Download
Share
Print this page
  1. Manuals
  2. Brands
  3. MTS Systems Manuals
  4. Controller
  5. FlexTest 793 Series
  6. Manual

MTS Systems FlexTest 793 Series Manual

Iim/gt/se controller
Hide thumbs

Advertisement

Quick Links

Download this manual
be certain.
®
MTS Models FlexTest
IIm/GT/SE Controller Hardware
Service Information for Controllers Using Series 793 Software:
- Hardware Descriptions
- Specifications
- Installation
- Cabling
100-147-133 G

Advertisement

loading
Need help?

Need help?

Do you have a question about the FlexTest 793 Series and is the answer not in the manual?

Questions and answers

Related Manuals for MTS Systems FlexTest 793 Series

Summary of Contents for MTS Systems FlexTest 793 Series

  • Page 1 be certain. ® MTS Models FlexTest IIm/GT/SE Controller Hardware Service Information for Controllers Using Series 793 Software: - Hardware Descriptions - Specifications - Installation - Cabling 100-147-133 G...
  • Page 2 MTS, FlexTest, Temposonics, and TestWare are registered trademarks of MTS Systems Corporation; MPT, Station Builder, and Station Manager are trademarks of MTS Systems Corporation within the United States. These trademarks may be protected in other countries. Microsoft and Windows are registered trademarks of Microsoft Corporation. All...

  • Page 3: Table Of Contents

    Contents Technical Support 9 How to Get Technical Support 9 Before You Contact MTS 10 If You Contact MTS by Phone 11 Problem Submittal Form in MTS Manuals 12 Preface 15 Before You Begin 15 Conventions 16 Documentation Conventions 16 Chapter 1 Introduction 19 FlexTest GT Controllers 20...
  • Page 4 Chapter 2 Installation 37 Installing the Model 493.10 Chassis (FTGT) 37 Connecting Electrical Power 38 Installing the Plug-in Modules 42 VMEbus Modules 43 Installing the Transition Panels 47 Installing the 493.02 Chassis (FlexTest SE) 49 Installing the Plug-in Modules 49 VMEbus Modules 50 Chassis Installation Options 51 Connecting Electrical Power 53...
  • Page 5 Chapter 3 FlexTest GT Controller Connections 81 CE EMC Compliant Cabling 83 Typical Cabling 84 Cable Part Numbers 85 Model 493.40 I/O Carrier Connections 87 Sensor Connections 88 Model 493.21B (DUC B) Jumpers 92 Digital Universal Conditioner (DUC BC) Switches 94 Full-Range Digital Universal Conditioner (FRDUC) Jumpers 97 Sensor Cables 100 Sensor Cable Specifications 100...
  • Page 6 Cabling and Programming Series 407 Controllers 151 How to Provide Program to a Series 407 Controller 151 Connecting Interlock Signals to 407 Controllers 156 Sending and Receiving Signals to a Model 407 Controller 162 Connecting Interlock Signals to 458 Controllers 164 Eurotherm Temperature Controller Connection 165 Miscellaneous Conditioner Output Connections 167 Cabling for External Command Inputs 168...
  • Page 7 Cabling for External Command Inputs 210 How to Enable and Run External Command Inputs 210 Cabling and Using External Readout Devices 213 How to Send Signals to External Readout Devices 213 Cable Part Numbers 216 Chapter 5 FlexTest SE Controller Connections 217 Stand-alone Cabling Overview 218 Automated Cabling Overview 219 Multiple Controller Connections 220...
  • Page 8 Appendix A Hydraulic Configurations 243 Model 493.02 Chassis Multiple Controller Interconnections 246 Independent HSM (no HPU) 246 Independent HSM (shared HPU) 247 Shared HSM (with HPU) 247 Shared HSM (no HPU) 248 Independent HSM with HPU (First On-Last Off) 249 Appendix B Model 493.07 Converter Box 251 Appendix C...

  • Page 9: Technical Support

    How to Get Technical Support Technical Support How to Get Technical Support Start with your The manuals supplied by MTS provide most of the information you need to use manuals and maintain your equipment. If your equipment includes software, look for online help and README files that contain additional product information.

  • Page 10: Before You Contact Mts

    Before You Contact MTS Before You Contact MTS MTS can help you more efficiently if you have the following information available when you contact us for support. Know your site The site number contains your company number and identifies your equipment number and system type (such as material testing or simulation).

  • Page 11: If You Contact Mts By Phone

    If You Contact MTS by Phone Know relevant For a computer problem, have the following information available: computer information • Manufacturer’s name and model number • Operating software type and service patch information • Amount of system memory • Amount of free space on the hard drive where the application resides •...

  • Page 12: Problem Submittal Form In Mts Manuals

    Problem Submittal Form in MTS Manuals Identify system type To enable the Call Center agent to connect you with the most qualified technical support specialist available, identify your system as one of the following types: • Electromechanical material test system •...
  • Page 13 Problem Submittal Form in MTS Manuals Access the Problem Submittal Form: • In the back of many MTS manuals (postage paid form to be mailed to MTS) • www.mts.com > Contact Us > Problem Submittal Form button (electronic form to be e-mailed to MTS) Models FlexTest®...
  • Page 14 Problem Submittal Form in MTS Manuals Models FlexTest® IIm/GT/SE Controller Hardware Technical Support...

  • Page 15: Preface

    Before You Begin Preface Before You Begin Safety first! Before you use your MTS product or system, read and understand the Safety manual and any other safety information provided with your system. Improper installation, operation, or maintenance can result in hazardous conditions that can cause severe personal injury or death, or damage to your equipment and specimen.

  • Page 16: Conventions

    Documentation Conventions Conventions Documentation Conventions The following paragraphs describe some of the conventions that are used in your MTS manuals. Hazard conventions Hazard notices may be embedded in this manual. These notices contain safety information that is specific to the activity to be performed. Hazard notices immediately precede the step or procedure that may lead to an associated hazard.

