Page 1 FlexTest™SE Service Information 100-077-222 C...
Page 2 MTS, Temposonics, and TestWare are registered trademarks of MTS Systems Corporation. FlexTest, MPT, MultiPurpose TestWare, Station Builder, Station Manager, and TestStar are trademarks of MTS Systems Corporation. Adobe is a registered trademark of Adobe Systems Inc. Acrobat is a trademark of Adobe Systems Inc.
Page 3: Table Of Contents
Contents Preface 9 About Your Manuals Conventions Technical Support Chapter 1 Introduction 19 Stand-Alone Configuration Basic Functions Automated Configuration Chapter 2 Installation 25 Installing the Plug-in Modules VMEbus Modules Chassis Installation Options Connecting Electrical Power Handle Kit Installation Model 493.02 Controller Service...
Page 4 Chapter 3 Cabling 39 CE EMC Compliant Cabling Stand-Alone Cabling Overview Automated Cabling Overview Multiple Controller Connections Cable Part Numbers Model 493.40 I/O Carrier Connections Valve Connections Analog I/O Connections Encoder Connections Accelerometer 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 5 Chapter 5 Sensors 81 Sensor Signals Transducer Connections Sensor Cables Specifications Sensor Cable Part Numbers Shunt Calibration Shunt Calibration/Bridge Completion I/O Carrier Module Chapter 6 Calibration 95 Before You Begin Calibrating an LVDT Abbreviated Procedure Calibrating a Force Sensor Abbreviated Procedure Calibrating Encoders Abbreviated Procedure Calibrating Temposonics Sensors...
Page 6 Chapter 7 Tuning 191 About Tuning If You’ve Never Tuned Before When to Tune Control Mode Characteristics How the Tuning Controls Work Creating a Tuning Program Other Considerations Monitoring Waveforms Tuning Displacement Tuning Force Auto tuning How to Auto-Tune Control Modes Tuning a CLC Control Mode Appendix A Hydraulic Configurations 221...
Page 7 Appendix B Model 493.07 HPU Converter 229 Appendix C Service Tools 231 FlexTest SE Service Tool Application Initializing a FlexTest SE Controller Updating System Options System Options Tab Unit Assignment Set Tab Chassis Attributes Tab Passwords Tab User Files Tab Index 243 Model 493.02 Controller Service...
Page 8 Model 493.02 Controller Service...
Page 9: Preface
Preface Safety first! Before you attempt to use your MTS equipment in your test system, read and understand the Safety manual. Like an automobile, your test system is very useful—but if misused, it is capable of deadly force. You should not be afraid of your test system, but you should always maintain a healthy respect for it.
Page 10: About Your Manuals
About Your Manuals About Your Manuals This manual provides detailed information about the installation, cabling, and set-up of the MTS FlexTest SE Controller, including all controller, computer (optional), sensor, I/O, and hydraulic connections. This manual also provides basic information about calibrating sensor/conditioner pairs, initial system tuning, and adjusting servovalves.
Page 11 (after you install your MTS software) from the PC desktop, as follows: Programs > FlexTest SE > Online Documentation If you have a stand-alone Controller, an electronic version of this manual is available on the 793 System Software CD that accompanies your Controller.
Page 12: Conventions
Conventions Conventions The following paragraphs describe some of the conventions that are used in your MTS manuals. Hazard conventions Hazard notices are embedded in this manual and contain safety information that is specific to the task to be performed. Hazard notices immediately precede the step or procedure that may lead to an associated hazard.
Page 13 Conventions Caution notices Caution notices indicate the presence of a hazard which will or can cause minor personal injury, cause minor equipment damage, or endanger test integrity if the caution is ignored. For example: CAUTION This specimen can develop sharp edges as a result of testing. Handling the specimen with unprotected hands can result in cuts and slivers.
Page 14: Technical Support
Technical Support Technical Support Start with your The manuals supplied by MTS provide most of the information you manuals will need to use and maintain your equipment. If your equipment includes MTS software, you should look for README files for additional product information.
Page 15 Technical Support Example site number: 571167 When you have more than one MTS system, the system number identifies which system you are calling about. You can find your job number in the papers sent to you when you ordered your system. Example system number: US1.42460 Know information from If you have contacted MTS about this problem before, we can recall...
Page 16 Technical Support Know relevant software For MTS software application problems, have the following information available. information • The software application’s name, version number, build number, and if available, software patch number. This information is displayed briefly when you launch the application, and can typically be found in the “About”...
Page 17 Technical Support Write down relevant Prepare yourself in case we need to call you back. information • Remember to ask for the notification number. • Record the name of the person who helped you. • Write down any specific instructions to be followed, such as data recording or performance monitoring.
Page 18 Technical Support Model 493.02 Controller Service Preface...
Page 19: Introduction
Chapter 1 Introduction Overview This chapter provides an overview of the MTS Model 493.02 FlexTest SE Controller. It describes the basic functions and components included in the Controller’s standard and automated configurations, and includes a table of specifications. Contents Stand-Alone Configuration Basic Functions Automated Configuration Model 493.02 Controller Service...
Page 20: Stand-Alone Configuration
Hold Stop Setup Recall Program Status Hydraulic Scope Interlock reset Enabled Meters Program Interlock Tuning High Emergency Stop Config enter Limits cancel High Monitor 1 Monitor 2 Navigate Menu Power TS-G436 FlexTest SE Front Panel Model 493.02 Controller Service Introduction...
Page 21 RUN 6TS BFL TYPE E PC -MIP DEBUG TYPE E PC-MIP PCI MEZZANNE C ARD TS-G435 FlexTest SE Back Panel Plug-In Modules In the standard configuration, the Controller’s VME chassis contains three plug-in modules: • A Model 498.96-4 Processor •...
Page 22: Basic Functions
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. Hydraulic Pressure The Controller provides complete control of the test system hydraulics.
Page 23: Automated Configuration
The “Automated” paths and procedures described in this manual procedures assume the FlexTest SE Controller is equipped with the PC-Supervision option, and that Exclusive Control is assigned to Station Manager. For more information about Station Manager, see the Model 793.00 System Software manual that accompanies your system.
Page 24 Automated Configuration Series 793 software The following products are available as options with the Model 793.00 options System Software bundle: ® • Model 793.10 MultiPurpose TestWare (MPT)—A sophisticated test design application. This application allows you to build test procedures by defining and linking modular test activities together and assigning triggering relationships between each activity.
Page 25: Installation
Chapter 2 Installation This section describes how to install the MTS FlexTest SE Chassis and connect it to your system components. Contents Installing the Plug-in Modules VMEbus Modules Chassis Installation Options Connecting Electrical Power Handle Kit Installation Model 493.02 Controller Service...
Page 26: Installing The Plug-In Modules
Installing the Plug-in Modules Installing the Plug-in Modules This section describes how to install the plug-in modules into the chassis. The modules plug into a backplane connector and are secured to the chassis with a screw at the top and at the bottom of the module faceplate.
Page 27: Vmebus Modules
Installing the Plug-in Modules VMEbus Modules The VMEbus compatible modules should be installed in chassis slots according to the following guidelines. • The processor module is installed in slot 1 • The I/O carrier module is installed in slot 2. •...
Page 28: Vmebus Modules
Installing the Plug-in Modules VMEbus Modules ODULE UNCTION Slot 1 PowerPC® Provides PIDF processing for the Controller and management of the other plug-in modules in the stand-alone configuration. Provides an interface between the Controller and an external computer in the automated configuration. Slot 2 Model 493.
Page 29 Installing the Plug-in Modules Model 493.40 I/O Carrier Daughter Boards (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 daughter board can support up to three accelerometers.
Page 30: Chassis Installation Options
High Power Monitor 2 Monitor 1 Navigate Menu Power TS-G436 Console installation The rack-mounted chassis can be installed in any Model 490.8x console. Install the console with the FlexTest SE Rack Mounting kit (part number 100-063-209). Model 493.02 Controller Service...
Page 31 Chassis Installation Options 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. Rack Mount Option The Controller chassis is designed to fit into a standard electronics rack.
Page 32: Connecting Electrical Power
Chassis Installation Options Connecting Electrical Power Electrical connections must be made by qualified personnel and conform to local codes and regulations. An electrical service panel to provide the electrical power feed (line voltage) to the chassis is not necessary, but may be required by local electrical codes. Note Local electrical codes supersede any information found here.
