate.
  • Page 43 Installing the 493.10 Chassis (FTGT) Placement of VMEbus modules in the front panel chassis Setting I/O Carrier Use the dipswitch (S1) and rotary dipswitch (S2) on each I/O Carrier addresses module to set its address in accord with its installed chassis slot as follows: DDRESS MTS 793 Controller Hardware...
  • Page 44 Installing the 493.10 Chassis (FTGT) Setting I/O Carrier The dipswitch settings for address C20 is shown below. Increment the module addresses rotary dipswitch as required to complete I/O Carrier module addressing. Setting GRES III The dipswitch settings for address C08 is shown below. Increment the module addresses rotary dipswitch as required to complete GRES III module addressing.
  • Page 45 Installing the 493.10 Chassis (FTGT) Front Panel VMEbus Modules ODEL ODULE UNCTION 493.40 I/O Carrier Supports up to four mezzanine cards. 493.43 Multi-Box I/O The optional module allows multiple controllers to share a master hardware synchronization clock and pass station interlock state information between each other. 493.50 ADDA II This optional module supports up to four 8-channel A/D...
  • Page 46 Installing the 493.10 Chassis (FTGT) I/O Carrier mezzanine cards (part 2 of 2) ODEL ODULE UNCTION 493.47 Encoder Processes the signals from an encoder or a Temposonics III transducer with an SSI interface. 493.48 Acceleration Conditioner Processes the signals from an accelerometer. Each Acceleration Conditioner mezzanine card can support up to three accelerometers.
  • Page 47 Placement of transition panels in the rear panel chassis Note Other transition modules may be used, contact MTS Systems Corporation for additional information. MTS 793 Controller Hardware Installation Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
  • Page 48 Installing the 493.10 Chassis (FTGT) Rear Panel Transition Panels ODEL ODULE UNCTION 493.71 RS485 Provides four channels of RS-485 interface, four channels of station stop interlocks, and four channels of emergency stop interlocks. The RS-485 interface channels are used for the Remote Station Controller and/or temperature controller.
  • Page 49 Installing the 493.02 Chassis (FlexTest SE) Installing the 493.02 Chassis (FlexTest SE) This section describes how to install the MTS FlexTest 493.02 chassis and connect it to your system components. Contents Installing the Plug-in Modules VMEbus Modules Chassis Installation Options Connecting Electrical Power Installing the Handle Kit Installing the Plug-in Modules...
  • Page 50 Installing the 493.02 Chassis (FlexTest SE) VMEbus Modules The VMEbus compatible modules should be installed in chassis slots according to the following guidelines. • The processor module is installed in slot 1 • The I/O carrier module is installed in slot 2. •...
  • Page 51 Installing the 493.02 Chassis (FlexTest SE) Model 493.40 I/O Carrier mezzanine cards ODEL ODULE UNCTION 493.14 Valve Driver Produces the control signal for a Series 252 Servovalve. 493.15 3–Stage Valve Driver Produces the control signal for a Series 256 or 257 Servovalve.
  • Page 52 Installing the 493.02 Chassis (FlexTest SE) Rack mounting When installing the chassis in an equipment rack allow a minimum of requirements 2 in. (5.1 cm) on either side of the Controller for air flow. There are no spacing requirements for the top or bottom of the Controller. If the equipment rack is equipped with doors, allow adequate clearance for the front and rear of the Controller.
  • Page 53 Installing the 493.02 Chassis (FlexTest SE) Connecting Electrical Power Electrical connections must be made by qualified personnel and conform to local codes and regulations. An electrical service panel to provide the electrical power feed (line voltage) to the chassis is not necessary, but may be required by local electrical codes.
  • Page 54 Installing the 493.02 Chassis (FlexTest SE) Rack Mount Configuration Chassis ground cable (PN 037-766-102) connected to the vertical conductive rail. Signal common cable (PN 037-766-101) connected to the power panel. System ground cable (PN 005-402-3xx) connected to the test frame or other components.
  • Page 55 Installing the 493.02 Chassis (FlexTest SE) • The power supply automatically selects the proper voltage range and line frequency. • The power supply is protected with an external circuit breaker in the On/Off switch that trips at a 5 amp overload. An internal fuse in the power supply is not user accessible or repairable.
  • Page 56 Installing the 493.02 Chassis (FlexTest SE) Rack Mounted Configuration Outlet Strip P ower 10 0–24 0 VAC 50 –60 Hz, 12– 6A R UN 6 TS BF L TYP E E PC -M IP TYP E E PC-M IP DEBUG PC I M EZ ZAN NE C ARD Power Panel MTS 793 Controller Hardware...
  • Page 57 Installing the 493.02 Chassis (FlexTest SE) Installing the Handle Kit The Controller may be equipped with an optional handle kit. The following procedure provides assembly and installation instructions for the handle kit (MTS PN 100-061-494). The following table and figure show the handle kit assembly components described in the procedure.
  • Page 58 Installing the 493.02 Chassis (FlexTest SE) 12 (handle-not shown) Handle Kit 1. Place one support arm (1) into one handle side leg (2), as shown in the handle kit assembly figure. 2. Set one of the clips (3) in place over the slender, straight portion of the support arm (1), just behind the circular end of the support arm.
  • Page 59 Installing the 493.02 Chassis (FlexTest SE) 6. Hold a ratchet housing (9) in place over the ratchet (8) and press the posts on the back side of the ratchet housing (9) into the mounting holes on the side panel of the Controller. 7.
  • Page 60 497.05 Hydraulic Control Panel (100-036-577) • 497.01 Analog Chassis (100-036-577) • 498.22/498.23 Test Processor (100-036-578)—for FlexTest IIm How To Connect the Chassis Power Cables You can plug the hydraulic control panel and the test processor chassis into the AC power strip inside the console.
  • Page 61 Installing 497/498 Electronics (FTIIm) How To Cable the Analog Chassis to the Hydraulic Control Panel Connect J50 DC Pwr on the 497.01 Analog Chassis rear panel to J50 on the 497.05 Hydraulic Control Panel rear panel. 497.05 Hydraulic Control Panel PN 046-239-1XX 497.01 Analog Chassis Grounding the Console and Chassis...
  • Page 62 Installing 497/498 Electronics (FTIIm) Model 497.01 Analog Chassis About Analog Chassis Slots Slot pairing Chassis slot assignments are grouped in pairs. If you have a conditioner in a slot, then you cannot have a valve driver installed in the slot paired with it. Slots are paired as follows: Slots 1–2 Slots 9–10 Slots 3–4...
  • Page 63 Installing 497/498 Electronics (FTIIm) Analog Chassis Plug-in Modules Before you install any plug-in modules, be sure they are configured properly for your system. The following is a brief description of the plug-in modules available for the chassis. Plug-in Modules ODEL ODULE UNCTION AC Conditioner...
  • Page 64 Installing 497/498 Electronics (FTIIm) How To Install or Remove a Plug-in Module Plug-in modules are static sensitive. Do not install or remove a module with electrical power on. Do not place modules that contain battery backup on a metal surface. Touch the console or other ground point before handling a module.