  • Page 17: Hypertext Links

    Documentation Conventions Illustrations Illustrations appear in this manual to clarify text. They are examples only and do not necessarily represent your actual system configuration, test application, or software. Electronic manual This manual is available as an electronic document in the Portable Document conventions File (PDF) format.
  • Page 18 Documentation Conventions Models FlexTest® IIm/GT/SE Controller Hardware Preface...

  • Page 19: Introduction

    Chapter 1 Introduction This manual contains installation, cabling, jumpering, and hardware interfacing information for MTS 793 Controllers. This chapter describes the hardware components and specifications of FlexTest GT, FlexTest SE, and FlexTest IIm Controllers. Contents FlexTest GT Controllers Model 493.10 Chassis Hydraulic Control Interlocks Specifications...

  • Page 20: Flextest Gt Controllers

    Model 493.10 Chassis FlexTest GT Controllers MTS FlexTest GT Controllers are fully digital Proportional, Integral, Derivative, Feedforward (PIDF) servocontrollers which use an identical chassis configuration. They provide complete control of up to eight channels distributed among up to eight stations. Optional station configurations are available (see “Hydraulic Configurations”...

  • Page 21: Power Supply

    Model 493.10 Chassis Front panel The Model 493.10 Chassis front panel has twelve slots; ten VMEbus slots and two slots (A and B) which are reserved. Rear panel The rear panel of the chassis has twelve transition bus slots. Two of these rear panel slots (slots A and B) can not be used with powered MTS transition modules.

  • Page 22: Hydraulic Control

    Hydraulic Control Cooling The chassis is cooled with a fan. An overtemperature sensor is part of the standard power supply assembly. If the internal chassis temperature exceeds 50ºC, this sensor will light an amber indicator located on the rear of the power supply module.

  • Page 23: Specifications

    Specifications Specifications FlexTest GT 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 100–240 V AC Input voltage 47–63 Hz Input frequency...

  • Page 24: Flextest Se Controllers

    Specifications FlexTest SE Controllers The MTS Model 493.02 FlexTest SE Controller is a fully digital Proportional, Integral, Derivative, Feedforward (PIDF) servocontroller. It provides complete control of one servohydraulic channel or station in an MTS test system. FlexTest SE Controller 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 25 Specifications FlexTest SE stand-alone A function generator (with a built-in cycle counter) in the controller provides function generation basic sine, square, triangle, and ramp command waveforms. For tests requiring complex waveforms, the controller provides an external command input to receive externally generated commands. The function generator waveform can be output to another MTS FlexTest SE Controller (or any external device) for synchronization.

  • Page 26: Model 493.02 Chassis

    Model 493.02 Chassis Model 493.02 Chassis FlexTest SE Controllers use the Model 493.02 Chassis. The Model 493.02 Chassis is a single-station, single-channel VMEbus chassis which, in a typical configuration, houses three plug-in modules: • A Series 498 Processor • A Model 493.40 I/O Carrier module •...

  • Page 27: Specifications

    Specifications 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 100–240 V AC Input voltage 47–63 Hz Input frequency...

  • Page 28: Flextest Iim Controllers

    Specifications 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 sixteen Controllers channels distributed among up to four stations in an MTS test system. The FlexTest IIm Controller is available in five standard configurations.
  • Page 29 Specifications FT IIm standard • 4, 6, 8, 12, or 16 channels of control configurations • 16 inputs and 16 outputs of user DIO • Per channel resources: – One valve driver output – One D/A output – One A/D input –...

  • Page 30: Model 497.01 Analog Chassis

    Model 497.01 Analog Chassis Model 497.01 Analog Chassis The plug-in modules installed in the 497.01 Analog Chassis provide four main functions: • Interlock control—An interlock control plug-in module provides programmable interlock signal mapping between the test processor and the modules installed in this analog chassis. •...

  • Page 31: Model 497.05 Hydraulic Control Panel

    Model 497.05 Hydraulic Control Panel Model 497.05 Hydraulic Control Panel The hydraulic control panel provides the following functions. • Control of up to four independent hydraulic service manifolds • Hydraulic power supply control • Interlock shutdown and latched indicators to show interlock status •...

  • Page 32: Model 498.22 Chassis With Test Processor (Ftiim)

    Model 498.22 Chassis with Test Processor (FTIIm) Model 498.22 Chassis with Test Processor (FTIIm) The Model 498.22 test processor chassis is a VMEbus chassis that houses up to twelve plug-in modules (including processor modules, ADDA modules, digital I/O modules, and so forth). It also accommodates various rear-panel transition modules (for connections to other hardware chassis and external equipment).

  • Page 33: Specifications

    Specifications 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 (standard supply maximum output, actual load depends on installed modules) Dimensions...
  • Page 34 Specifications 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) Models FlexTest®...
  • Page 35 Specifications Model 498.22 Chassis Specifications ARAMETER PECIFICATION Dimensions Height 40 cm (15.75 in) Width 48.3 cm (19 in) Depth 55.9 cm (22 in) Weight 18 kg (40 lb) plus 0.5 kg (1 lb) per module Rack mounting requirements: Clearance-each side 5.7 cm (2.25 in) for air flow Clearance-back 15.3 cm (6.0 in) for cabling...
  • Page 36 Specifications Models FlexTest® IIm/GT/SE Controller Hardware Introduction...

  • Page 37: Installation

    Chapter 2 Installation This chapter describes how to install the Controller chassis and connect it to system components. Contents Installing the Model 493.10 Chassis (FTGT) Installing the 493.02 Chassis (FlexTest SE) Installing 497/498 Electronics (FTIIm) Installing the Model 493.10 Chassis (FTGT) The chassis can be installed in an equipment rack console or in a standalone configuration.