Page 33 Chassis Installation Options Rack Mount Configuration Chassis ground cable (P/N 377661-02) connected to the vertical conductive rail. Signal common cable (P/N 377661-01) connected to the power panel. System ground cable (P/N 054023-xx) connected to the test frame or other components. The AC power ground is through the power cord.
Page 34 Chassis Installation Options • 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 ampere overload. An internal fuse in the power supply is not user accessible or repairable.
Page 35 Chassis Installation Options Rack Mounted Configuration Outlet Strip Po we r 100–240 VAC 50–60 Hz, 12–6A RUN 6 T S BF L RS T T Y P E E P C- M I P DE B UG TYPE E P C -M I P P C I ME Z Z AN N E CARD Power Panel Model 493.02 Controller Service...
Page 36: Handle Kit Installation
Handle Kit Installation Handle Kit Installation The Controller may be equipped with an optional handle kit. The following procedure provides assembly and installation instructions for the handle kit (MTS part number 100-061-494). The following table and figure show the handle kit assembly components described in the procedure.
Page 37 Handle Kit Installation 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 38 Handle Kit Installation 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. Insert a Phillips screwdriver through the hole in the button (7) and lightly tighten the screw (5).
Page 39: Cabling
Chapter 3 Cabling This section describes the cable connections to the MTS FlexTest SE Chassis. Note For information on connecting power cables, see “Connecting Electrical Power” on page 32. Contents CE EMC Compliant Cabling Stand-Alone Cabling Overview Automated Cabling Overview...
Page 40: Ce Emc Compliant Cabling
CE EMC Compliant Cabling CE EMC Compliant Cabling CE EMC compliant cabling is required for all systems shipped to Europe. All cabling specifications in this chapter conform to the European CE EMC requirements. Cable fabrication All of the cables listed on the Cable Selector drawing are CE EMC compliant when used in an MTS system.
Page 41: Stand-Alone Cabling Overview
CE EMC Compliant Cabling Stand-Alone Cabling Overview Force Sensor Actuator 525442-xx Manifold (HSM) 561264-xx Hydra ulic Powe r Unit Contr Servovalve 397083-xx Intlk LVDT 464403-xx Jumper Plug 100-057-245 397137-xx E-Stop Jumper Plug 100-007-947 Box Out Jumper Plug 100-057-246 Power 100–240 VAC 50–60 Hz, 12–6A RUN 6TS BFL TYPE E PC-MIP...
Page 42: Automated Cabling Overview
CE EMC Compliant Cabling Automated Cabling Overview Force Sensor Cable with Transducer ID module Actuator 525425-xx Manifold (HSM) Cable from Transducer ID module 561264-xx 525442-xx Hydra ulic Power Unit Contr Servovalve 397083-xx LVDT Cable with Transducer E-Stop ID module 556342-xx 525431-xx Cable from Workstation...
Page 43: Multiple Controller Connections
CE EMC Compliant Cabling Multiple Controller Connections Connect two or more FlexTest SE controllers in a master-slave configuration as shown below. The indicated cables on each controller must be connected before the controllers are turned on. Master 563160-xx Slave 1...
Page 44 CE EMC Compliant Cabling Power up sequence Turn on the master controller first and allow its software to fully boot before turning on the slave controllers. The slaves must be turned on in their chain-designated order; Slave 1 before Slave 2. Failure to observe this power up order will result in interlocks and will require you to restart all controllers.
Page 45: Cable Part Numbers
The following is a list of the most common cables, see the System Cable/Jumper Plug 493 Package Selection drawing (MTS part number 700-000-656) for the most current and additional cable part numbers. FlexTest SE Cables (part 1 of 2) ABLE ESCRIPTION...
Page 46: Cable Part Numbers
Cable Part Numbers FlexTest SE Cables (part 2 of 2) ABLE ESCRIPTION ODULE UMPER † ONNECTOR UMBER Box In 563160-xx 493.42 J51 Box Out 563160-xx 493.42 J52 100-057-246 Digital Input (Dig In) Per System 493.42 J54 Digital Output (Dig Out) Per System 493.42 J55...
Page 47: Model 493.40 I/O Carrier Connections
Model 493.46 D/A Converter Automated Option If the MTS FlexTest SE Controller is equipped with the automated option, it includes a PC, MTS Series 793 software and various types of files, including a hardware interface file (.hwi) file. The .hwi file...
Page 48: Valve Connections
Model 493.40 I/O Carrier Connections Valve Connections The following types of valve connections are supported: • Single or dual Series 252 Servovalve(s) can be controlled with a Model 493.14 Valve Driver daughter board. • A Series 256 Servovalve can be controlled with a Model 493.15 3 Stage Valve Driver daughter board.
Page 49 Model 493.40 I/O Carrier Connections 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 50 Model 493.40 I/O Carrier Connections 256 servovalve The Series 256 Servovalve is a 3-stage servovalve. The Model 493.15 connections 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 51 Model 493.40 I/O Carrier Connections 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.
Page 52: Analog I/O Connections
Model 493.40 I/O Carrier Connections Analog I/O Connections The Model 493.45 A/D and Model 493.46 D/A daughter boards are installed in the Model 493.40 I/O Carrier front panel module. Note The external analog source can be a stand-alone function generator, another controller, or a computer controlled analog output.
Page 53 Model 493.40 I/O Carrier Connections D/A Connections Digital-to-analog daughter cards support up to six program or readout signals to external devices. • Each D/A signal is an analog From output within ±10 volts. External J4 - J7 Device • Each readout signal is from a 16 bit digital to analog converter.
Page 54: Encoder Connections
Model 493.40 I/O Carrier Connections Encoder Connections Each encoder requires installation of a Model 493.47 Encoder Interface daughter board on the Model 493.40 I/O Carrier board. The I/O Carrier connector is based on the location of the daughter board installed on the board of the I/O Carrier module.
Page 55: Accelerometer Connections
Model 493.40 I/O Carrier Connections Accelerometer Connections An accelerometer requires the Model 493.48 Acceleration daughter board installed in a Model 493.40 I/O Carrier module. • Each Model 493.48 Acceleration daughter board supports up to three accelerometers. I/O Carrier jumper Before installing a Model 493.48 Acceleration Conditioner daughter settings board in a Model 493.40 I/O Carrier module, specific jumpers must be set.
Page 56: Workstation Connection
Model 493.40 I/O Carrier Connections Workstation Connection The workstation computer is connected to the MVME PowerPC® 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...
Page 57: Service Connection
Model 493.40 I/O Carrier Connections Service Connection 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. From External Daughter...
Page 58: Model 493.42 System I/O Connections
Model 493.42 System I/O Connections Model 493.42 System I/O Connections The Model 493.42 System I/O module is a dual-wide VME-based slave board used in the MTS FlexTest SE Controller. • Provides box-in and box-out, analog and digital I/O, E-Stop, and HSM and HPU control.
Page 59: J25 Hydraulic Power Unit Connection
Model 493.42 System I/O Connections J25 Hydraulic Power Unit Connection Connector J25 HPU controls the hydraulic power unit (HPU). • The connector provides 24 V logic signals to control the HPU. • The connector may be connected directly to a Model 505 or 24 PLC HPU or to a Model 493.07 HPU Converter Box, which allows any MTS HPU to be connected to the chassis with the following exceptions:...
Page 60 Model 493.42 System I/O Connections T o/From T o/From Chassis HPS On Sense Over Temp Low Level HPS 24 Vdc Start Start Relay Motor Relay High Hi Pressure Solenoid +24 Vdc To J24 pin 13 E-stop HPS Interlock To J29 pin 8 Relay Controller 24 Vdc HPS Defeat Voltage...
Page 61: J28 Hydraulic Service Manifold Connector
Model 493.42 System I/O Connections J28 Hydraulic Service Manifold Connector Connector J28 HSM controls the pressure of a hydraulic service manifold. The controller software can configure the connector for solenoid or proportional control of a 24 volt hydraulic service manifold. From Chassis T o HSM +24 V...
Page 62: J29 Emergency Stop Connections
Model 493.42 System I/O Connections J29 Emergency Stop Connections Connector J29 E-STOP provides an output to external devices when an emergency stop signal is generated. This connector may also be used with an external E-stop. J29 Connector Pin Assignments UNCTION Xhead 24V Fused +24V Xhead intlk com...
Page 63 Model 493.42 System I/O Connections Cable specification • 15 contact type D male EMI connector. • Backshell–EMI metallized plastic. • Cable–24 AWG 4 connector with braided shield, with the braid connected to a metallized plastic backshell at the chassis and to ground at the emergency stop station.
Page 64: J43 Interlock
Model 493.42 System I/O Connections J43 Interlock Connector J43 Interlock contains one optically isolated interlock input and one relay contact interlock output. Note The intlk out relay (Pin 6) is normally energized when no interlocks are active. So even though Pin 6 is a NO (normally open) relay contact, it is actually normally closed when no interlocks are active.
Page 65: J49 Auxiliary Power
Model 493.42 System I/O Connections J49 Auxiliary Power Connector J49 Aux Pwr provides +5 V DC, ±15 V DC, and 24 V DC from the chassis internal power supply to drive external high level conditioners, proximity switches, solenoids, and so forth. •...
Page 66: J51 Box In
Model 493.42 System I/O Connections J51 Box In Connector J51 Box In allows the MTS FlexTest SE controller to receive clock, hydraulic, and interlock signals from another MTS FlexTest SE controller. J51 Connector Pin Assignments UNCTION +clk in +External clock input...