  • Page 65 Installing 497/498 Electronics (FTIIm) Analog Chassis Transition Modules Transition modules located on the 497.01 rear panel provide signal transfer between the 497 modules and external devices. One digital transition module and up to eight analog transition modules can be installed in this chassis. Each transition module plugs into the backplane connectors and connects to two chassis slot locations.
  • Page 66 Installing 497/498 Electronics (FTIIm) Transition Module Connectors Cable connections to external devices are made from the 497.01 chassis rear panel connectors. J101–J1601 System connectors J101 through J1601 (JX01) are 15-pin D-type connectors located on the chassis rear panel. They connect either a valve driver to a servovalve or a conditioner to a transducer.
  • Page 67 Adding an Analog Chassis to Your Console To accommodate higher channel counts, it may be necessary to add one or more 497.01 Analog Chassis to your FlexTest IIm console. Depending on the number of analog chassis installed, you may have to modify switch settings and jumpers on the communication boards in your 497.05 Hydraulic Control Panel and in the 497.01 Analog Chassis.
  • Page 68 Installing 497/498 Electronics (FTIIm) Communication Modules Switch and Jumper Settings X1 S (S3) X1, X2, X3 HASSIS WITCH UMPERS UMPER For a single analog chassis: 497 .01 Analog Chassis 1 Set to 1 Remove Install 3 and 4 497 .05 Hydraulic Control Panel Set to 2 Install Install 1 and 2...
  • Page 69 Connect your 497.01 Analog Chassis to J1. This connector communicates hydraulic status with the 498.22 Test Processor chassis. This connector is not used in a standard FlexTest IIm system. J15A–J17D Each HSM channel has a set of three user defined interlock inputs (Interlock 1, Interlock 2, and Shutdown).
  • Page 70 The following table provides a brief description of the plug-in modules installed in your test processor chassis. Test Processor Plug-in Modules ODULE UNCTION Processor Modules Standard FlexTest IIm Controllers have two processors installed in the 498.22 Chassis: • The first processor (in slot 1) communicates with the external computer. •...
  • Page 71 Installing 497/498 Electronics (FTIIm) ADDA II mezzanine cards ODULE UNCTION 493.55 A/D Converts up to eight external analog signals to digital signals for use by the controller. This board requires the optional ADDA II module. 493.56 D/A Converts up to eight internal digital signals to analog signals for use by external devices.
  • Page 72 Installing 497/498 Electronics (FTIIm) Test Processor Transition Modules Transition modules are screwed into the back of the test processor chassis. Each rear-panel transition module corresponds to a plug-in module (or plug-in module mezzanine card) installed in the front of the chassis. Transition modules interface with the other test components via connectors for external digital, analog, and communication cables.
  • Page 73 In order to use these digital inputs and outputs, this module must be connected to a 498 Digital I/O Access Panel. Note On some custom FlexTest IIm Controllers, this module must be connected to a 498 Remote Digital I/O Access Panel. 493.80 Encoder Transition Interfaces with up to four encoders.
  • Page 74 Chapter 3 FlexTest GT Controller Connections This section describes the cable connections to the Model 493.10 Chassis. Note For information on connecting power cables, see “Connecting Electrical Power” on page 38. Contents CE EMC Compliant Cabling Typical Cabling Cable Part Numbers Model 493.40 I/O Carrier Connections Sensor Connections Sensor Cables...
  • Page 75 Digital I/O Connections Workstation Connection Remote Station Controller Connection Service Connections Cabling and Programming Model 407 Controllers How to Provide Program to a Model 407 Controller Connecting Interlock Signals to 407 Controllers Sending and Receiving Signals to a Model 407 Controller Connecting Interlock Signals to 458 Controllers Eurotherm Temperature Controller Connection Miscellaneous Conditioner Output Connections...
  • Page 76 • Disconnect the overall shield from the metallized back shell at the external device and add a capacitor (approximately 0.01 μf) to one end of the cable between the shield and the metallized backshell. • Disconnect the overall shield from the metallized back shell at the external device.
  • Page 77 Cable Part Numbers System cables The following is a list of the most common cables, see the System Cable/Jumper Plug 493 Package Selection drawing (MTS PN 700-000- 656) for the most current and additional cable part numbers. System Cables (part 1 of 2) ABLE ESCRIPTION ODULE...
  • Page 78 System Cables (part 2 of 2) ABLE ESCRIPTION ODULE UMPER UMBER * LUG † ONNECTOR Interlock—Station per system 493.74 J43 100-007-948 Remote Station Control—with E-Stop 055-634-2XX 493.71 J50 055-634-101 Remote Station Control—with Station Stop 055-634-3XX 493.71 J50 055-634-101 Workstation Link (Ethernet cable) 051-996-8XX ‡...
  • Page 79 • Valve connections require a valve driver mezzanine card be installed in the I/O Carrier module. The following valve drivers can be installed: – Model 493.14 Valve Driver – Model 493.15 3-Stage Valve Driver • Analog I/O connections require an A/D or D/A mezzanine card be installed in the I/O Carrier module.
  • Page 80 Excitation and feedback signals are passed through to the transducer, as shown. If purchased as an option, a transducer ID module is located in the transducer cable. Excitation and feedback signals are passed through to the transducer. MTS 793 Controller Hardware FlexTest GT Controller Connections Artisan Technology Group - Quality Instrumentation ...
  • Page 81 LVDT connections An LVDT requires an AC conditioning mezzanine card. Temposonics II The connection requires a DC conditioning mezzanine card. MTS 793 Controller Hardware FlexTest GT Controller Connections Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
  • Page 82 Temposonics III The connection requires a DC conditioning mezzanine card. MTS 793 Controller Hardware FlexTest GT Controller Connections Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
  • Page 83 Force/strain sensor Force and strain sensors require a DC conditioning mezzanine card. connections Model 493.21B (DUC B) Jumpers The following jumpers are for the Model 493.21B Digital Universal Conditioner). The jumpers are labeled W instead of X; the W jumpers are solder pads.
  • Page 84 4- or 8-wire Jumpers W2 and W3 establish the correct shunt calibration connections sensor cable for 4-wire and 8-wire sensor cables. The length of the sensor cable determines which type of cable is used. Short cables are typically 4- wire cables while long cables are typically 8-wire cables. •...
  • Page 85 Excitation Jumpers W5 and W7 select the local (on board) or remote (through a cable) excitation sensor connection. • The local selection is used with 4-wire transducer connections. • The remote selection is used with 8-wire transducer connections. • Jumper W7 configures the + excitation signal. •...
  • Page 86 4- or 8-Wire Switches S1-1, S1-2, S1-3, and S1-4 establish the correct shunt sensor cable calibration connections for 4-wire and 8-wire sensor cables. The length of the sensor cable determines which type of cable is used. Short cables are typically 4-wire cables while long cables are typically 8-wire cables.
  • Page 87 Sensor Cable Settings (4/8-Wire) REQUIRED CONNECTION SWITCH SETTINGS -EX to -FBR shunt in 8-wire S1-1 OFF configuration S1-2 OFF S1-3 OFF S1-4 ON -EX to +FBR shunt in 8-wire S1-1 OFF configuration S1-2 OFF S1-3 ON S1-4 OFF Bridge balance Switch S1-5 changes the offset of the bridge balance circuit.