  • Page 38: Stand-Alone Installation

    Connecting Electrical Power Stand-alone The stand-alone chassis can be placed on the floor. The chassis location is limited installation only by the length of the system cables. The front panel of the chassis can be removed to access the VMEbus plug-in modules. Console installation The rack-mounted chassis can be installed in any Model 490.8x console.
  • Page 39 Connecting Electrical Power Note Local electrical codes supersede any information found here. Grounding The chassis will not function correctly if it is not grounded as shown. Be sure your power source is also properly grounded. The chassis includes two grounds: a chassis ground and a signal ground.
  • Page 40 Connecting Electrical Power Proper grounding is required for safe operation. It is also required to meet EMC emission and susceptibility requirements. Power All equipment related to the chassis should be connected on the same fused power circuit. The power supply can accept single-phase voltages within 90–264 V AC at frequencies between 47–63 Hz.
  • Page 41 Connecting Electrical Power Note Be sure to locate the chassis so you have adequate access to disconnect the power cord from the chassis. Outlet Strip Power Over Temp J39 Power Monitor Power Line Voltage Outlet Strip Outlet Strip (printer, etc) w/ circuit breaker Outlet Strip Line...

  • Page 42: 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. A hardware interface file (.hwi file extension) defines each type of module and maps each module location for the system software.

  • Page 43: Vmebus Modules

    VMEbus Modules VMEbus Modules The VMEbus compatible modules should be installed in the front panel chassis slots according to the following guidelines. • The processor module(s) must be located in the first (and second) slots. • The GRESIII module (if used) should be located in slot 10. It may also be located in slot 2 if a second processor is not used.

  • Page 44: Module Addresses

    VMEbus Modules Setting I/O Carrier Use the dipswitch (S1) and rotary dipswitch (S2) on each I/O Carrier module to addresses set its address in accord with its installed chassis slot as follows: DDRESS Setting I/O Carrier The dipswitch settings for address C20 is shown below. Increment the rotary module addresses dipswitch as required to complete I/O Carrier module addressing.
  • Page 45 VMEbus Modules The rotary dipswitch settings for address C40 are shown below. Increment the front panel dipswitch as required to complete ADDA II module addressing. 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...
  • Page 46 VMEbus Modules I/O Carrier Mezzanine Cards (part 2 of 2) ODEL ODULE UNCTION 493.46 Converts up to six internal digital signals to analog signals for use by external devices. 493.47 Encoder Processes the signals from an encoder or a Temposonics III transducer with an SSI interface.

  • Page 47: Installing The Transition Panels

    Installing the Transition Panels Installing the Transition Panels The transition panels need to be installed in specific slots of the rear panel chassis. This is done to allow proper air flow in the chassis. For consistency, install the modules according to the following guidelines. Starting from the left chassis slot (slot 10) and working to the right, install the modules as shown.
  • Page 48 Installing the Transition Panels Note Other transition modules may be used, contact MTS Systems Corporation for additional information. 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.

  • Page 49: Installing The 493.02 Chassis (Flextest Se)

    Installing the Plug-in Modules Installing the 493.02 Chassis (FlexTest SE) This section describes how to install the MTS FlexTest 493.02 chassis and connect it to your system components. Contents Installing the Plug-in Modules VMEbus Modules Chassis Installation Options Connecting Electrical Power Installing the Handle Kit Installing the Plug-in Modules This section describes how to install the plug-in modules into the chassis.

  • Page 50: Vmebus Modules

    VMEbus Modules VMEbus Modules The VMEbus compatible modules should be installed in chassis slots according to the following guidelines. • The processor module is installed in slot 1 • The I/O carrier module is installed in slot 2. • The System I/O module is installed in slots 4 and 5. Placement of VMEbus modules in the chassis...

  • Page 51: Chassis Installation Options

    Chassis Installation Options 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. 493.25 Universal Conditioner Processes the signals from either an AC or DC-type sensors.
  • Page 52 Chassis Installation Options Rack mounting When installing the chassis in an equipment rack allow a minimum of 2 in. (5.1 requirements cm) on either side of the controller for air flow. There are no spacing requirements for the top or bottom of the controller. If the equipment rack is equipped with doors, allow adequate clearance for the front and rear of the controller.

  • Page 53: Connecting Electrical Power

    Connecting Electrical Power Connecting Electrical Power Electrical connections must be made by qualified personnel and conform to local codes and regulations. An electrical service panel to provide the electrical power feed (line voltage) to the chassis is not necessary, but may be required by local electrical codes.
  • Page 54 Connecting Electrical Power Rack Mount Configuration Chassis ground cable (PN 037-766-102) connected to the vertical conductive rail. Signal common cable (PN 037-766-101) connected to the power panel. System ground cable (PN 005-402-3xx) connected to the test frame or other components. The AC power ground is through the power cord.
  • Page 55 Connecting Electrical Power Power All equipment related to the chassis should be connected on the same fused power circuit. • The power supply can accept single-phase voltages within 90–264 V AC at frequencies between 47–63 Hz. • The maximum continuous power usage is approximately 300 W. The current draw depends on the local voltage supply.
  • Page 56 Connecting Electrical Power Note Be sure to locate the chassis so you have adequate access to disconnect the power cord from the chassis. Stand-Alone Configuration Power 100–240 VAC 50–60 Hz, 12–6A RU N 6TS BFL TYPE E PC- MIP DEBUG TYPE E PC-MIP P CI MEZZANNE CARD Line...
  • Page 57 Connecting Electrical Power Rack Mounted Configuration Outlet Strip Power 100–240 VAC 50–60 Hz, 12–6A R UN 6TS BF L TYP E E PC-M IP TYP E E P C-M IP DEBUG PC I M E Z Z AN NE C ARD Power Panel Models FlexTest®...

  • Page 58: Installing The Handle Kit

    Installing the Handle Kit Installing the Handle Kit The controller may be equipped with an optional handle kit. The following procedure provides assembly and installation instructions for the handle kit (MTS PN 100-061-494). The following table and figure show the handle kit assembly components described in the procedure.
  • Page 59 Installing the Handle Kit 12 (handle-not shown) Handle Kit 1. Place one support arm (1) into one handle side leg (2), as shown in the handle kit assembly figure. 2. Set one of the clips (3) in place over the slender, straight portion of the support arm (1), just behind the circular end of the support arm.
  • Page 60 Installing the Handle Kit 7. Insert a Phillips screwdriver through the hole in the button (7) and lightly tighten the screw (5). 8. Assemble the remaining handle kit components to the other handle side leg (2) according to steps 1 through 7 and mount the side leg to the mounting holes on the opposite side of the controller.