Page 67: J52 Box Out
Model 493.42 System I/O Connections J52 Box Out Connector J52 Box Out allows the MTS FlexTest SE controller to send clock, hydraulic, and interlock signals to another MTS FlexTest SE controller. J52 Connector Pin Assignments UNCTION +clk in +External clock output...
Page 68: J54 Digital Inputs
Model 493.42 System I/O Connections 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. •...
Page 69: J55 Digital Outputs
Model 493.42 System I/O Connections 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 70 Model 493.42 System I/O Connections Model 493.02 Controller Service...
Page 71: Servovalve Controls
Refer to “How to Warm Up the Station Hydraulics” in Chapter 2, Common Tasks of the FlexTest SE User’s manual for a detailed procedure. When to adjust You make servovalve adjustments to optimize the valve response to your program commands.
Page 72 Use the following paragraphs to determine when to perform each servovalve adjustment. Note During system installation, perform all of the adjustments in this section. Initial adjustments Perform initial adjustments when initially installing the system or replacing a hydraulic component. These adjustments, such as setting servovalve polarity, are only needed once and should not require readjustment.
Page 73: Setting The Servovalve Polarity
This procedure allows you to determine servovalve polarity by observing actuator movements while applying a positive Setpoint command to the actuator. Refer to “How to Set Servovalve Polarity” in Chapter 2, Common Tasks of the FlexTest SE User’s manual for a detailed procedure. Model 493.02 Controller Service...
Page 74: Getting Things Ready
30 minutes using an 80% full-scale length command at about 0.1 Hz. Refer to “How to Warm Up Station Hydraulics” in Chapter 2, Common Tasks of the FlexTest SE User’s manual for a detailed procedure. Model 493.02 Controller Service...
Page 75: Adjusting Valve Balance
The hydraulic fluid and the servovalve are at operating temperature. • Command compensators are turned off. Procedure Refer to “How to Balance the Servovalve” in Chapter 2, Common Tasks of the FlexTest SE User’s manual for a detailed valve balancing procedure. Model 493.02 Controller Service...
Page 76: Dither
The hydraulic fluid and the servovalve are at operating temperature. • Command compensators are turned off. Adjusting dither Refer to “How to Adjust Dither ” in Chapter 2, Common Tasks of the amplitude FlexTest SE User’s manual for a detailed dither amplitude adjustment procedure. Model 493.02 Controller Service...
Page 77: Tuning The Inner Loop
Tuning the Inner loop Tuning the Inner loop Perform inner loop tuning when initially installing a system or fine- tuning a system that employs 3-stage valve drivers. The inner loop proportional gain and rate derivative adjustments are the same types of adjustments as used with the PIDF tuning controls.
Page 78: Zero The Spool Position Signal
Tuning the Inner loop Zero the Spool Position Signal This task matches the electronic null of the spool position signal with the mechanical null position of the servovalve pilot spool. During inner loop tuning, it may be necessary to complete this procedure if the spool position signal voltage is not approximately equal (though opposite polarity) at opposite endcaps of a servovalve.
Page 79: Inner Loop Signals
2. Connect a DVM or oscilloscope to the appropriate BNC Output Channel on the service cable, depending on which slot the valve driver occupies in the I/O Carrier module. You can also set up the FlexTest SE scope or meters to monitor inner loop signals. Note Only the Spool Position signal is available to the FlexTest SE meters or scope.
Page 80 Tuning the Inner loop Model 493.02 Controller Service...
Page 81: Sensors
Chapter 5 Sensors This chapter describes sensor signals, connections, and cabling. Shunt calibration for DC sensors is also described. Contents Sensor Signals Transducer Connections Sensor Cables Shunt Calibration Shunt Calibration/Bridge Completion Model 493.02 Controller Service...
Page 82: Sensor Signals
Controller’s VME chassis. The DUC must be configured for the DC mode. A force transducer (load cell) requires DC conditioning. Full-Range DUC The Model 493.25 DUC module used with your FlexTest SE controller Conditioner is a full-range conditioner that provides one calibrated range for each sensor.
Page 83: Transducer Connections
Transducer Connections Transducer Connections Transducer connections require a conditioner daughter board be installed in the I/O Carrier module. The following conditioners can be installed: • Model 493.25 Digital Universal Conditioner • Model 493.47 Encoder • Model 493.48 Acceleration Conditioner Each Model 493.40 I/O Carrier module can include up to four daughter boards.
Page 84 Transducer Connections LVDT connections An LVDT requires an AC conditioning daughter board. AC Sensor Inner (LVDT) Guard Temposonics II A Temposonics II transducer requires a DC conditioning daughter connections board. FROM TEMPOSONICS II RETURN TRANSDUCER +FDBK FDBK -FDBK REMOTE SIG GND Circuit DATA TO ID DATA FROM ID...
Page 85 Transducer Connections Temposonics III A Temposonics III transducer requires a DC conditioning daughter connections board. +24 V 493.74 AUX POWER +24 V Data Data FROM 493.40 CARRIER MODULE TEMPOSONICS III (TEMPOSONICS III SENSOR DAUGHTER BOARD) Clock Clock Force/strain sensor Force and strain sensors require a DC conditioning daughter board. connections Inner Guard...
Page 86: Sensor Cables
Transducer Connections 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 87: Sensor Cable Part Numbers
Transducer Connections 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. ABLE ESCRIPTION ABLE ODULE ONNECTOR 120º 562348-XX 493.40 J4–J7 300º 562531-XX 493.40 J4–J7 Extensometer 633 capacitive...
Page 88 Transducer Connections 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 89: Shunt Calibration
Shunt Calibration Shunt Calibration You can verify the calibration accuracy of a DC sensor/conditioner pair through shunt calibration. Shunt calibration works by shunting a precision resistor across one arm of the sensor’s bridge. A current shunt calibration value, taken before a test, should be compared to the shunt calibration reference value recorded when the sensor was last calibrated.
Page 90 Shunt Calibration 3. Turn on hydraulic power. 4. Zero the DC sensor output. Stand-Alone: Path: Setup > Force > Offset/Zero > Manual Offset Adjust the Manual Offset for a 0 kN output. The sensor output must be 0.000 kN for a proper shunt calibration. Automated: Adjust the Manual Cmd slider on the Manual Command window for a 0 kN output.
Page 91 If it does, select Auto Offset to zero the force output. 9. Perform a shunt calibration. Refer to “How to Perform a Shunt Calibration” in Chapter 2, Common Tasks of the FlexTest SE User’s manual for a detailed procedure. Model 493.02 Controller Service...
Page 92: Shunt Calibration/Bridge Completion
Shunt Calibration Shunt Calibration/Bridge Completion On a typical system, shunt calibration and bridge completion resistor installation is completed on the I/O Carrier module. If you have purchased optional sensor cables with transducer ID modules, shunt calibration and bridge resistors are installed on these modules.
Page 93 Shunt Calibration Bridge completion Each of the four I/O option card slots on the I/O Carrier module circuits provides support for up to three bridge completion resistors as well as a shunt calibration resistor. The bridge completion resistors can be installed into sockets on the I/O Carrier printed wiring board.
Page 94 Shunt Calibration Model 493.02 Controller Service...
Page 95: Calibration
Chapter 6 Calibration This chapter describes how to calibrate the sensors connected to your system. All sensors require calibration to ensure that their outputs accurately represent the physical condition they sense (e.g., force or displacement). When you calibrate a sensor you are calibrating the test system to properly interpret the sensor signal.
Page 96 Some steps include examples or helpful information. Note Procedures for “Automated Controllers” assumes the FlexTest SE Controller is equipped with the PC-Supervision option, and that Exclusive Control is assigned to Station Manager. For more information about Station Manager, see the Model 793.00 System...
Page 97: Before You Begin
30 minutes using a 80% full-scale length command at about 0.1 Hz. Refer to “How to Warm Up Station Hydraulics” in the Chapter 2, Common Tasks of the FlexTest SE User’s manual for a detailed procedure. Signal polarity...
Page 98 Before You Begin Full-range The FlexTest SE controller uses a full-range conditioner. Consider the conditioners following when calibrating sensors that use full-range conditioners, such as the 493.25 DUC: • Full-range conditioners allow a gain/linearization calibration option which require you to set up a linearized data table during sensor calibration.
Page 99: Calibrating An Lvdt
Station Manager, see the Model 793.00 System Software manual that accompanies your system. Calibration Types The FlexTest SE controller’s full-range conditioner allows you to choose Gain/Delta K or Gain/Linearization calibration for LVDTs. The other calibration types, mv/v Pos Tension and mv/v Pos Comp are typically not used for LVDT calibration.
Page 100 Calibrating an LVDT Pre-calibration tuning Use the following procedure for initial tuning of the LVDT sensor channel prior to calibration. Pre-tuning is especially important if the LVDT has never been calibrated. 1. Select the Calibration access level. Stand-Alone— Path: Config > Access Level > Calibration Automated—...