  • Page 88 Excitation sense Switches S1-6 and S1-7 select the local (on board) or remote (through a cable) excitation sensor connection. • The local selection is used with 4-wire transducer connections. • The remote selection is used with 8-wire transducer connections. • Switch S1-7 configures the + excitation signal.
  • Page 89 Full-Range Digital Universal Conditioner (FRDUC) Jumpers The following jumpers are for the Model 493.25 Full-Range Digital Universal Conditioner. The jumpers are labeled W instead of X; the W jumpers are solder pads. The following jumper descriptions are from the 493.XX Module Setup configuration drawing (PN 049-336-301). Active guard Jumper W1 enables or disables an active guard for the sensor cable.
  • Page 90 • Both jumpers should be set for the same configuration. Local Remote ±Shunt cal The shunt calibration resistor can be installed on the Full Range Digital Universal Conditioner module, or, in the transducer ID module. R33 assigns a positive or negative excitation to the shunt calibration resistor if installed on the Full Range Digital Universal Conditioner module (not the transducer ID module).
  • Page 91 Sensor Cables A typical system is provided with a standard set of sensor cables as specified on the System Cable/Jumper Plug 493 Package Selection drawing (PN 700-000-656). Refer to this drawing for the most current part numbers. Standard sensor cables do not have ID modules. Sensor cables with an ID module built into them are available as an option.
  • Page 92 Sensor cable part numbers Sensor cables See the System Cable/Jumper Plug 493 Package Selection drawing (PN without ID Module 700-000-656) for the most current sensor cable part numbers. Sensor Cables and Connectors ABLE ESCRIPTION ABLE ONNECTOR 120º 056-234-8XX 493.40 J4–J7 300º...
  • Page 93 Sensor cables with ID See the System Cable/Jumper Plug 493 Package Selection drawing (PN Module 700-000-656) for the most sensor cable current part numbers. Each sensor includes a cable with an ID module built into it. Use a system cable to bridge the sensor cable to the rear panel of the controller chassis.
  • Page 94 I/O Carrier Module Shunt calibration The I/O Carrier module has a shunt calibration connector on its front connector panel that allows up to four shunt resistors (1 per slot) to be plugged in. The SHUNT CAL connector is labeled to indicate which slot the shunt calibration resistor is tied to.
  • Page 95 MTS 793 Controller Hardware FlexTest GT Controller Connections Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
  • Page 96 Transducer Identification Modules Transducer ID modules (located at the end of the sensor cable) are optional components that can store sensor calibration information just like a sensor calibration file. Since the calibration information stays with the sensors, transducer ID modules make it easier to change sensors.
  • Page 97 The circuit card has the bridge completion and shunt calibration resistors on one side, and the transducer ID circuit on the other. • R6, R7, and R8 are the bridge completion resistors • R9 is the shunt calibration resistor The following is the schematic diagram of the bridge balance and bridge completion circuit.
  • Page 98 Valve Connections The following types of valve connections are supported: • Single or dual Series 252 Servovalve(s) can be controlled with a Model 493.14 Valve Driver mezzanine card. • A Series 256 Servovalve can be controlled with a Model 493.15 3 Stage Valve Driver mezzanine card.
  • Page 99 252 servovalve The Series 252 Servovalve is a 2-stage servovalve. The Model 493.14 connections Valve Driver supports single or dual valve configurations. The following figure shows the connections at the valve driver and the connections between the valve and the valve driver. See “Cable Part Numbers”...
  • Page 100 257 valve connections The Series 257 Servovalve is a 3-stage servovalve that requires a power driver. The Model 493.15 Valve Driver supports the inner loop signals. The following figure shows the connections between the valve driver and the valve. See “Cable Part Numbers”...
  • Page 101 MTS 793 Controller Hardware FlexTest GT Controller Connections Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
  • Page 102 Multiple Universal Driver Connections For special applications, the Model 493.79 Multiple Universal Driver (MUD) board provides up to six drivers that can be used to drive standard 252 servovalves. Inputs to this board originate from a Model 493.46 D/A board on a Model 493.40 I/O Carrier Module. A Y-cable (PN 100-006-173) connects the I/O Carrier module (15 pin, D-Type) to J9/J10 on a MUD board (RJ45).
  • Page 103 Output connections Each valve driver output is an RJ50 connection that contains two valve drive output lines and a cable loss detection loop. Cable loss detection The cable loss detection wire loops out to the servovalve and back to the driver output allowing MUD board logic to detect a cable break or a cable disconnect at the MUD board output.
  • Page 104 Analog I/O Connections The Model 493.45 A/D and Model 493.46 D/A mezzanine cards are installed in the Model 493.40 I/O Carrier front panel module. A connection from the front panel mezzanine card to a rear panel BNC transition module allows easy access to the analog channels. Note The external analog source can be a stand alone function generator, another controller, or a computer controlled analog output.
  • Page 105 Analog inputs The analog-to-digital mezzanine cards accommodate up to six analog input signals. Each A/D input signal must be within ±10 volts. • Use pin 3 or 6 to prevent problems with floating grounds between devices. • Analog inputs can be connected at the BNC connectors of a Model 493.75 Analog In transition module and the outputs from this module are...
  • Page 106 D/A Connections Digital-to-analog mezzanine cards support up to six program or readout signals to external devices. Each D/A signal is an analog output within ±10 volts. • Each readout signal is from a 16 bit digital to analog converter. • Each output is a ±10 V analog output.
  • Page 107 Cable specification The cable specifications apply to both the analog inputs and analog outputs. The cable from the front panel of the I/O Carrier module has the following specification: • 15-contact type D male EMI connector. • Backshell–EMI metallized plastic. •...
  • Page 108 Accelerometer Connections An accelerometer requires the Model 493.48 Acceleration mezzanine card (installed in a Model 493.40 I/O Carrier module) and the Model 493.78 Accelerometer Transition Board. • Each Model 493.48 Acceleration mezzanine card supports up to three accelerometers. • The transition board accommodates two types of accelerometers: Low impedance Voltage Mode (LIVM) type accelerometers and High Level Signal Conditioned type accelerometers.
  • Page 109 I/O Carrier jumper Before installing a Model 493.48 Acceleration Conditioner mezzanine settings card in a Model 493.40 I/O Carrier module, specific jumpers must be set. Jumper settings depend on the number and configuration of your system accelerometers. In the example shown below, the Acceleration Conditioner supports three accelerometers.
  • Page 110 Encoder Connections I/O Carrier Module For an ADDA configuration using an I/O Carrier module, each encoder Configuration requires installation of a Model 493.47 Encoder Interface mezzanine card on the Model 493.40 I/O Carrier board. The I/O Carrier connector is based on the location of the mezzanine card installed on the board of the I/O Carrier module.
  • Page 111 Optional ADDA II For the optional ADDA II configuration, each encoder requires Configuration installation of a Model 493.59 Universal Encoder mezzanine card on the Model 493.50 ADDA II module. The Model 493.80 Encoder Transition module provides up to four channels of encoder interface between the Model 493.50 ADDA II module and various incremental, Temposonics, or other digital or serial transducers.