  • Page 61: Installing 497/498 Electronics (Ftiim)

    Connecting the Console and Chassis Power Installing 497/498 Electronics (FTIIm) Contents Connecting the Console and Chassis Power Grounding the Console and Chassis Model 497.01 Analog Chassis About Analog Chassis Slots Analog Chassis Plug-in Modules Analog Chassis Transition Modules Adding an Analog Chassis to Your Console Model 497.05 Hydraulic Control Panel Test Processor Plug-in Modules Test Processor Transition Modules...

  • Page 62: How To Cable The Analog Chassis To The Hydraulic Control Panel

    How To Cable the Analog Chassis to the Hydraulic How To Cable the Analog Chassis to the Hydraulic Control Panel Connect J50 DC Pwr on the 497.01 Analog Chassis rear panel to J50 on the 497.05 Hydraulic Control Panel rear panel. 497.05 Hydraulic Control Panel PN 046-239-1xx 497.01 Analog Chassis...

  • Page 63: Model 497.01 Analog Chassis

    Model 497.01 Analog Chassis 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...

  • Page 64: Analog Chassis Plug-In Modules

    Analog Chassis Plug-in Modules Analog Chassis Plug-in Modules Before you install any plug-in modules, be sure they are configured properly for your system. The following is a brief description of the plug-in modules available for the chassis. Plug-in Modules ODEL ODULE UNCTION Processes signals from AC-type sensors such as LVDTs or...

  • Page 65: How To Install Or Remove A Plug-In Module

    How to Install or Remove a Plug-in Module How to Install or Remove a Plug-in Module Plug-in modules are static sensitive. Do not install or remove a module with electrical power on. Do not place modules that contain battery backup on a metal surface. Touch the console or other ground point before handling a module.

  • Page 66: Analog Chassis Transition Modules

    Analog Chassis Transition Modules Analog Chassis Transition Modules Transition modules located on the Model 497.01Rear Panel provide signal transfer between the Model 497 modules and external devices. One digital transition module and up to eight analog transition modules can be installed in this chassis.

  • Page 67: Transition Module Connectors

    Transition Module Connectors Transition Module Connectors Cable connections to external devices are made from the 497.01 chassis rear panel connectors. J101–J1601 System connectors J101 through J1601 (JX01) are 15-pin D-type connectors located on the chassis rear panel. They connect either a valve driver to a servovalve or a conditioner to a transducer.
  • Page 68 Transition Module Connectors Single chassis If you have a single analog chassis: configuration First install a cable from a Series 498 host computer serial port (debug) to J51 Intlk In on the Model 497.05 Hydraulic Control Panel, then from J52 Intlk Out to J51 Intlk In on the Model 497.01 Analog Chassis.

  • Page 69: Adding An Analog Chassis To Your Console

    Adding an Analog Chassis to Your Console Adding an Analog Chassis to Your Console To accommodate higher channel counts, it may be necessary to add one or more Model 497.01 Analog Chassis’ to your FlexTest IIm console. Depending on the number of analog chassis installed, you may have to modify switch settings and jumpers on the communication boards in your 497.05 Hydraulic Control Panel and in the 497.01 Analog Chassis.
  • Page 70 Adding an Analog Chassis to Your Console Jumper and switch The following graphic illustrates the jumper locations on the Model 497.36 locations Communication Module. Communication Module Jumper and Switch Locations Models FlexTest® IIm/GT/SE Controller Hardware Installation...

  • Page 71: Model 497.05 Hydraulic Control Panel

    Model 497.05 Hydraulic Control Panel Model 497.05 Hydraulic Control Panel The rear panel connectors of the hydraulic control panel are cabled to the hydraulic components of your system. The connectors also interface with the Model 497.01 Analog Chassis and Model 498.22 Test Processor chassis. J15C J15B J15A...

  • Page 72: Test Processor Plug-In Modules

    Test Processor Plug-in Modules Test Processor Plug-in Modules The following table provides a brief description of the plug-in modules installed in your test processor chassis. Test Processor Plug-In Modules ODULE UNCTION Processor Modules Standard FlexTest IIm Controllers have two processors installed in the Model 498.22 Chassis: •...
  • Page 73 Test Processor Plug-in Modules 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 74: Test Processor Transition Modules

    Test Processor Transition Modules Test Processor Transition Modules Transition modules are screwed into the back of the test processor chassis. Each rear-panel transition module corresponds to a plug-in module (or plug-in module mezzanine card) installed in the front of the chassis. Transition modules interface with the other test components via connectors for external digital, analog, and communication cables.
  • Page 75 Test Processor Transition Modules Test Processor Transition Modules RANSITION ODULE UNCTION 498 Analog Out This module includes eight BNC connectors that provide analog outputs from the Model 498.65 ADDA module. These outputs are associated with a D/A mezzanine card. Four analog outputs are available with the standard ADDA module.

  • Page 76: Ups Systems

    UPS Systems UPS Systems UPS Systems for FlexTest 60, 100, 200, and GT Controllers To provide an increased level of safety, such as needed to address current European Machinery Directive, any system using an FT60, FT100, FT200, or FTGT servo controller must have an acceptable Uninterruptable Power Supply (UPS) properly integrated into the system.

  • Page 77: Ups Systems For Flextest 40 And Flextest Se Servocontrollers

    UPS Systems for FlexTest 40 and FlexTest SE UPS Systems for FlexTest 40 and FlexTest SE Servocontrollers To provide an increased level of safety and to address current European Machinery Directive, any system using an FT40, or FTSE servo controller must have an acceptable Uninterruptible Power Supply (UPS) properly integrated into the system.

  • Page 78: Specifications-Ups Systems Used With Mts Controllers

    Specifications–UPS Systems Used with MTS The addition of a low battery warning relay contact out from the UPS will provide additional system safety protection by letting the controller know that the UPS battery is low. Specifications–UPS Systems Used with MTS Controllers Any UPS used with an MTS system must comply with these specifications.