Page 101 Calibrating an LVDT 5. Set conditioner polarity to Normal (default) so that a positive command extends the actuator. Stand-Alone — Path: Setup > Disp > Calibration > Polarity > Normal Automated — On the Calibration tab, select Normal for conditioner Polarity. 6.
Page 102 Calibrating an LVDT 10. Check hydraulic and program interlock indicators. Stand-Alone — If the Hydraulic Interlock or Program Interlock indicator is lit on the front panel, determine the cause, correct it, and then click Reset. Automated — If the Interlock or Program indicator is lit on the Station Controls panel, determine the cause, correct it, and then click Reset or Reset/Override.
Page 103 Calibrating an LVDT Actuator fully retracted If the actuator is fully retracted and applying a positive Setpoint or Manual Cmd does not extend it, zero the or extended command, remove hydraulic pressure, and change the servovalve polarity. Then retry this test. If it still does not move, return to Step 7 and increase the gain setting.
Page 104 Calibrating an LVDT 15. Set up scope parameters to display the channel’s command and feedback signals. Stand-Alone — Select Scope on the front panel. Automated — In the Station Manager toolbar, click the Scope button to display the Scope window. 16.
Page 105: Abbreviated Procedure
Calibrating an LVDT Abbreviated Procedure Online readers All procedure entries are hypertext links. Click on any entry to jump to the corresponding page. The following abbreviated procedure outlines a displacement sensor (LVDT) calibration process. More detailed calibration information is available on the pages listed. Task 1, “Get things ready,”...
Page 106: Task 1 Get Things Ready
Calibrating an LVDT Task 1 Get things ready Perform the following before you start sensor calibration. 1. Locate relevant documentation. • You need information about the sensor such as the serial number, model number, excitation voltage, displacement, etc. This information can be found on the appropriate Calibration Data sheet included with your system, or the Final Inspection card included with all MTS sensors.
Page 107 Calibrating an LVDT For more information on using the Station Signals panel, refer to “About the Station Signals Panel” in Chapter 3, Station Manager of the Model 793.00 System Software manual. 4. Select the desired calibration type. Stand-Alone— Path: Setup > Disp > Calibration > Cal Type Automated —...
Page 108: Task 2 Turn On Hydraulic Pressure
Calibrating an LVDT Task 2 Turn on hydraulic pressure This task activates the hydraulic pressure. Do not place any part of your body in the path of a moving actuator. A crush zone exists between the actuator and any equipment in the path of its movement.
Page 109: Task 3 Verify The Conditioner Polarity
Calibrating an LVDT Task 3 Verify the conditioner polarity This task checks the polarity of the conditioner. Different types of test systems are configured with different conditioner polarities. The polarity of the conditioner, the polarity of the valve driver, and the orientation of system cabling all play a role in controlling the actuator and determining how signals are displayed.
Page 110: Task 4 Set The Phase
Calibrating an LVDT Task 4 Set the phase This task determines the proper phase adjustment. The phase adjustment matches the phase of the AC feedback signal to the 10 kHz demodulation excitation signal. 1. Fully retract the actuator. Stand-Alone— Using the front panel Dial, adjust the Setpoint to fully retract the actuator.
Page 111: Task 5 Set The Zero And Offset
Calibrating an LVDT Task 5 Set the zero and offset Establishing zero requires the actuator to be set at mid-displacement when you calibrate the LVDT for equal amounts of actuator extension and retraction. Suppose you have an actuator with ±10 cm displacement—which actually has a 20 cm displacement.
Page 112 Calibrating an LVDT • Encoder • You may need to place the dial indicator on a block to measure the mid-displacement position. • Be sure to zero the dial indicator after you position it properly. 2. Ensure that displacement control mode is selected. Stand-Alone —...
Page 113 Calibrating an LVDT Automated: Move the Manual Cmd slider to apply a positive command (extend the actuator). Adjust the Manual Cmd slider to fully extend the actuator and note the displacement signal value in the Station Signals panel. Adjust the Manual Cmd slider to fully retract the actuator and note the displacement signal value in the Station Signals panel.
Page 114: Task 6 Gain/Delta K Calibration
Calibrating an LVDT Task 6 Gain/Delta K Calibration If you using Gain/Delta-K for your calibration type, complete the following procedure. If not, complete Task 7 Gain/Linearization Calibration on page 119 Calibrate actuator LVDTs can be retraction calibrated so that a ∆K >...
Page 115 Calibrating an LVDT hydraulics and increase the Pre-Amp gain. You can then turn on hydraulics and continue to adjust the Post-Amp gain. Note This procedure assumes a positive command extends the actuator and a negative command retracts the actuator. If not, use the opposite polarity for any values given.
Page 116 Calibrating an LVDT At this point, unless the conditioner is already in calibration, the actuator’s physical retraction will not equal your commanded value. You will adjust gain in the next step so that the actuator’s physical retraction and your commanded retraction match. Example: Suppose your actuator has a 100% retraction of -10 cm.
Page 117 Calibrating an LVDT control mode. Increase the proportional gain (P Gain on the Tuning menu) to correct sluggish actuator movement. Increase the reset integration value (I Gain) to help the feedback match the command. At this point, unless the conditioner is already calibrated, the actuator’s physical extension will not equal your commanded value.
Page 118 Calibrating an LVDT 2. Record the data points for LVDT retraction. Stand-Alone: Adjust the Setpoint to achieve zero command. Adjust the dial indicator for a zero reference. Adjust the Setpoint to 20% retraction and record the dial indicator reading. Repeat this step for 40%, 60%, 80%, and 100% actuator retraction.
Page 119: Task 7 Gain/Linearization Calibration
Calibrating an LVDT Task 7 Gain/Linearization Calibration If you are using Gain/Linearization for your calibration type, complete the following procedure. If not, complete Task 6 Gain/Delta K Calibration on page 114. Important Using linearization data requires specific conditioner zeroing practices. Ensure that Electrical Zero Lock on the Offset/ Zero menu is set to Locked.
Page 120 Calibrating an LVDT Note If the actuator response is sluggish and/or the signal value does not match the command, you will need to adjust the tuning of this control mode. Increase the proportional gain (P Gain on the Calibration submenu or tab) to correct sluggish actuator movement.
Page 121 Calibrating an LVDT Repeat steps D and E for other retraction commands (typically at -4, -6, -8, -10, -20, -40, -70, and -100 percent of full scale). Automated: Adjust the Manual Cmd slider for a 0% command. Record the dial indicator value for the 0% command. Enter the corresponding conditioner feedback reading in the Conditioner column at the appropriate row in the window.
Page 122 Calibrating an LVDT 7. On the Linearization Data window, enter the dial indicator and conditioner feedback readings for all command points previously recorded. Stand-Alone— Path: Setup > Disp > Calibration > Cal Type > Gain/Linearization > Linearization Data Automated— Click Linearization Data on the Calibration tab to open the Linearization Data window.
Page 123 Calibrating an LVDT LVDT recalibration If the LVDT has been previously calibrated, use the following procedure: 1. Locate the calibration data sheet for the appropriate conditioner. 2. Ensure that system hydraulics is off. 3. Open the Linearization Data window. Stand-Alone—Path: Setup > Disp > Calibration > Cal Type > Gain/Linearization >...
Page 124 Calibrating an LVDT 7. Reset Linearization Data window to default values. Stand-Alone—Path: Setup > Disp > Calibration > Cal Type > Gain/Linearization > <<Reset>> Automated— Click Reset on the Linearization Data window. 8. Apply a retraction command that is 80% of the full scale range. Stand-Alone: Use the front panel Dial to adjust the Setpoint for 80% of the full scale range.
Page 125 Calibrating an LVDT 9. Adjust gain to retract the actuator until it equals your retraction command. Stand-Alone— Path: Setup > Disp > Calibration > Cal Type > Gain/Linearization > Post-Amp Gain Automated— Adjust the Post-Amp Gain slider control on the Calibration tab Adjust Post-Amp Gain until your dial indicator or other readout device shows that the actuator’s physical retraction equals your...
Page 126 Calibrating an LVDT Record the dial indicator and conditioner feedback values at the -2% row of your record sheet. Repeat steps D and E for other retraction commands (typically at -4, -6, -8, -10, -20, -40, -70, and -100 percent of full scale).
Page 127: Task 8 Save The Calibration
Calibrating an LVDT 13. On the Linearization Data window, enter the dial indicator and conditioner feedback readings for all command points previously recorded on a separate sheet. 14. Turn on system hydraulics. 15. Verify linearization data. Stand-Alone: Using the front panel Dial, adjust the Setpoint for each retraction and extension command point on the Linearization Data window.
Page 128: Calibrating A Force Sensor
• A DVM to monitor the output of the load standard. Calibration Types The FlexTest SE controller’s full-range conditioner allows you to choose Gain/Delta K, Gain/Linearization, mV/V Positive Tension, or mV/V Positive Compression calibration. Important note Procedures for “Automated Controllers”...