  • Page 112 Remote Setpoint Adjust Connections A Remote Setpoint Adjust (RSA) control is an optional, standalone hardware device that uses an incremental or absolute encoder to control actuator setpoints. Each RSA control pod requires installation of a Model 493.47 Encoder Interface mezzanine card on the Model 493.40 I/O Carrier board. The I/O Carrier connector is based on the location of the mezzanine card installed on the board of the I/O Carrier module.
  • Page 113 ADDA II Connections Each optional Model 493.50 ADDA II module supports up to four mezzanine cards. Each installed mezzanine card is assigned a specific ADDA II module front panel connector (J11–J18). A hardware interface file (hwi) defines each type of module (and their associated mezzanine cards) and maps each module location for the system software.
  • Page 114 ADDA II Module I/O The Model 493.55 A/D, Model 493.57 DSPAD, and Model 493.56 D/A Connections mezzanine cards are installed in the Model 493.50 ADD II module assembly. A connection from the front panel connector to a rear panel BNC transition module allows easy access to the analog channels. Note The external analog source can be a stand alone function generator, another controller, or a computer controlled analog output.
  • Page 115 Analog inputs The analog-to-digital mezzanine cards accommodate up to eight analog input signals. Each A/D input signal must be within ±10 volts. • Analog inputs can be connected at the BNC connectors of a Model 493.81 Analog In transition module and the outputs from this module are connected to the Model 493.50 ADDA II module.
  • Page 116 D/A Connections Digital-to-analog mezzanine cards support up to eight program or readout signals to external devices. Each D/A signal is an analog output within ±10 volts. • Each readout signal is from a 16 bit digital to analog converter. • Each output is a ±10 V analog output.
  • Page 117 ADDA II Universal Each encoder requires a Model 493.59 Universal Encoder mezzanine Encoder Connections card installed on the Model 493.50 ADDA II module. Up to four encoders can be connected to the Model 493.80 ADDA II Encoder Transition module when the Model 493.50 ADDA II module is fully populated with Universal Encoder cards.
  • Page 118 Emergency Connector J24 E-STOP In stop input accommodates an external emergency stop switch. As shown, several connectors maintain the continuity of the emergency stop interlock. Cable specifications J23 E-STOP Out is a 9 pin type D male connector • 9-contact type D female EMI connector •...
  • Page 119 J25 Hydraulic Power Unit Connection Connector J25 HPS on the Model 493.73 HPU transition board controls the hydraulic power unit (HPU). • The module produces 24 V logic signals to control the HPU. • The Model 493.07 HPU Converter Box allows any MTS HPU to be connected to the chassis with the following exceptions: –...
  • Page 120 J25 Diagram System I/O Connector J54 Sys I/O provides three digital inputs and one digital output. The inputs are connected to the high and low inputs of an opto-isolator. The output is from the collector (+) and emitter (-). See “Digital I/O Connections”...
  • Page 121 Cable specification J54 Sys I/O is a 15-contact type D female connector. • 15-contact type D male EMI connector. • Backshell–EMI metallized plastic. • Cable–24 AWG 4 connector with overall foil shield, (Belden 9534 or equivalent) with drain wire connected to metallized plastic backshell at the chassis and to ground at the emergency stop station.
  • Page 122 Cable specification • P28 is a 4-contact CPC male connector (AMP Incorporated). • Cable for on/off HSMs–18 AWG/2 conductor with overall foil shield (Carol C2534 or equivalent) with drain wire connected to pin 3 at the chassis. • Cable for high/low HSMs–18 AWG/4 conductor with overall foil shield (Carol C2543 or equivalent) with drain wire connected to pin 3 at the chassis.
  • Page 123 Important Unless there is a special need, HSM OFF MODE should not be set to RAMP . For your safety, keep this setting at STEP . • HSM low pressure setting as a percentage of full-scale (LOW PERCENT) • HSM high pressure setting as a percentage of full-scale (HIGH PERCENT) •...
  • Page 124 • Cable for all load frames without crosshead locks–22 AWG, 6 conductor with overall foil shield Alpha 5386C or equivalent with drain wire connected to pin 9 at both ends of the cable (pin 9 may be pin E at the load frame). Jumper plug If connector J29 is not used, you must install a jumper plug to maintain the integrity of the interlocks.
  • Page 125 Cable specification • 9-contact type D male EMI connector. • Backshell–EMI metallized plastic. • Cable–shielded twisted pairs (24 AWG minimum) with drain wire(s) connected to the metallized backshell at the chassis. Power Channel inputs can be 3 volts (minimum) and 26 volts (maximum) characteristics from an external voltage source.
  • Page 126 Output specifications The specifications for the interlock status opto-isolator outputs are as follows: • Output Format: open collector, open emitter transistor • Maximum Voltage: 26 V DC • Minimum Guaranteed Output Current Drive: 20 mA (30 mA typical) @ 1.0 V max Jumper X5 Jumper setting X5 selects the source for interlock status output.
  • Page 127 Cable specification • 9-contact type D male EMI connector • Backshell–EMI metallized plastic • Cable–shielded twisted pairs (22 AWG minimum) with drain wire(s) connected to the metallized backshell at the chassis. Digital I/O Connections The Model 493.72 Digital I/O transition module has two connectors; one provides connections for sixteen digital inputs and the other provides connections for sixteen digital outputs.
  • Page 128 Digital inputs The J3 In connector accommodates up to sixteen digital signals from external devices. You can use digital input signals to trigger test events with your controller applications. • All of the inputs are optically isolated and support relay contacts or logic inputs (see the following figure).
  • Page 129 • Jumpers select the debounce time for each group of four inputs. Jumper X2 configures inputs 1–4. Jumper X3 configures inputs 5– 8. Jumper X4 configures inputs 9–12. Jumper X5 configures inputs 13–16. – Not using a jumper sets the debounce to 20 msec. –...
  • Page 130 Note The maximum output current can vary from unit to unit. The minimum guaranteed output current is 6 mA and the maximum output current is 20 mA. You can connect the digital outputs in parallel to increase the current drive. When connected in parallel, the station must be configured so all paralleled outputs are driven from the same event.
  • Page 131 Digital I/O The digital inputs and outputs can be cabled to an optional digital I/O access panel access box. The box is a convenient way to wire digital sources and destination to the Model 493.72 Digital I/O transition module. Connectors J10 and J20 on the side of the module and on top of the module are the same.
  • Page 132 Workstation Connection The workstation computer is connected to the Model 498.96 Processor module installed in the VMEbus of the chassis. It is an Ethernet 10/100 Base-T connection. The workstation computer must have a dedicated Ethernet compatible connector. Note If your processor has more than one Ethernet 10/100 Base T connection, use the connection labeled LAN 1.
  • Page 133 Remote Station Controller Connection The optional Remote Station Controller (RSC) module requires a Model 498.71B GRES III VMEbus module and a Model 493.71 Serial Interface transition module to be installed in the chassis. The RSC can be connected to any of the four J50 connectors of the serial interface. An interlock is permanently assigned to each J50 connector (e.g., J50A= Interlock 1).
  • Page 134 Hwi file additions In order to use one or more RSCs with your Model 493.10 Chassis, two sections must be added to your hwi file, an RSC section and a GRES III section. Note Remote Station Controllers are not available with the optional 6 or 8- station system configurations Note If you specified RSC support when you ordered your test system,...