  • Page 79: Ups Connections For The Model 493.73 Hpu Board (Ft60, Ft100, Ft200, Ftgt)

    UPS Connections for the Model 493.73 HPU Board UPS Connections for the Model 493.73 HPU Board (FT60, FT100, FT200, FTGT) The following drawing shows UPS connections for the Model 493.73 HPU board. Once connected, use your controller software to add UPS hardware resources and configure the various UPS options.

  • Page 80: Ups Connections For The Model 493.42 System Board (Flextest Se )

    UPS Connections for the Model 493.42 System UPS Connections for the Model 493.42 System board (FlexTest SE ) The following drawing shows UPS connections for the Model 493.42 System board. Once connected, you must use your controller software to configure the various UPS options.

  • Page 81: Flextest Gt Controller Connections

    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 82 Digital I/O Connections Workstation Connection Remote Station Controller Connection Service Connections Cabling and Programming Series 407 Controllers How to Provide Program to a Series 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 83: 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 84: Typical Cabling

    Typical Cabling Typical Cabling For additional cables, see “Cable Part Numbers” on page 85. Hydra ulic Power Unit Contr 039-713-7xx Workstation 051-996-8xx Servovalve 039-708-3xx 056-126-5xx Load Unit Control 056-126-4xx Actuator Manifold (HSM) Power Over MTS Sysrtems Corp Temp J39 Power Monitor 14000 Technologyu Dr.

  • Page 85: Cable Part Numbers

    Cable Part Numbers Cable Part Numbers System cables The following is a list of the most common cables, see the System Cable/Jumper Plug 493 Package Selection drawing (MTS PN 700-000-656) for the most current and additional cable part numbers. System Cables (part 1 of 2) †...
  • Page 86 Cable Part Numbers System Cables (part 2 of 2) LUG † ABLE ESCRIPTION ODULE UMPER UMBER * ONNECTOR HPU 505 or 24V PLC Pump (for more information see 039-713- 493.73 J25 039-713-301 “Hydraulic Configurations” on page 243) HSM 298.11 on/off 039-701- 493.74 J28 HSM Proportional 298.12...

  • Page 87: Model 493.40 I/O Carrier Connections

    Model 493.40 I/O Carrier Connections Model 493.40 I/O Carrier Connections Each Model 493.40 I/O Carrier module can include up to four mezzanine cards. Each installed mezzanine card is assigned a specific I/O Carrier module front panel connector (J4–J7 I/O). A hardware interface file (hwi) defines each type of module (and their associated mezzanine cards) and maps each module location for the system software.

  • Page 88: Sensor Connections

    Sensor Connections Sensor Connections Sensor connections require a conditioner mezzanine card be installed in the I/O Carrier module. The following conditioners can be installed: Note Model 493.21B Digital Universal Conditioners are not compatible with stand-alone FlexTest SE Controllers. • Model 493.21B Digital Universal Conditioner •...
  • Page 89 Sensor Connections Excitation and feedback signals are passed through to the transducer, as shown. T o/From J4 - J7 Conditioner + Excitation - Excitation To/From Guard Transducer + Feedback - Feedback If purchased as an option, a transducer ID module is located in the transducer cable.
  • Page 90 Sensor Connections LVDT connections An LVDT requires an AC conditioning mezzanine card. Backshell AC Sensor Inner (LVDT) Guard Transducer ID Module Remote Cal Remote Cal Data to ID ID Circuit Data from ID Sig Gnd Temposonics II The connection requires a DC conditioning mezzanine card. FROM TEMPOSONICS II RETURN...
  • Page 91 Sensor Connections Temposonics III The connection requires a DC conditioning mezzanine card. +24 V 493.74 AUX POWER +24 V Data Data FROM 493.40 CARRIER MODULE TEMPOSONICS III (TEMPOSONICS III SENSOR DAUGHTER BOARD) Clock Clock Models FlexTest® IIm/GT/SE Controller Hardware FlexTest GT Controller Connections...

  • Page 92: Model 493.21B (Duc B) Jumpers

    Model 493.21B (DUC B) Jumpers Force/strain sensor Force and strain sensors require a DC conditioning mezzanine card. connections Backshell Inner Guard DC Sensor -FBR Future Transducer ID Module +FBR Future -EXS Future +EXS Future Remote Cal Remote Cal Data to ID ID Circuit Data from ID Sig Gnd...

  • Page 93: Bridge Balance

    Model 493.21B (DUC B) Jumpers 4- or 8-wire Jumpers W2 and W3 establish the correct shunt calibration connections for 4- sensor cable wire and 8-wire sensor cables. The length of the sensor cable determines which type of cable is used. Short cables are typically 4-wire cables while long cables are typically 8-wire cables.

  • Page 94: Digital Universal Conditioner (Duc Bc) Switches

    Digital Universal Conditioner (DUC BC) Switches Excitation Jumpers W5 and W7 select the local (on board) or remote (through a cable) excitation sensor connection. • The local selection is used with 4-wire transducer connections. • The remote selection is used with 8-wire transducer connections. •...
  • Page 95 Digital Universal Conditioner (DUC BC) Switches 4- or 8-Wire Switches S1-1, S1-2, S1-3, and S1-4 establish the correct shunt calibration sensor cable connections for 4-wire and 8-wire sensor cables. The length of the sensor cable determines which type of cable is used. Short cables are typically 4-wire cables while long cables are typically 8-wire cables.
  • Page 96 Digital Universal Conditioner (DUC BC) Switches Bridge balance Switch S1-5 changes the offset of the bridge balance circuit. If the zero offset is too large when the sensor bridge is balanced, you should enable this feature (it adds a 100 kΩ resistor to the input of the conditioner preamp). Enabl Disable S1-5 OFF...