Page 129: Abbreviated Procedure
Calibrating a Force Sensor Abbreviated Procedure Online Readers All procedure entries are hypertext links. Click on any entry to jump to the corresponding page. The following abbreviated procedure outlines a force sensor (load cell) calibration process. More detailed calibration information is available on the pages listed.
Page 130 Calibrating a Force Sensor Task 1 Get things ready Perform the following before you start sensor calibration. 1. Locate relevant documentation (e.g., sensor information, conditioner serial number, and calibration tool ID numbers) 2. Set up to monitor load standard output. 3.
Page 131 Calibrating a Force Sensor 5. Mount the force standard. The illustration shows a load standard in-line with the force train coupled with the force sensor. The load standard reacts like a stiff specimen. Be sure the gain settings (PID) for the Force Transducer control mode are appropriate.
Page 132 Calibrating a Force Sensor Task 2 Turn on hydraulic pressure Do not place any part of your body in the path of a moving actuator. A crush zone exists between the actuator and any equipment in the path of its movement. Immediate and unexpected actuator response is possible when you apply hydraulic pressure to your system.
Page 133 Calibrating a Force Sensor Task 3 Verify the conditioner polarity This task checks the polarity of the conditioner. Different types of test systems are configured with different conditioner polarities. The polarity of the conditioner, the polarity of the valve driver, and the connection positions of system cabling all play a role in controlling the actuator and determining how signals are displayed.
Page 134 Calibrating a Force Sensor Task 4 Set the zero and offset This task records the load standard readout as the zero reference. Using a load standard Stand-Alone — Adjust the Setpoint for 0 kN. Then zero the load standard readout. Path: Status > Setpoint Automated —...
Page 135 Calibrating a Force Sensor Task 5 Gain/Delta K Calibration If you using Gain/Delta-K for your calibration type, complete the following procedure. If not, complete Task 6 Gain/Linearization Calibration on page 142 or Task 7 Millivolt/Volt Calibration on page 153 Calibrate tension Force sensors can be calibrated so that a positive output represents actuator compression and a negative output represents actuator tension, and vice versa.
Page 136 Calibrating a Force Sensor and the software will calculate the Pre-Amp and Post-Amp gain values automatically. When you are calibrating an DC conditioner, use the Post-Amp gain control to increase gain. If more gain is needed, you must disable hydraulics and increase the Pre-Amp gain. You can then turn on hydraulics and continue to adjust the Post-Amp gain.
Page 137 Calibrating a Force Sensor During the initial calibration and tuning of your system, it may require repeated adjustment for the tensile force command and feedback values to match. Note If the actuator response is sluggish and/or the signal value does not match the command, you will need to adjust the tuning of this control mode.
Page 138 Calibrating a Force Sensor 2. Apply a compressive force command that is 80% of the range’s full scale. Stand-Alone: Enable the front panel Dial. Using the Dial, adjust the Setpoint for a compressive force command that is 80% of the full scale range. Verify that your force transducer feedback signal is 80% of the full scale range.
Page 139 Calibrating a Force Sensor 3. Adjust Delta K until the actual compressive force equals your compressive force command. Adjust DeltaK on the Calibration submenu or tab to increase the compressive force reading on the load standard until it equals your compressive force command. Record data points The accuracy tolerance of your data depends on the manufacturer of your sensor.
Page 140 Calibrating a Force Sensor Using a load standard • Adjust Manual Cmd slider for 0 kN. Then zero the load standard readout. Using dead weights • Remove all dead weights. On the Inputs panel, click on the Offset/Zero tab, and then adjust Manual Offset for a signal value of 0 kN on the DVM or Station Signals panel.
Page 141 Calibrating a Force Sensor Using a load standard • Adjust the Manual Cmd slider for 0 kN. Then zero the load standard readout. Using dead weights • Remove all dead weights. Then adjust the Offset control for a Signal Value of 0 kN on the Input Signals window.
Page 142 Calibrating a Force Sensor Task 6 Gain/Linearization Calibration If you are using Gain/Linearization for your calibration type, complete the following procedure. If not, complete Task 5 Gain/Delta K Calibration on page 135 or Task 7 Millivolt/Volt Calibration on page 153. Important Using linearization data requires specific conditioner zeroing practices.
Page 143 Calibrating a Force Sensor Using the Dial, adjust the Setpoint for a tensile force command that is 80% of the full scale range. Verify that your force transducer feedback signal is 80% of the full scale range. Automated: Open the Manual Command window, and then click on the Enable Manual Command.
Page 144 Calibrating a Force Sensor 5. Apply a compressive force command that is 80% of the full scale range. Stand-Alone: Using the front panel Dial, adjust the Setpoint for a compressive force command that is 80% of the full scale range. Verify that your force transducer feedback signal is 80% of the full scale range.
Page 145 Calibrating a Force Sensor Automated: Adjust the Manual Cmd slider for a 0% command. Record the force standard’s readout value and corresponding conditioner feedback reading at 0% command. Adjust the Manual Cmd slider for a -2% tensile force command. D. Record the force standard’s readout value and its corresponding conditioner feedback reading in the -2% row of your record sheet.
Page 146 Calibrating a Force Sensor 9. On the Linearization Data window, enter the force standard values and corresponding conditioner feedback readings for all command points previously recorded on a separate sheet. Stand-Alone— Path: Setup > Force > Calibration > Cal Type > Gain/Linearization >...
Page 147 Calibrating a Force Sensor Force transducer If the force transducer has been previously calibrated, use the recalibration following procedure: 1. Locate the calibration data sheet for the appropriate conditioner. 2. Turn off system hydraulics. 3. Click Linearization Data to open the Linearization Data window. Stand-Alone—...
Page 148 Calibrating a Force Sensor 7. Reset Linearization Data window to default values. Stand-Alone— Path: Setup > Force > Calibration > Cal Type > Gain/Linearization > <<Reset>> Automated— Click Reset on the Linearization Data window to return to default values. 8. Exercise the force standard. Stand-Alone—...
Page 149 Calibrating a Force Sensor Note If the actuator response is sluggish and/or the signal value does not match the command, you will need to adjust the tuning of this control mode. Increase the proportional gain (P Gain on the Tuning menu) to correct sluggish actuator movement.
Page 150 Calibrating a Force Sensor 12. Record conditioner feedback readings at predetermined tensile force command points. Note After shutting down system hydraulics, you will enter these recorded readings on the Linearization Data window. Stand-Alone: Use the Dial to adjust the Setpoint for a 0% command. Record the force standard’s readout value and corresponding conditioner feedback reading in the 0% row of your record sheet.
Page 151 Calibrating a Force Sensor 13. Record conditioner feedback readings at predetermined compressive force command points. Stand-Alone: Use the Dial to adjust the Setpoint for a +2% compressive force command. Record the force standard’s readout value and corresponding conditioner feedback reading in the +2% row of your record sheet.
Page 152 Calibrating a Force Sensor Check validity before entering each pair of values on a new Calibration Data Sheet. Automated: Adjust the Manual Cmd slider for each retraction and extension command point on the Linearization Data window. At each command point, verify both the force standard value (Standard) and its corresponding conditioner feedback value (Conditioner).
Page 153 Calibrating a Force Sensor Task 7 Millivolt/Volt Calibration If you are using mV/V Calibration for your calibration type, complete the following procedure. If not, complete Task 5 Gain/Delta K Calibration on page 135 or Task 6 Gain/Linearization Calibration on page 142. Millivolt/volt calibration is used for transducers that have two different slopes (positive and negative).
Page 154 Calibrating a Force Sensor Conditioner Output Voltage Gain ---------------------------------------------------------------------------------------------------------- - × Excitation Voltage Compression mV/V Where: Conditioner Output Voltage is typically 10 Vdc. Excitation Voltage is specified using the Excitation entry box on the Calibration submenu or tab. Compression is specified using the Negative Compression or Positive Compressive entry box on the Calibration submenu or tab.
Page 155 Calibrating a Force Sensor Automated: On the Inputs panel, enter the full scale force values in the Fullscale Min/Max entry boxes. Adjust Pos Tension for the required tension sensitivity value (+mv/v). Adjust Neg Compression for the required compression sensitivity value (-mv/V). D.
Page 156 Calibrating a Force Sensor Automated: Enter the full scale force values in the Fullscale Min/Max entry boxes. Adjust Neg Tension for the required tension sensitivity value (+mv/v). Adjust Pos Compression for the required compression sensitivity value (-mv/V). D. Adjust Excitation for the required calibration excitation value (Vdc).