  • Page 135 I/O Carrier service The J3 Service connector on the Model 493.40 I/O Carrier module provides the monitor output from each of the four I/O option cards installed. It is an 8-pin RJ-45 connector. Important The signals at the J3 Service connector are provided for service and troubleshooting only.
  • Page 136 Cabling and Programming Model 407 Controllers This section describes: • Cabling and programming the FlexTest GT Controller to analog program and feedback signals from a Model 407 Controller. • Connecting FlexTest GT Controllers to interlock signals from a Model 407 Controller. •...
  • Page 137 Do not interrupt Model 493.10 Chassis power when you are programming another controller. A power interrupt may cause the external controller to react to a zero command and move the actuator unexpectedly. Ensure power cannot be removed accidently while a test is in progress. For more detailed information about analog I/O connections, see “Analog I/O Connections”...
  • Page 138 Multiple 407 Controller Connections 2. On the 793 Controller, create a station configuration file. Use the Station Builder application to define controller resources to provide program to the 407 Controller. When you create this type of station configuration, you typically select an analog output for the channel output resource, and Program Only or Program with Feedback for the channel type.
  • Page 139 Note Because of wiring considerations between 793 and 407 Controllers, you must assign an HSM in the station configuration file even if an HSM does not control power to the external controller. 3. On the 793 Controller, adjust the program signals. Use the Station Manager application to adjust the full scale, polarity, gain, and offset for the external controller channel (Display menu >...
  • Page 140 Note The operational sequence in the following step may not be intuitive. This sequence is necessary because of how the 793 and 407 Controllers are cabled together. The following step assumes that at power up, hydraulics are off, the 793 Controller has a hydraulic and a program interlock active, and the 407 Controller has a hydraulic interlock active.
  • Page 141 Connecting Interlock Signals to 407 Controllers The Model 793 Controller monitors digital I/O interlock signals through the Model 493.74 HSM transition module’s J43A and J43B connectors. Use these connectors when connecting to Model 407 Controllers. Model 493.74 HSM transition module connectors are as shown in the figure that follows.
  • Page 142 Single 407 Controller The following figure shows how to cable interlocks for a single station Interlock Connections Model 407 Controller to the Model 493.10 Chassis (via its Model 493.74 HSM transition module). Use the specified interlock cable (PN 056-455-0xx) to make these connections. How to Jumper the The following figure shows how to cable the hydraulic terminal on a single station Model 407 Controller.
  • Page 143 Multiple 407 The following figure shows how to cable interlocks for multiple Model Controller interlock 407 Controllers to the Model 493.10 Chassis (via its Model 493.74 HSM connections transition module). Use the specified interlock cable (PN 056-455-0xx) to make these connections for each Model 407 Controller station. MTS 793 Controller Hardware FlexTest GT Controller Connections Artisan Technology Group - Quality Instrumentation ...
  • Page 144 How to connect The following figure shows how to cable hydraulic terminals on multiple station Model 407 Controllers, where each Model 407 hydraulic terminals on Controller can run an independent test program. Repeat this scheme multiple station 407 for each additional Model 407 Controller. Controllers Intlk Intlk...
  • Page 145 Interlock connections The following figure shows how to cable interlocks when a master for master/dependent Model 407 Controller is daisy-chained with three other dependent 407 Controllers Model 407 Controllers to run a single test program on a FlexTest GT Controller (via its Model 493.74 HSM transition module). Use the specified four-channel master/dependent interlock cable (PN 056-448- 9XX) to make these connections for each Model 407 Controller station.
  • Page 146 How to connect The following figure shows how to cable hydraulic terminals on three Model 407 Controllers in a master-dependent daisy-chain. Note that the hydraulic terminals on last dependent controller in any daisy-chain must have jumper plugs master-dependent 407 installed in its Hyd Out and Intlk In terminals. Controllers Sending and Receiving Signals to a Model 407 Controller After cabling the Model 407 Controller, you must configure it to receive...
  • Page 147 407 Configuration Menu ARAMETER ETTING Eng Units — EOC Act — CYC Src PROGRAM SetPt R 150%/s (or highest) Span R 300%/s (or highest) Hyd Cnfg — Intlk Cnfg MASTER P/V Sens — Span Cnfg CMD Sel EXT IN Prog Out —...
  • Page 148 407 Amplitude Control Menu ARAMETER ETTING Ampl Cntrl Fdback — Mean — Ampl — AMC Gain — 407 Digital I/O Menu ARAMETER ETTING Din1 Definition Program in RUN Din1 RUN/STOP Din1Pol ACT HI Din2 Definition Hydraulic Interlock Din2 Interlock Din2Pol ACT LOW Dout1 Definition Hydraulics ON...
  • Page 149 Connecting Interlock Signals to 458 Controllers FlexTest GT Controllers monitor digital I/O interlock signals through the Model 493.74 HSM transition module. Eurotherm Temperature Controller Connection When equipped with a Model 498.71B GRES III plug-in module, your controller can program and control one or more Series 2200/2400 Eurotherm Temperature Controllers via the J50 serial connectors on a Model 493.71 Serial Interface transition module.
  • Page 150 Temperature For more information on adding the Eurotherm hwi file resource, see controller hardware the MTS 793 Utility Software manual. resource Program the Use Station Builder to configure a Eurotherm temperature controller. temperature controller Use Jumper Plug 055-634-101 in these connectors. MTS 793 Controller Hardware FlexTest GT Controller Connections Artisan Technology Group - Quality Instrumentation ...
  • Page 151 Miscellaneous Conditioner Output Connections The following table shows connector assignments for various MTS products you can use with your the Model 493.10 Chassis. Conditioning Sensors with Other MTS Products MTS P RODUCT ENSOR UTPUT Model 408.81 Testing Panel/ Sensor output is available at the rear-panel connector Model 408.82 DC Conditioner J201 or J202.
  • Page 152 Cabling for External Command Inputs Cabled properly, Model 793 Controllers can receive programming from an external controller. How to Enable and Run External Command Inputs 1. Cable the controllers. Cable the external programmer analog out connector to a Model 493.75 Analog In module BNC connector. 2.
  • Page 153 Cabling and Using External Readout Devices Cabled appropriately, your controller can send station signals to external readout devices such as oscilloscopes and digital-volt-meters. You define which signal is sent to the readout device using the Station Setup window’s Readout panel. Refer to “Working with Readout Devices”...
  • Page 154 The following table provides a description of the various station signals. Station Signals IGNAL ESCRIPTION Time Displays the time reference signal derived from the internal clock that increments continually. This signal exists to support data acquisition by test program applications, such as Basic TestWare and MultiPurpose TestWare.
  • Page 155 How to Send Signals to External Readout Devices 1. Cable your controller to the readout device. Cable your FlexTest IIm analog output connector to the readout device. Analog I/O connectors are located on the rear of the test processor chassis. Connect an external readout device analog input to a BNC connector on a Model 493.76 Analog Out module.
  • Page 156 Multi-Box I/O Module The optional Model 493.43 Multi-Box I/O module allows multiple controllers to share a master hardware synchronization clock and pass station interlock state information between each other. In addition, this front panel module also provides user station interlock inputs and outputs.