  • Page 97: Full-Range Digital Universal Conditioner (Frduc) Jumpers

    Full-Range Digital Universal Conditioner (FRDUC) Full-Range Digital Universal Conditioner (FRDUC) Jumpers The following jumpers are for the Model 493.25 Full-Range Digital Universal Conditioner. The jumpers are labeled W instead of X; the W jumpers are solder pads. The following jumper descriptions are from the 493.xx Module Setup configuration drawing (PN 049-336-301).
  • Page 98 Full-Range Digital Universal Conditioner (FRDUC) Excitation sense Jumpers W5 and W7 select the local (on board) or remote (through a cable) excitation sensor connection. • The local selection is used with 4-wire transducer connections. • The remote selection is used with 8-wire transducer connections. •...
  • Page 99 Full-Range Digital Universal Conditioner (FRDUC) Bridge balance R32 changes the offset of the bridge balance circuit. If the zero offset is too large when the sensor bridge is balanced, you should add an appropriately sized resistor. Default (No Resistor) Positive Offset Negative Offset Models FlexTest®...

  • Page 100: Sensor Cables

    Sensor Cables Sensor Cables A typical system is provided with a standard set of sensor cables as specified on the System Cable/Jumper Plug 493 Package Selection drawing (PN 700-000- 656). Refer to this drawing for the most current part numbers. Standard sensor cables do not have ID modules.

  • Page 101: Sensor Cable Part Numbers

    Sensor Cable Part Numbers Sensor Cable Part Numbers Sensor cables without See the System Cable/Jumper Plug 493 Package Selection drawing (PN 700-000- ID Module 656) for the most current sensor cable part numbers. Sensor Cables and Connectors ABLE ESCRIPTION ABLE ONNECTOR 120º...
  • Page 102 Sensor Cable Part Numbers Sensor cables with ID See the System Cable/Jumper Plug 493 Package Selection drawing (PN 700-000- Module 656) for the most sensor cable current part numbers. Each sensor includes a cable with an ID module built into it. Use a system cable to bridge the sensor cable to the rear panel of the controller chassis.

  • Page 103: Shunt Calibration/Bridge Completion Resistor Installation

    Shunt Calibration/Bridge Completion Resistor Shunt Calibration/Bridge Completion Resistor Installation On a typical system, shunt calibration and bridge completion resistor installation is completed on the I/O Carrier module. If you have purchased optional sensor cables with transducer ID modules, shunt calibration and bridge resistors are installed on these modules. I/O Carrier Module Shunt calibration The I/O Carrier module has a shunt calibration connector on its front panel that...
  • Page 104 I/O Carrier Module The following figures show three typical bridge configurations for a DC conditioner installed on an I/O Carrier module. Models FlexTest® IIm/GT/SE Controller Hardware FlexTest GT Controller Connections...
  • Page 105 I/O Carrier Module Models FlexTest® IIm/GT/SE Controller Hardware FlexTest GT Controller Connections...

  • Page 106: Transducer Identification Modules

    Transducer Identification Modules Transducer Identification Modules Transducer ID modules (located at the end of the sensor cable) are optional components that can store sensor calibration information just like a sensor calibration file. Since the calibration information stays with the sensors, transducer ID modules make it easier to change sensors.
  • Page 107 Transducer Identification Modules The following is the schematic diagram of the bridge balance and bridge completion circuit. Sensor ID Module Pre-amp Rcomp (R6) Rcomp (R7) -FBR Rcomp (R8) Vout Note For information about assigning sensors and saving data with Transducer ID Modules, see the MTS 793 Control Software manual. Models FlexTest®...

  • Page 108: Valve Connections

    Valve Connections Valve Connections The following types of valve connections are supported: • Single or dual Series 252 Servovalve(s) can be controlled with a Model 493.14 Valve Driver mezzanine card. • A Series 256 Servovalve can be controlled with a Model 493.15 3 Stage Valve Driver mezzanine card.
  • Page 109 Valve Connections Series 252 Servovalve The Series 252 Servovalve is a 2-stage servovalve. The Model 493.14 Valve connections Driver supports single or dual valve configurations. The following figure shows the connections at the valve driver and the connections between the valve and the valve driver.
  • Page 110 Valve Connections Series 256 Servovalve The Series 256 Servovalve is a 3-stage servovalve. The Model 493.15 Valve connections Driver supports the inner loop signals. The following figure shows the connections between the valve driver and the valve. To connect the valve to the I/ O Carrier module, see “Cable Part Numbers”...
  • Page 111 Valve Connections Series 257 Valve The Series 257 Servovalve is a 3-stage servovalve that requires a power driver. connections The Model 493.15 Valve Driver supports the inner loop signals. The following figure shows the connections between the valve driver and the valve. To connect the valve to the I/O Carrier module, see “Cable Part Numbers”...

  • Page 112: Multiple Universal Driver Connections

    Multiple Universal Driver Connections Multiple Universal Driver Connections For special applications, the Model 493.79 Multiple Universal Driver (MUD) board provides up to six drivers that can be used to drive standard 252 servovalves. Inputs to this board originate from a Model 493.46 D/A board on a Model 493.40 I/O Carrier Module.
  • Page 113 Multiple Universal Driver Connections Output connections Each valve driver output is an RJ50 connection that contains two valve drive output lines and a cable loss detection loop. Cable loss detection The cable loss detection wire loops out to the servovalve and back to the driver output allowing MUD board logic to detect a cable break or a cable disconnect at the MUD board output.

  • Page 114: Analog I/O Connections

    Analog I/O Connections Analog I/O Connections The Model 493.45 A/D and Model 493.46 D/A mezzanine cards are installed in the Model 493.40 I/O Carrier front panel module. A connection from the front panel mezzanine card to a rear panel BNC transition module allows easy access to the analog channels.

  • Page 115: Analog Inputs

    Analog I/O Connections Analog inputs The analog-to-digital mezzanine cards accommodate up to six analog input signals. Each A/D input signal must be within ±10 volts. From J4 - J7 Input 1 Analog Ground Input 2 Analog Ground Input 3 Input 4 Input 5 Input 6 •...
  • Page 116 Analog I/O Connections Model 493.77 Filter The following filter modules are available for board mounting at the BNC Modules connectors of a Model 493.77 Filtered Analog Input transition module: Filter Module Specifications SSEMBLY UMBER 047-774-401 Bessel 047-774-402 Bessel 047-774-403 Bessel 047-774-404 Bessel 047-774-405...
  • Page 117 Analog I/O Connections D/A Connections Digital-to-analog mezzanine cards support up to six program or readout signals to external devices. Each D/A signal is an analog output within ±10 volts. From External J4 - J7 Device Output 1 Output 2 Output 3 Output 4 Output 5 Output 6...
  • Page 118 Analog I/O Connections Cable specification The cable specifications apply to both the analog inputs and analog outputs. The cable from the front panel of the I/O Carrier module has the following specification: • 15-contact type D male EMI connector. • Backshell–EMI metallized plastic.