Page 157 Calibrating a Force Sensor Task 8 Establish the shunt calibration reference Each resistive bridge type transducer (DC sensor) uses a shunt resistor to check the calibration accuracy of the sensor/conditioner combination. Each DC conditioner supports a shunt resistor. 1. Turn off hydraulic power. 2.
Page 158 Calibrating a Force Sensor 6. Determine the shunt calibration resistor from the following table: RIDGE ENSITIVITY ANGE ESISTOR (% F ESISTANCE CALE ALUE 350 Ω 2 mV/V 100% 49.9 k 100 k 249 k 499 k 350 Ω 1 mV/V 100% 100 k 200 k...
Page 159 Calibrating a Force Sensor 8. If you do not have transducer ID modules on your sensor cables, install the shunt calibration resistor as follows: Select the appropriate shunt calibration resistor. Bend the resistor leads 90º for a 0.3 inch separation. Cut the resistor leads 0.12 inch from the bend.
Page 160 Calibrating a Force Sensor 10. Perform shunt calibration. Stand-Alone: Path: Setup > Force > Calibration > Select Cal Type Select required Shunt Display units. Ensure that Shunt State (+) is set to On. Polarity is always positive. Note the Shunt Ref (+) value, it should be 60%–90% (80% is ideal) of the calibrated range of the sensor.
Page 161: Calibrating Encoders
The most common use for these controls is to establish a zero position after a specimen has been installed. Important note Procedures for “Automated Controllers” assumes the FlexTest SE Controller is equipped with the PC-Supervision option, and that Exclusive Control is assigned to Station Manager. For more information about Station Manager, see the Model 793.00 System Software manual...
Page 162: Abbreviated Procedure
Calibrating Encoders Abbreviated Procedure Online readers All procedure entries are hypertext links. Click on any entry to jump to the corresponding page. The following abbreviated procedure outlines an encoder calibration process. More detailed calibration information is available on the pages listed.
Page 163 Calibrating Encoders Task 1 Get things ready Perform the following before you start encoder calibration. 1. Locate relevant documentation. When calibrating an encoder, you will need information about the encoder such as the serial number, model number, and a specification called measuring step (resolution). 2.
Page 164 Calibrating Encoders For Automated systems, you can also use the Station Signals panel to monitor sensor output. On the Station Manager Display menu, select Station Setup. In the navigation pane, select Station Signals to display the Station Signals panel to monitor current values for user-defined signals.
Page 165 Calibrating Encoders Task 4 Turn on hydraulic pressure This task sets up the Control Panel so you can turn on the hydraulic pressure. Do not place any part of your body in the path of a moving actuator. A crush zone exists between the actuator and any equipment in the path of its movement.
Page 166 Calibrating Encoders Automated: Adjust the Manual Cmd slider on the Manual Command window to move the actuator to the position you want to assign as zero. Use Control Mode on the Change control modes on the Control Panel. Select any control mode that does not use the encoder.
Page 167: Calibrating Temposonics Sensors
(Model 493.47 Encoder Interface) is installed in the Model 493.40 Carrier I/O board. Important note Procedures for “Automated Controllers” assumes the FlexTest SE Controller is equipped with the PC-Supervision option, and that Exclusive Control is assigned to Station Manager. For more information about Station Manager, see the Model 793.00 System Software manual...
Page 168: Abbreviated Procedure
Calibrating Temposonics Sensors Abbreviated Procedure Online readers All procedure entries are hypertext links. Click on any entry to jump to the corresponding page. The following abbreviated procedure outlines a Temposonics sensor calibration process. More detailed calibration information is available on the pages listed. Task 1, “Get things ready,”...
Page 169: Task 1 Get Things Ready
Calibrating Temposonics Sensors Task 1 Get things ready 1. Review “Before You Begin” on page 97 2. Locate relevant documentation. When calibrating a Temposonics sensor, you will need information about the sensor such as the serial number, model number, and a specification called measuring step (resolution). 3.
Page 170 Calibrating Temposonics Sensors For Automated systems, you can also use the Station Signals panel to monitor sensor output. On the Station Manager Display menu, select Station Setup. In the navigation pane, select Station Signals to display the Station Signals panel to monitor current values for user-defined signals.
Page 171 Calibrating Temposonics Sensors Task 3 Assign the calibration file Note This task applies to automated FT SE controllers only. This task links a sensor calibration file (created in Task 2) to a hardware resource; effectively selecting one of the sensor ranges for the input signal definition.
Page 172: Task 5 Set The Zero Position
Calibrating Temposonics Sensors Task 5 Set the zero position The zero position can be set anywhere within the full-scale range of the Temposonics sensor. Stand-Alone: Using the front panel Dial, adjust the Setpoint to move the actuator to the position you want to assign as zero. Select any control mode that does not use the encoder.
Page 173: Task 6 Save The Calibration
Calibrating Temposonics Sensors Task 6 Save the calibration It is important that you save your sensor calibration values. Stand-Alone— Path: Setup > Open/Save Parameters > <<Save>> Automated— On the Station Setup window Inputs panel, click the Calibration tab, and then Save. This saves current calibration values on the Calibration, Sensor, and Shunt tabs to the sensor calibration file.
Page 174: Calibrating An Extensometer
• A digital voltmeter (DVM) Important note Procedures for “Automated Controllers” assumes the FlexTest SE Controller is equipped with the PC-Supervision option, and that Exclusive Control is assigned to Station Manager. For more information about Station Manager, see the Model 793.00 System Software manual that accompanies your system.
Page 175 Calibrating an Extensometer Task 1 Get things ready 1. Review “Before You Begin” on page 97. 2. Locate all relevant documentation including information about the extensometer such as the serial number, model number, etc. 3. Select Calibration for Access Level. Path: Config >...
Page 176 Task 2 again. For more detailed information on applying hydraulic pressure and clearing interlocks, refer to FlexTest SE User’s manual. Model 493.02 Controller Service...
Page 177 Calibrating an Extensometer Task 3 Adjust offset This task verifies the sensor’s zero position and offsets any imbalance due to specimen size, forces from test components, cable length, and so forth. The zero position can be set anywhere within the full-scale range of the strain sensor.
Page 178 Calibrating an Extensometer Task 4 Gain/Delta K Calibration If you are using Gain/Delta K for your calibration type, complete the following procedure. If not, complete Task 5 Gain/Linearization Calibration on page 180. Calibrate the negative This task calibrates the extensometer negative output using the output (tension) calibration Gain controls.
Page 179 Calibrating an Extensometer Note If you cannot apply enough Post-amp gain to achieve an 80% value, you will need to disable hydraulics, change the Excitation voltage, enable hydraulics, and then repeat this task. D. Repeat steps 1–4 for a 20%, 40%, 60%, and 100% negative output.
Page 180 Calibrating an Extensometer Task 5 Gain/Linearization Calibration If you are using Gain/Linearization for your calibration type, complete the following procedure. If not, complete Task 4 Gain/Delta K Calibration on page 178. Important Using linearization data requires specific conditioner zeroing practices. Ensure that Electrical Zero Lock on the Offset/ Zero menu is set to Locked.
Page 181 Calibrating an Extensometer During the initial calibration and tuning of your system, it may require repeated adjustment for the negative strain command and feedback values to match. At this point, unless the conditioner is already in calibration, the negative strain applied to the extensometer will not equal your commanded value.
Page 182 Calibrating an Extensometer Automated: Adjust the Manual Cmd slider on the Manual Command window for a 0% command. Record the calibrator’s readout value and the corresponding conditioner feedback reading in the 0% row of your record sheet. Adjust the Manual Cmd slider for a -2% strain command. D.
Page 183 Calibrating an Extensometer 9. On the Linearization Data window, enter the calibrator readout values and corresponding conditioner feedback readings for all command points previously recorded on a separate sheet. Stand-Alone— Path: Setup > Strain > Calibration > Cal Type > Gain/Linearization >...
Page 184 Calibrating an Extensometer Extensometer If the extensometer has been previously calibrated, use the following recalibration procedure: 1. Locate the calibration data sheet for the appropriate conditioner. 2. Turn off system hydraulics. 3. Click Linearization Data to open the Linearization Data window. 4.
Page 185 Calibrating an Extensometer 9. Apply a negative strain command that is 80% of the negative full scale range. Adjust the Setpoint (Stand-Alone) or Manual Cmd slider (Automated) for a negative strain command that is 80% of the full scale range. Verify that your extensometer feedback signal is 80% of the full scale range.