  • Page 157 Cable specifications • Connector: 25-contact, type D, male, EMI • Backshell: EMI, metalized plastic • Twisted pairs with overall braided shield. Braided shield is terminated to conductive backshell at the chassis. Jumper plug Use MTS jumper plug PN 100-079-233. MTS 793 Controller Hardware FlexTest GT Controller Connections Artisan Technology Group - Quality Instrumentation ...
  • Page 158 J9 Interlock OUT Connector J9 Interlock OUT provides four station interlock outputs that can be connected to a multiple MTS controller box interlock chain. Electrical Normally, Open = Interlock, 1 A maximum @ 30 V DC/AC maximum specifications Cable specification •...
  • Page 159 J51 Box In The J51 Box In connector provides an interface for connecting multiple MTS controller boxes together to allow sharing of station interlock status and a master synchronization clock. Master/dependent The master/dependent input setting (connector pin 8) determines input whether a controller box is master or dependent in the multi-box chain.
  • Page 160 J52 Box Out The J52 Box Out connector provides an interface for connecting multiple MTS controller boxes together to allow sharing of station interlock status and a master synchronization clock. Last controller jumper The last controller box in a chain must have a jumper plug (MTS PN 100-079-126) on its J52 Box Out connector.
  • Page 161 MTS 793 Controller Hardware FlexTest GT Controller Connections Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
  • Page 162 Chapter 4 FlexTest IIm Controller Connections Note For information on connecting power cables, see “Connecting the Console and Chassis Power” on page 59. Note For information about CE compliance, see “CE EMC Compliant Cabling” on page 74. Contents Workstation Connection...
  • Page 163 + Feedback Return (+ Valve 2) - Feedback Return (- Valve 2) Serial Data (future) - Excitation Sense Shield to Backshell MTS 793 Controller Hardware FlexTest IIm Controller Connections Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
  • Page 164 Guard The additional wires for an DC Sensor 8-wire connection are -FBR shown with dashed lines. +FBR -EXS +EXS MTS 793 Controller Hardware FlexTest IIm Controller Connections Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
  • Page 165 For valves phased opposite hydraulically, reverse A and D on P2. + Valve Command 1 – Valve Command 1 MTS 793 Controller Hardware FlexTest IIm Controller Connections Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
  • Page 166 Model 497.01 Analog Chassis Rear Panel J1401 J1301 J601 J501 J201 J101 Force Force (load sensor) Valve Valve LVDT LVDT (displacement sensor) MTS 793 Controller Hardware FlexTest IIm Controller Connections Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
  • Page 167 047-808-502 050-053-401 CH 7 CH 7 CH 8 CH 8 (CH 1-4) (CH 1-4) (CH 5-8) (CH 5-8) 047-808-502 MTS 793 Controller Hardware FlexTest IIm Controller Connections Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
  • Page 168 The external analog source can be a stand alone function generator, another controller, or a computer controlled analog output. MTS 793 Controller Hardware FlexTest IIm Controller Connections Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
  • Page 169 ADDA II Module I/O Connections MTS 793 Controller Hardware FlexTest IIm Controller Connections Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
  • Page 170 Model 493.50 ADDA II module. This configuration is typically used for A/D mezzanine cards that requires filtering. MTS 793 Controller Hardware FlexTest IIm Controller Connections Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
  • Page 171 BNC connectors of a Model 493.82 Analog Out transition module for external devices (DVM, oscilloscope) MTS 793 Controller Hardware FlexTest IIm Controller Connections Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
  • Page 172 Up to sixteen encoders can be connected to the Model 493.80 ADDA II Encoder Transition module when the Model 493.50 ADDA II module is fully populated with Universal Encoder cards. MTS 793 Controller Hardware FlexTest IIm Controller Connections Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
  • Page 173 Hydraulic Connections You must connect your external hydraulic equipment to the Model 497.05 Hydraulic Control Panel. The FlexTest IIm hardware supports control of up to four hydraulic stations simultaneously. FlexTest IIm Hydraulic Connections Hydraulic Power Unit J28C J28B J28D J28A...
  • Page 174 039-719-901 or jumper pins: 2 and 3; 3 and 7; 9 and 19; 10 and 12; 11 and 16; 17 and 18. MTS 793 Controller Hardware FlexTest IIm Controller Connections Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
  • Page 175 290.XX/294.XX HSM, high/low, 24 V DC, PN 039-705-5XX 18/ 3 SJO – 298.11 HSM, on/off, 24 V DC, PN 039-708-1XX 18/2 SJO MTS 793 Controller Hardware FlexTest IIm Controller Connections Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
  • Page 176 The System Digital I/O and Digital I/O transition modules along with the paddle board are located on the rear panel of the 498.XX Test Processor. MTS 793 Controller Hardware FlexTest IIm Controller Connections Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
  • Page 177 • Two spare digital inputs • Two spare digital outputs The interlock connectors require jumpers under the following conditions: MTS 793 Controller Hardware FlexTest IIm Controller Connections Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
  • Page 178 This shows how to connect an external switch or set of relay contacts to one of the station interlocks: MTS 793 Controller Hardware FlexTest IIm Controller Connections Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
  • Page 179 Model 497 .05 Hydraulic Control Panel 046-350-902 Model 497 .01 Analog Chassis Debug 056-027-101 Model 498.22 Test Processor MTS 793 Controller Hardware FlexTest IIm Controller Connections Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
  • Page 180 R IA Paddle module. Board 7 - 8 15 - 16 7 - 8 15 - 16 MTS 793 Controller Hardware FlexTest IIm Controller Connections Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
  • Page 181 • Each digital input connector on the built-in Digital I/O Access panel (FlexTest IIm) supports two channels. • Each digital input supports a differential TTL to +30 V DC signal or a switch or relay contact switching the on-board 12 V supply.
  • Page 182 • Each digital output is an open collector/open emitter rated at 30 V DC max at 50 mA max. MTS 793 Controller Hardware FlexTest IIm Controller Connections Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
  • Page 183 (it is rated for 12 volt common –Even Channel # maximum 250 mA current). + Even Channel # +12 V DC MTS 793 Controller Hardware FlexTest IIm Controller Connections Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
  • Page 184 +/-Ex ADDA rotational encoders. FAIL RESET Temposonics III A Temposonics Transition Module sensor is usually mounted inside an actuator. MTS 793 Controller Hardware FlexTest IIm Controller Connections Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
  • Page 185 Model 493.50 ADDA II module and various incremental, Temposonics, or other digital and serial data transducers. MTS 793 Controller Hardware FlexTest IIm Controller Connections Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
  • Page 186 ADDA II Configuration MTS 793 Controller Hardware FlexTest IIm Controller Connections Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
  • Page 187 Remote Station Controller (RSC) Connections When equipped with a GRES III plug-in module and a corresponding 498 RS-485 transition module, your FlexTest IIm controller can accommodate up to four remote station controllers (one RSC for each station). Each RSC connects to a J50 serial connector on the 498 RS-485 transition module.
  • Page 188 “How to Program an External Controller” on page 187. When programming Series 2200 and 2400 Eurotherm temperature controllers, the FlexTest IIm controller supports a special serial connection and software setup. For more information, see “Programming Eurotherm Temperature Controllers” on page 191.