  • Page 119: Accelerometer Connections

    Accelerometer Connections Accelerometer Connections An accelerometer requires the Model 493.48 Acceleration mezzanine card (installed in a Model 493.40 I/O Carrier module) and the Model 493.78 Accelerometer Transition Board. • Each Model 493.48 Acceleration mezzanine card supports up to three accelerometers. •...
  • Page 120 Accelerometer Connections In the example shown below, the Acceleration Conditioner supports three accelerometers. The indicated three jumpers must be set on the I/O Carrier module. Analog Bus#1 X101 Analog Bus#2 X102 Analog Bus#3 X103 Analog Bus#4 X104 Analog Bus#5 X105 X201 X202 X203...

  • Page 121: Encoder Connections

    Encoder Connections Encoder Connections I/O Carrier module For an ADDA configuration using an I/O Carrier module, each encoder requires configuration installation of a Model 493.47 Encoder Interface mezzanine card on the Model 493.40 I/O Carrier board. The I/O Carrier connector is based on the location of the mezzanine card installed on the board of the I/O Carrier module.
  • Page 122 Encoder Connections Optional ADDA II For the optional ADDA II configuration, each encoder requires installation of a configuration Model 493.59 Universal Encoder mezzanine card on the Model 493.50 ADDA II 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 123: Remote Setpoint Adjust Connections

    Remote Setpoint Adjust Connections Remote Setpoint Adjust Connections A Remote Setpoint Adjust (RSA) control is an optional, stand-alone hardware device that uses an incremental or absolute encoder to control actuator setpoints. Each RSA control pod requires installation of a Model 493.47 Encoder Interface mezzanine card on the Model 493.40 I/O Carrier board.

  • Page 124: Adda Ii Connections

    ADDA II Connections ADDA II Connections Each optional Model 493.50 ADDA II module supports up to four mezzanine cards. Each installed mezzanine card is assigned a specific ADDA II module front panel connector (J11–J18). A hardware interface file (.hwi) defines each type of module (and their associated mezzanine cards) and maps each module location for the system software.
  • Page 125 ADDA II Connections 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.
  • Page 126 ADDA II Connections Analog inputs The analog-to-digital mezzanine cards accommodate up to eight analog input signals. Each A/D input signal must be within ±10 volts. • Analog inputs can be connected at the BNC connectors of a Model 493.81 Analog In transition module and the outputs from this module are connected to the Model 493.50 ADDA II module.
  • Page 127 ADDA II Connections D/A connections Digital-to-analog mezzanine cards support up to eight program or readout signals to external devices. Each D/A signal is an analog output within ±10 volts. • Each readout signal is from a 16 bit digital to analog converter. •...
  • Page 128 ADDA II Connections ADDA II Universal Each encoder requires a Model 493.59 Universal Encoder mezzanine card Encoder connections installed on the Model 493.50 ADDA II module. Up to four encoders can be connected to the Model 493.80 ADDA II Encoder Transition module when the Model 493.50 ADDA II module is fully populated with Universal Encoder cards.

  • Page 129: Emergency Stop Connections

    Emergency Stop Connections Emergency Stop Connections Connectors J23 E-STOP Out and J24 E-STOP In are located on the Model 493.73 HPU transition board. The Emergency Stop switch and signal are part of a controller-wide interlock system. Emergency Connector J23 E-STOP Out provides an output to external devices when an stop output emergency stop signal is generated.
  • Page 130 Emergency Stop Connections J24 E-STOP In is a 15 pin 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 131: J25 Hydraulic Power Unit Connection

    J25 Hydraulic Power Unit Connection J25 Hydraulic Power Unit Connection Connector J25 HPS on the Model 493.73 HPU transition board controls the hydraulic power unit (HPU). • The module produces 24 V logic signals to control the HPU. • The Model 493.07 HPU Converter Box allows any MTS HPU to be connected to the chassis with the following exceptions: –...
  • Page 132 J25 Hydraulic Power Unit Connection J25 Diagram 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...
  • Page 133 J25 Hydraulic Power Unit Connection System I/O Connector J54 Sys I/O provides three digital inputs and one digital output. The inputs are connected to the high and low inputs of an opto-isolator. The output is from the collector (+) and emitter (-). For circuit drawings, see the “Digital I/O Connections”...

  • Page 134: Station Connections

    Station Connections Station Connections Each Model 493.74 HSM transition board controls up to two stations. A standard chassis configuration supports up to four stations. Each station has the following connections • J28 Hydraulic service manifold (HSM) • J29 Load unit •...

  • Page 135: Proportional Output

    J28 Hydraulic Service Manifold Connector Proportional output The proportional output is configured with the controller software. • The output signal can be ramped from 20 mA (minimum) to 700 mA (maximum) which corresponds with 50 psi (0.4 MPa) and 3000 psi (21 MPa).

  • Page 136: J29 Load Unit

    J29 Load Unit J29 Load Unit Connector J29 Load Unit connects to the load unit lift/lock panel. Pins 1, 2, 3, and 4 can be +24 V DC configured for contacts (with Cross † jumpers X and X ) or a logic Head signal (without jumpers X Lock...

  • Page 137: J43 Interlock

    J43 Interlock J43 Interlock Connector J43 Interlock accommodates two general purpose inputs to be connected to the interlock chain. • Input 1 is dedicated as a station interlock. • Input 2 is dedicated as a program interlock. • Both inputs are optically isolated. •...