Page 186 Calibrating an Extensometer 12. Record conditioner feedback readings at predetermined negative strain command points. Note After shutting down system hydraulics, you will enter these recorded readings on the Linearization Data window. Stand-Alone: Use the Dial to adjust the Setpoint for a 0% command. Record the calibrator’s readout value and the corresponding conditioner feedback in the 0% row of your record sheet.
Page 187 Calibrating an Extensometer 13. Record conditioner feedback readings at predetermined positive strain command points. Stand-Alone: Use the Dial to adjust the Setpoint for a +2% positive strain command. Record the calibrator’s readout value and the conditioner feedback reading at the +2% row of your record sheet. Repeat steps A and B for other positive strain commands (typically at +4, +6, +8, +10, +20, +40, +70, and +100 percent of full scale).
Page 188 Calibrating an Extensometer Task 6 Establish the shunt calibration reference Each DC conditioner supports a shunt resistor. To establish the shunt reference value, perform the following tasks. 1. Disable hydraulic pressure and remove the calibrator. 2. Activate hydraulic pressure and zero the strain sensor output. Adjust the Setpoint (Stand-Alone) or Manual Cmd slider (Automated) for a 0 cm/cm output.
Page 189 Calibrating an Extensometer RIDGE ANGE ESISTOR (% F ESISTANCE ENSITIVITY CALE ALUE 700 Ω 2 mV/V 100% 100 k 200 k 499 k 1000 k 700 Ω 1 mV/V 100% 200 k 402 k 1000 k 2000 k 5. Install the shunt calibration resistor as follows: Select the appropriate shunt calibration resistor.
Page 190 Calibrating an Extensometer 6. Perform shunt calibration. Stand-Alone: Path: Setup > Strain > Calibration > Select Cal Type > Select required Shunt Display units. Ensure that Shunt State (+) is set to On. Polarity is always positive. Note the Shunt Reference (+) value, it should be 60%–90% (80% is ideal) of the calibrated range of the sensor.
Page 191 Chapter 7 Tuning Tuning affects the response and stability of the servo-control loop. Proper tuning improves the performance of the system. Note Precise tuning is not necessary. A good tuning adjustment is one that produces near-optimal behavior over a wide variety of conditions.
Page 192: About Tuning
About Tuning About Tuning When you tune, you are setting the stability and response of the servo control loop. Proper tuning improves the performance of the test system. Time Lag (phase shift) Error Proper tuning reduces error and phase lag. Program Command Feedback (higher Proportional gain) Feedback (lower Proportional gain)
Page 193: If You've Never Tuned Before
About Tuning If You’ve Never Tuned Before If you are unfamiliar with the tuning controls, review the following guidelines. Before you start tuning you should: • Define upper and lower limits for the displacement and force sensor before you start tuning. •...
Page 194: When To Tune
About Tuning When to Tune Tuning is needed whenever any of the following events occurs: • A gross change in the compliance or size of the test specimen. For example, you were testing steel and change to rubber. • The servohydraulic configuration has changed. For example, a servovalve is replaced or changed to a different capacity.
Page 195 The “Automated” paths and procedures described in this manual procedures assume the FlexTest SE Controller is equipped with the PC-Supervision option, and that Exclusive Control is assigned to Station Manager. For more information about Station Manager, see the Model 793.00 System Software manual that accompanies your system.
Page 196: Control Mode Characteristics
About Tuning Control Mode Characteristics A control mode uses a program command and sensor feedback to control the servovalve. The controller uses a group of gain controls— proportional, integral, derivative, and feed forward gain. These controls are called PIDF. The PIDF controller can also incorporate stabilization gain and an adjustable forward loop filter.
Page 197 About Tuning Command sources The program command source can come from an internal source (such as the Function Generator application) or from an external device (such as an external profiler or function generator). Displacement control Displacement control mode uses the LVDT sensor in the actuator as the controlling feedback source.
Page 198 Channel limited channels require two feedback signals. See “Tuning a CLC Control Mode” on page 219 Refer to “Tuning” in Chapter 3, Menus Descriptions of the FlexTest SE Users Manual for more information about CLC tuning controls and guidelines. Dual Compensation...
Page 199: How The Tuning Controls Work
About Tuning How the Tuning Controls Work The controller system software includes five tuning controls. You do not need to use all of the controls to properly tune your system. In fact, most testing can be accomplished with just the proportional gain adjustment.
Page 200 About Tuning Proportional gain (P) Proportional gain is used for all tuning situations. It introduces a control factor that is proportional to the error signal. Proportional gain increases system response by boosting the effect of the error signal on the servovalve. The tuning command is shown as a gray square waveform, and the black...
Page 201 About Tuning Integral gain (I) Integral gain introduces “an integral of the error signal” that gradually, over time, boosts the low-frequency response of the servovalve command. Integral gain increases system response during static or low-frequency operation and maintains the mean level at high-frequency operation. It can offset a DC or steady-state error, such as that caused by valve imbalance.
Page 202 About Tuning Derivative gain (D) Derivative gain is used with dynamic test programs. It 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.
Page 203 About Tuning Feed forward gain (F) Feed forward gain is like derivative gain 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.
Page 204 About Tuning ∆ Delta P ( Delta P is a differential pressure sensor that measures the difference in pressure at each end of the actuator. It compensates for hydraulic compliance (compressed hydraulic fluid acts like a spring). Delta P improves displacement control of heavy mass loaded systems. Delta P is typically used on systems with large hydraulic fluid flow rates.
Page 205 About Tuning Acceleration Test systems with specimens affected by acceleration resonances can use a mass accelerometer signal for stabilization. Acceleration stabilization stabilization dampens the resonances (vibrations) affecting the specimen. Typical systems that benefit from acceleration stabilization include: • Load units that operate at high frequencies with massive grips •...
Page 206 (Filter Min) that is approximately the actuator frequency and a high cut-off frequency (Filter Max) approximately 5-10 times the actuator frequency. Refer to “Tuning” in Chapter 3, Menus Descriptions of the FlexTest SE Users Manual for more information about the stabilization filter settings. Automated Systems See “How to Enable a Tuning Filter”...
Page 207: Creating A Tuning Program
About Tuning Creating a Tuning Program The purpose of a tuning program is to produce a command that reflects the most demanding system response expected from a test. Note The Function Generator is very useful for quickly setting up a tuning program.
Page 208 About Tuning Square/Tapered Square A square waveform requires the servovalve to open rapidly to a large opening. It is the most demanding waveform because it requires the maximum response from the servoloop system. It also places a large acceleration on the test system and specimen. Tapered square waves taper from 0% to 100% amplitude at the beginning of execution, and from 100% to 0% at the end of execution.
Page 209 About Tuning Random function When tuning AIC compensator configurations, it is necessary to generator generate random functions to properly simulate typical test conditions. Random functions employ a pre-emphasis filter to make the convergence rate constant over all frequencies. The random function options include: •...
Page 210: Other Considerations
About Tuning Other Considerations Servovalves Most of the servovalve adjustments are performed during the system installation and do not require periodic adjustment. There are two types of servovalves: • Three-stage servovalves, such as the MTS Series 256 and 257 Servovalves, have an inner loop control system which must be tuned before the outer loop can be tuned.
Page 211: Monitoring Waveforms
About Tuning Tuning without a A specimen is required to tune force and strain control modes. Initial force tuning may be accomplished with the actuator up against the specimen force sensor. The actuator acts as a specimen reacting against the force sensor.
Page 212 About Tuning 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. Monitoring the The error signal shows similar characteristics as a feedback signal. The error signal error signal represents the difference between the command and sensor feedback.
Page 213 If you do not have an oscilloscope, use the controller scope feature for controller scope tuning control modes. Review the following: • Select Scope on the FlexTest SE front panel (Stand-Alone) or Scope on the Station Manager Display menu (Automated). • Select a continuous sweep.
Page 214 About Tuning For more information on the controller scope, refer to the FlexTest SE Users manual. Using an oscilloscope An oscilloscope has a higher resolution and is faster than the software controller scope. Review the following: • You must have a Readout defined.
Page 215: Tuning Displacement
• You have created a station parameter set. Tuning procedure Refer to “How to manually tune the displacement control mode” in Chapter 2, Common Tasks of the FlexTest SE Users manual for a detailed tuning procedure. Model 493.02 Controller Service...