  • Page 189 Filtered Analog Input BNC connector. For conditioner output locations on various MTS devices, see “Sample conditioner output connections” on page 190. MTS 793 Controller Hardware FlexTest IIm Controller Connections Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
  • Page 190 A/D installed on the Model 493.50 mezzanine card installed on ADDA II module. the Model 493.50 ADDA II module. MTS 793 Controller Hardware FlexTest IIm Controller Connections Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
  • Page 191 Sample conditioner This table shows connector assignments for various MTS products you output connections can use with your FlexTest IIm controller. Conditioning Sensors with Other MTS Products MTS P RODUCT ENSOR UTPUT Model 408.81 Testing Panel/ Sensor output is available at the rear-panel connector Model 408.82 DC Conditioner...
  • Page 192 Refer to the MTS 793 Application Software manual.for more information. Programming Eurotherm Temperature Controllers When equipped with a GRES III plug-in module, your FlexTest IIm controller can program and control one or more Series 2200/2400 Eurotherm Temperature Controllers via the J50 serial connectors on the 498 RS-485 transition module.
  • Page 193 Refer to “How to Program a Eurotherm Temperature Controller” in the Controller MTS 793 Control Software manual for more information. MTS 793 Controller Hardware FlexTest IIm Controller Connections Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
  • Page 194 Filter connector. Analog I/O connectors are located on the rear of the test processor chassis. Note If you cable the hardware before you create a station configuration file, note the connector you use on the FlexTest IIm rear console. INPUT FILTER CH 1...
  • Page 195 “Create a readout channel with Station Builder.” on page 195. “Adjust the readout signal in Station Manager.” on page 195. MTS 793 Controller Hardware FlexTest IIm Controller Connections Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
  • Page 196 Task 1 Cable your controller to the readout device. Cable your FlexTest IIm analog output connector to the readout device. Analog I/O connectors are located on the rear of the test processor chassis. Connect a 498 Analog Out connector to the external readout device analog input.
  • Page 197 1. For CE configurations, there are CE versions of these cables. Refer to the System Cable Package Selection-FlexTest drawing (PN 047-922-501) for these cable numbers. MTS 793 Controller Hardware FlexTest IIm Controller Connections Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
  • Page 198 Chapter 5 FlexTest SE Controller Connections This section describes the connections to the MTS 493.02 Chassis. Note For information on connecting power cables, see “Connecting Electrical Power” on page 52. Note For information about CE compliance, see “CE EMC Compliant Cabling”...
  • Page 199 Standalone Cabling Overview MTS 793 Controller Hardware Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
  • Page 200 Automated Cabling Overview MTS 793 Controller Hardware Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
  • Page 201 Multiple Controller Connections About multiple Some characteristics of a multiple Controller network are as follows: Controller networks • Each Controller in the network provides control for one station with up to two channels. • A hub connects each Controller in the network to the supervising •...
  • Page 202 Master-dependent Connect two or more FlexTest SE Controllers in a master-dependent FlexTest SE configuration as shown below. Controllers Note The indicated cables on each controller must be connected before the controllers are turned on. Use the J51 Box In and J52 Box Out connectors on the 493.42 System I/O module in the Controller’s rear panel to connect one Controller to another.
  • Page 203 Interlock function Power must be applied to all Controllers in the chain for proper interlock operation. If power is not applied to any one of the Controllers, you will not be able to clear an interlock condition in any of the Controllers. Also, if a cable becomes disconnected from a dependent controller’s Box In connector, or if a cable is inadvertently connected to the Box In connector on the master controller, an interlock is set which cannot...
  • Page 204 Model 493.02 Chassis Cables (part 2 of 2) ABLE ESCRIPTION ODULE UMPER UMBER * LUG † ONNECTOR Auxiliary Power (Aux Pwr) Per System 493.42 J48 Box In 056-316-0xx 493.42 J51 Box Out 056-316-0xx 493.42 J52 100-057-246 Digital Input (Dig In) Per System 493.42 J54 Digital Output (Dig Out)
  • Page 205 Adding I/O Carrier For automated controllers, a second I/O Carrier module can be added to support a second channel or to expand sensor conditioning. Its addition can also be used to support more A/D and D/A channels. Note If you are upgrading your system, a faster processor may be required.
  • Page 206 Valve Connections Valve Connections 252 servovalve connections 256 servovalve connections 257 valve connections Analog I/O Connections The Model 493.45 A/D and Model 493.46 D/A mezzanine cards are installed in the Model 493.40 I/O Carrier front panel module. Note The external analog source can be a standalone function generator, another controller, or a computer controlled analog output.
  • Page 207 D/A Connections Digital-to-analog mezzanine cards support up to six program or readout signals to external devices. • Each D/A signal is an analog output within ±10 volts. • Each readout signal is from a 16 bit digital to analog converter. •...
  • Page 208 Workstation Connection The workstation computer is connected to the processor module installed in the VMEbus of the chassis. It is an Ethernet 10/100 Base-T connection. The workstation computer must have an Ethernet compatible connector. RUN 6TS BFL TYPE E PC-MIP DEBUG TYPE E PC-MIP PCI MEZZANNE CARD...
  • Page 209 Model 493.42 System I/O Connections The Model 493.42 System I/O module is a dual-wide VME-based slave board used in the Model 493.02 chassis. • Provides box-in and box-out, analog and digital I/O, E-Stop, and HSM and HPU control. • Contains three general purpose digital input channels and three general purpose digital output channels.
  • Page 210 Control voltages for hydraulic power units vary between models. The HPU interface between the Model 493.42 System I/O board and an HPU is 24 volt logic signals. Connecting J25 to a non-compliant HPU can damage the module. DO NOT connect 24 V DC relay circuitry or 115 V AC circuitry to connector J25 on the Model 493.42 System I/O board.
  • Page 211 J29 Connector Pin Assignments (part 2 of 2) UNCTION Local E stop Local E stop loop (connected to pin 7) No connection Local E stop Local E stop loop (connected to pin 5) HPU E stop E stop loop from HPU (connect to pin 13) No connection No connection No connection...
  • Page 212 J43 Connector Pin Assignments UNCTION intlk in 24V 24 V through 6.6K resistor intlk in high High side of opto-isolator (opto off = intlk) intlk in low Low side of opto-isolator intlk in comm 24 V common No connection intlk out NO Normally open relay contact intlk out COM Common relay contact...
  • Page 213 CJ51 Box In Connector J51 Box In allows the Model 493.02 chassis to receive clock, hydraulic, and interlock signals from another Model 493.02 chassis. J51 Connector Pin Assignments UNCTION +clk in +External clock input hyd high in Hydraulic high input reset in Interlock reset request input signal return...
  • Page 214 J52 Box Out Connector J52 Box Out allows the Model 493.02 chassis to send clock, hydraulic, and interlock signals to another Model 493.02 chassis. J52 Connector Pin Assignments UNCTION +clk in +External clock output hyd high out Hydraulic high output reset out Interlock reset request output ground...