Page 216: Tuning Force
• You have created a station parameter set. Tuning procedure Refer to “How to manually tune the force control mode” in Chapter 2, Common Tasks of the FlexTest SE Users manual for a detailed tuning procedure. Model 493.02 Controller Service...
Page 217: Auto Tuning
Auto tuning Auto tuning Purpose The auto tuning feature automatically calculates tuning values for PIDF control modes. Note Auto tuning is only available for PIDF control modes. How auto tuning The auto tuner disregards your current PIDF gain settings. It applies works the minimum required drive signal to ramp the feedback to 80% of the auto tuning limits.
Page 218 Auto tuning How to Auto-Tune Control Modes First, auto-tune the displacement control mode. Then install a dummy specimen and auto-tune the force control mode. Auto-tune the See “How to auto-tune” in Chapter 2, Common Tasks of the FlextTest displacement control SE User’s manual for a detailed procedure.
Page 219 P feedback. Refer to “Tuning” in Chapter 3, Menus Descriptions of the FlexTest SE Users Manual for more information about CLC tuning controls and guidelines.
Page 220 Auto tuning Model 493.02 Controller Service...
Page 221 Appendix A Hydraulic Configurations This section describes how to connect the Model 493.02 Chassis to a variety of MTS hydraulic configurations. You will use the following connectors and cables to connect the Model 493.02 Chassis to your HPU or HPS: 493 Chassis to •...
Page 222 Single 493 Chassis with a 24 V PLC pump (506.52-.92) or 505 pump 397137-XX 493.02 Chassis Note The following three configurations have cables to support both 24 V DC and 115 V AC control voltages. A 493.07 HPU Converter Box is available for each voltage (not both).
Page 223 Compatible Controllers 397107-XX (24 V DC) High-Level Y cable 397108-XX (1 15 V AC) 054078-01 (24 V DC) 054018-01 (1 15 V AC) 397138-XX (24 V DC) 397146-XX (1 15 V AC) 493.07 493.02 Pump Chassis Interface 397087-XX (24 V DC) 458* or 397088-XX (1 15 V AC) 490.01*...
Page 224 Multiple Controller Interconnections FlexTest SE supports the following hydraulic interconnections for multiple controller configurations: • Independent HSM control with no HPU • Independent HSM control with a shared HPU • Shared HSM with an HPU • Shared HSM without HPU •...
Page 225 Independent HSM (shared HPU) Power Type = HPU/HSM Power Type = HPU/HSM FlexTest SE FlexTest SE Interlock/Hydraulics reset reset 563160-xx Emergency Stop Emergency Stop enter enter cancel cancel Monitor 1 Monitor 2 Monitor 1 Monitor 2 J28 HSM J25 HPU...
Page 226 Shared HSM (with HPU) Power Type = HPU/HSM Power Type = Slave HSM Interlock/Hydraulics FlexTest SE FlexTest SE reset reset 563160-xx Emergency Stop enter Emergency Stop enter cancel cancel Monitor 1 Monitor 2 Monitor 1 Monitor 2 J28 HSM J25 HPU...
Page 227 Shared HSM (no HPU) Power Type = HSM Only Power Type = Slave HSM Interlock/Hydraulics FlexTest SE FlexTest SE reset reset 563160-xx Emergency Stop Emergency Stop enter enter cancel cancel Monitor 1 Monitor 2 Monitor 1 Monitor 2 J28 HSM...
Page 228 397137-xx HSM 1 HSM 2 For this controller configuration: • Two or more FlexTest SE controllers are connected. • An HSM is connected to each controller only. • Select Auto. HPU/HSM for Power Type on the controller to which both a HSM and HPU is connected.
Page 229 Appendix B Model 493.07 HPU Converter The 493.07 HPU Converter (PN 499694-xx) is designed to connect the 493.02 chassis to a hydraulic power unit (HPU) such as MTS Model 506 HPS or equivalent relay-operated pump. The HPU converter converts logic-level signals to and from the 493.02 chassis to relay signals used by the HPU pump.
Page 230 Disconnect all cables from the Model 493.07 HPU Converter before removing the cover. Failure to do so could expose the operator to dangerous voltages. If the HPU Converter remains connected to a 120 volt HPS, this voltage will be present. Always remove all cable before removing the cover. Jumper As shipped, the HPU interface on the 493.07 HPU Converter is configurations...
Page 231 Appendix C Service Tools A Service Tool application is provided with FlexTest SE systems to perform the following tasks: • Install or update new versions of 793 software for both stand- alone and automated configurations, including multi-controller systems • Backup and restore test information files including hardware configuration (.hwi), station configuration (.cfg), and *.txt files.
Page 232 Copy required system files to a specified controller. • Copy/restore required user files to a specified controller. • Backup user files from the FlexTest SE controller to your PC. • Modify system options stored in the registry.ini file that is specific to a particular controller.
Page 233 You will not be prompted to verify overwriting any existing files. Update User Copies all user files to the selected FlexTest SE controller. If the same file Files exists on the controller, the user will be prompted to verify overwriting the existing file.
Page 234 Service Tool Application (part 2 of 2) ESCRIPTION Unregister Deletes a controller-specific folder from the "Boxes" folder on the disk. Controller Note You have the option of not deleting this "Boxes" folder containing both the .hwi and config files. Enable Enables a selected controller.
Page 235 Initializing a FlexTest SE Controller To initialize a FlexTest SE controller, use the FlexTest SE Service Tool application to perform the following functions: • Locate all available controllers and display controller information on the Service Tool window, including controller ID and IP address •...
Page 236 (e.g., box a) in the "Boxes" folder on your PC registry. The .hwi file and config folder are then copied to this new folder from the controller being registered. 6. Enable the selected controller. Select Enable Controller on the FlexTest SE Service Tool Application window. Model 493.02 Controller Service...
Page 237 Updating System Options Selecting Update System Options on the FlexTest SE Service Tool Application window opens the System Options window which allows you to configure the FlexTest SE registry.ini file You can use the System Options window to change system options, passwords, and chassis attributes.
Page 238 Unit Assignment Set Tab Use the Unit Assignment Set tab to enter the file name for a default Unit Assignment Set. Model 493.02 Controller Service...
Page 239 Chassis Attributes Tab Use the Chassis Attributes to: • Enter a name for the controller selected on the FlexTest SE Service Tool Application window. • Enter a unique ID number for the controller selected on the FlexTest SE Service Tool Application window.
Page 240 Passwords Tab Use the Passwords tab to enter passwords for tuning, calibration, and configuration level access for the selected controller. Important Passwords should only containing characters found on the controller front panel’s numeric keypad. These are the only keys available when entering passwords in stand- alone mode.
Page 241 User Files Tab The User Files tab allows you to select the name of both the hardware configuration file and station configuration file for the controller selected on the FlexTest SE Service Tool Application window. Model 493.02 Controller Service...
Page 242 Model 493.02 Controller Service...
Page 243 Index Numerics balance, adjust valve Box In (J51) Box Out (J52) bridge completion 252 servovalve I/O carrier module I/O carrier connection 256 servovalve I/O carrier connection 257 servovalve I/O carrier module connection 493.07 HPU Converter 493.42 System I/O cable specifications auxiliary power connection (J43) analog I/O E-stop connection (J29)
Page 244 calibration AC conditioners (displacement) DC conditioners (force) encoders d gain. see derivative gain gain controls daughter boards hydraulics turn on 108, 132, 165, DC conditioners LVDT calibration phase adjustment checking polarity shunt DC sensor calibration shunt, performing shunt calibration Temposonics sensors shunt resistor table using full-range conditioner delta P sensors, stabilizing with...
Page 245 extensometer calibration grounding adjust offset low-frequency ground loops calibrate compression grounding chassis calibrate tension gain/delta K gain/linearization recalibration record data shunt calibration reference HPU connector (J25) HPU transition board E-stop cable specifications E-STOP connectors HPU cable specifications feed forward gain force control proportional output force sensor calibration...
Page 246 J49 auxiliary power connector J51 Box In connections J52 Box Out connections J54 Digital Input connections offset, setting J55 Dig Out connection displacement sensor jumpers force sensor HPU converter LVDT J25 HPU options J29 E-stop input system software J43 interlock oscilloscope J52 Box Out tuning use...
Page 247 service tools temposonics calibration application signal monitoring initializing controller Temposonics sensor calibration setting passwords calibration file updating system options connections servovalve defining an input adjust valve balance setting zero adjusting dither amplitude Temposonics sensors cable specifications transducer cables dither part numbers I/O carrier connection specifications polarity check...
Page 248 zero, setting displacement sensor encoders 161, force sensor LVDT Temposonics sensor Model 493.02 Controller Service...

MTS Systems FlexTest SE Service Information

Table of Contents

Chapter 1 Introduction

Installation

Chapter 2 Installation

Cabling

Chapter 3 Cabling

Chapter 4 Servovalve Controls

Chapter 5 Sensors

Chapter 6 Calibration

Section 4

Section 5

Tuning

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Summary of Contents for MTS Systems FlexTest SE

Table of Contents