  • Page 215 J54 Digital Inputs Connector J54 Dig In accommodates up to three digital signals from external devices. You can use digital input signals to trigger test events with your controller applications. • All of the inputs are optically isolated. • Channel inputs can be 3 volts (minimum) and 26 volts (maximum) from an external voltage source.
  • Page 216 J55 Digital Outputs Connector J55 Dig Out provides three general purpose digital outputs that can send digital logic signals to external switches or logic devices. • The digital output relays are rated for a maximum of 1 Amp max, 30 V DC/AC max. •...
  • Page 217 Standalone mode 1. Press Setup on the console front panel menu. 2. Scroll down the Setup menu to Digital Output 1. 3. Press the button next to Digital Output 1. 4. Press the button next to Assignment until the state Run/Stop is shown.
  • Page 218 4. Add a temperature control channel to the station configuration file. Configuring the To use a FlexTest SE Controller with a temperature controller, Debug Serial Port configure the Debug Serial Port as follows: 1. Access the 498.96 processor circuit card in the Controller’s chassis. 2.
  • Page 219 To do this, use the MTS HWI File Editor application (installed with MTS 793 software) to open the Controller’s hardware interface file. (The typical path to this application is: Start > Programs > MTS Systems Software > Service Tools > HWI File Editor.) To add the resource, select the Miscellaneous tab and select 1 for temperature controllers, then save the file.
  • Page 220 Adding a temperature After updating the hardware interface file, you must add a temperature control channel to the control channel to the Controller’s station configuration file. station configuration file To do this, use the Station Builder application to open the station configuration file, then add temperature controller input (Temp Control 1-Input) and output (Temp Control 2-Output) resources to a Program w/Feedback type channel.
  • Page 221 MTS 793 Controller Hardware Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
  • Page 222 Appendix A Hydraulic Configurations This section describes how to connect the Model 493.10 Chassis (FlexTest GT Controllers) and the Model 493.02 Chassis (FlexTest SE) to a variety of MTS hydraulic configurations. Use the following connectors and cables to connect the Model 493.10/ 02 Chassis to your HPU with a Model 493.07 Converter Box: Note See Appendix B: Model 493.07 Converter Box on...
  • Page 223 Single Model 493.02 chassis with a 24 V PLC pump (506.52-.92) or 505 pump 039-713-7XX 493.02 Chassis Note The following three configurations have cables to support both 24 V DC and 115 V AC control voltages. A Model 493.07 Converter Box is available for each voltage (not both).
  • Page 224 Compatible Controllers 039-710-7XX (24 V DC) High-level Y cable 039-710-8XX (115 V AC) 005-407-801 (24 V DC) 005-401-801 (115 V AC) 039-713-8XX (24 V DC) 039-714-6XX (115 V AC) 493.07 493.10 Converter Box Chassis 039-708-7XX (24 V DC) 458* or 039-708-8XX (115 V AC) 490.01* 497.05*...
  • Page 225 See“Multiple Controller Connections” on page 200 and the FlexTest SE User’s Manual for more detailed information multiple controller configurations. Independent HSM (no HPU) For this multiple controller configuration: • Each controller has an independent hydraulic service manifold (HSM). • No hydraulic power unit (HPU) is connected. •...
  • Page 226 • Each controller has an independent hydraulic service manifold (HSM). • An HPU is shared by all connected controllers via Y-cables. • Select HPU/HSM for Power Type on each connected controller. Path: Config > Edit Hardware > Power Options > Power Type >...
  • Page 227 • Select Slave HSM for Power Type on controllers connected to the master controller. Independent HSM with HPU (FO-LO) Note This interconnect option is only available for controllers on the same interlock. For this controller configuration: • Two or more FlexTest SE Controllers are connected. •...
  • Page 228 Appendix B Model 493.07 Converter Box This section describes how to jumper the Model 493.07 Converter Box to connect the Model 493.10 chassis and other controller types to a hydraulic power unit (HPU). The Converter Box converts logic-level signals to and from the Model 493.10 chassis to relay signals used by the HPU pump.
  • Page 229 Disconnect all cables from the Model 493.07 Converter Box before removing the cover. Failure to do so could expose the operator to dangerous voltages. If the Converter Box remains connected to a 120 volt HPU, this voltage will be present. Always remove all cable before removing the cover. Jumper As shipped, the HPU interface on the Model 493.07 Converter Box is configurations...
  • Page 230 Appendix C Chassis Maintenance This section describes how to maintain your MTS controller chassis. Cleaning the chassis Remove any dust from the chassis with Endust™ for Electronics or equivalent. Cleaning the air filter Be sure the cooling fan is operational and not clogged. Clean or replace the filter as required.
  • Page 231 MTS 793 Controller Hardware Chassis Maintenance Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
  • Page 232 Appendix D Optional Station Configurations This section describes how to configure your Model 493.10 Chassis (FlexTest GT Controllers) to support an optional six or eight stations. When configuring your system for a six or eight stations you must consider the following: •...
  • Page 233 Remote Station Control (RSC) is not supported for 6-station configurations. 8-Station Configuration The 8-Station configuration can provide eight channels of control. A typical 8-Channel/8-Station configuration requires 16 Digital Universal Conditioners and 8 two-stage valve drivers. HSM power limits HSM power current is limited to 1.5 A per HSM. Interlocks For 8-station configurations the hwi file must contain the line INTERLOCKS=8.
  • Page 234 Index Numerics 252 servovalve AC conditioners I/O carrier connection 98, 204, 205, connections 256 servovalve AC power connections I/O carrier connection accelerometer 257 servovalve I/O carrier connection 107, I/O carrier module connection ADDA 407 controller cabling programming to receive, send signals connections 493.07 HPU Converter daughter boards...
  • Page 235 cabling AC sensor connections ADDA cable numbers cable specifications console/chassis power analog I/O 106, DC sensor connections digital I/O digital I/O digital inputs E-stop digital output Eurotherm temperature controller 148, 191, J24 E-stop input external controllers 151, 187, J25 HPS (497.05) front panel J25 HPU 118, J4-J7 A/D inputs...
  • Page 236 J3 In connector AC power J54 Dig In connector configurations, FlexTest IIm Controller digital inputs, connections connecting digital outputs electrical power cable specification 129, external readout devices J4 out connector connection J55 Dig Out connector...
  • Page 237 I/O carrier module 252 servovalve connection 98, 204, 205, 256 servovalve connection 257 servovalve connection grounding accelerometer connection 107, chassis AC power analog I/O cable specifications 106, console/chassis analog I/O connection 103, low-frequency ground loops analog I/O connections grounding chassis analog inputs 104, bridge completion circuits connecting force/strain sensor...
  • Page 238 jumpers power cabling 52, ± shunt cal power connections 4/8 wire sensor cable 83, 85, 493.10 chassis 498 System Digital I/O pressure control active guard 82, 84, programming bridge balance 83, 86, Eurotherm temperature controller digital I/O transition module receiving from external controllers digital universal conditioner (DUC) 82, 84, sending to external controllers encoder configuration...
  • Page 239 FlexTest IIm Controller station connections station signals workstation connection 131, available for monitoring 152, descriptions external readout of 154, system cables analog I/O 106, part number list 76, servovalve cables system cables/jumpers System I/O module connections temperature controllers, connecting.

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