  • Page 138: J44 Run/Stop

    J44 Run/Stop J44 Run/Stop Run/Stop status Connector J44 Run/Stop provides the run/stop status of the controller to external devices. • Two form C contacts provide the run/stop status. • The contacts are rated 1.0 A at 30 V (AC or DC). From Chassis External Devices...
  • Page 139 J44 Run/Stop 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 140: J49 Auxiliary Power

    J49 Auxiliary Power J49 Auxiliary Power Connector J49 Aux Pwr provides +5 V DC, ±15 V DC, and 24 V DC from the chassis internal power supply to drive external high level conditioners, proximity switches, solenoids, and so forth. • The outputs are fused at 0.75 A to protect the power supply from an external short.

  • Page 141: Digital I/O Connections

    Digital I/O Connections Digital I/O Connections The Model 493.72 Digital I/O transition module has two connectors; one provides connections for sixteen digital inputs and the other provides connections for sixteen digital outputs. From From External Device 493.72 Digital Input External Device 493.72 Digital Output Channel 1 Output Channel 1 Input...

  • Page 142: Digital Inputs

    Digital I/O Connections Digital inputs The J3 In connector accommodates up to sixteen digital signals from external devices. You can use digital input signals to trigger test events with your controller applications. • All of the inputs are optically isolated and support relay contacts or logic inputs (see the following figure).

  • Page 143: Digital Outputs

    Digital I/O Connections Digital outputs Connector J4 Out provides sixteen general purpose digital outputs that can send digital logic signals to external switches or logic devices. • Minimum output current drive is 6 mA. Maximum output current drive is 20 Note The maximum output current can vary from unit to unit.
  • Page 144 Digital I/O Connections Digital I/O The digital inputs and outputs can be cabled to an optional digital I/O access box. access panel The box is a convenient way to wire digital sources and destination to the Model 493.72 Digital I/O transition module. 493.72 Digital I/O +12V...

  • Page 145: Workstation Connection

    Workstation Connection Workstation Connection The workstation computer is connected to the Model 498.96 Processor module installed in the VMEbus of the chassis. It is an Ethernet 10/100 Base-T connection. The workstation computer must have a dedicated Ethernet compatible connector. 498.98-2 Power PC Note If your processor has more than one Ethernet 10/100...
  • Page 146 Workstation Connection The symbol shown here indicates that you must not connect telecommunications equipment to the equipment showing this symbol. Several modules have connectors that look similar to a phone connector. Special cables are required. Installing telecommunications equipment cables can cause equipment damage to the electrical components of the chassis or to your telecommunications system.

  • Page 147: Remote Station Controller Connection

    Remote Station Controller Connection Remote Station Controller Connection The optional Remote Station Controller (RSC) module requires a Model 498.71B GRES III VMEbus module and a Model 493.71 Serial Interface transition module to be installed in the chassis. The RSC can be connected to any of the four J50 connectors of the serial interface.
  • Page 148 Remote Station Controller Connection Hwi file additions In order to use one or more RSCs with your Model 493.10 Chassis, two sections must be added 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, these...

  • Page 149: Service Connections

    Service Connections Service Connections The Model 493.10 Chassis can have several service connectors. There are two types of connectors: • The chassis connection monitors the power supply. • The connection on the I/O Carrier module monitors the output of each mezzanine card.
  • Page 150 Service Connections I/O Carrier service The J3 Service connector on the Model 493.40 I/O Carrier module provides the monitor output from each of the four I/O option cards installed. It is an 8-pin RJ- 45 connector. From External Daughter Device Boards Slot 1 Monitor Slot 1 Ground...

  • Page 151: Cabling And Programming Series 407 Controllers

    Cabling and Programming Series 407 Controllers Cabling and Programming Series 407 Controllers This section describes: • Cabling and programming the FlexTest GT Controller to analog program and feedback signals from a Series 407 Controller. • Connecting FlexTest GT Controllers to interlock signals from a Series 407 Controller.
  • Page 152 How to Provide Program to a Series 407 Controller Do not interrupt Model 493.10 Chassis power when you are programming another controller. A power interrupt may cause the external controller to react to a zero command and move the actuator unexpectedly. Ensure that power cannot be removed accidently while a test is in progress.
  • Page 153 How to Provide Program to a Series 407 Controller Multiple 407 Controller Connections Conditioner Conditioner Monitor Monitor 493.76 Filtered 493.76 Analog Out Program In Analog Input Analog Out Filtered In Ch 1 Ch 1 Ch 2 Ch 2 Ch 3 Ch 3 Conditioner Conditioner...
  • Page 154 How to Provide Program to a Series 407 Controller Use the Station Manager application to adjust the full scale, polarity, gain, and offset for the external controller channel (Display menu > Station Setup). If your station configuration includes sensor feedback, you can also adjust the full scale, gain, polarity, and offset of the incoming sensor signals, as well as limits.
  • Page 155 How to Provide Program to a Series 407 Controller D. On the 407 Controller, clear the hydraulic Interlock: – Press the Alt Function button. –Press the Reset button (“9” on the key pad). The Interlock indicator on the front panel should extinguish. On the 407 Controller, apply hydraulic pressure with the Hydraulic Pressure buttons.

  • Page 156: Connecting Interlock Signals To 407 Controllers

    Connecting Interlock Signals to 407 Controllers Connecting Interlock Signals to 407 Controllers The Model 793 Controller monitors digital I/O interlock signals through the Model 493.74 HSM transition module’s J43A and J43B connectors. Use these connectors when connecting to Model 407 Controllers. Model 493.74 HSM transition module connectors are as shown in the figure that follows.
  • Page 157 Connecting Interlock Signals to 407 Controllers How to jumper the The following figure shows how to cable the hydraulic terminal on a single hydraulic terminal on a station Model 407 Controller. single station Model 407 Controller 407 Controller No Connection Jumper Plug PN 049-635-901 Intlk...
  • Page 158 Connecting Interlock Signals to 407 Controllers Multiple 407 Controller The following figure shows how to cable interlocks for multiple Model 407 interlock connections Controllers to the Model 493.10 Chassis (via its Model 493.74 HSM transition module). Use the specified interlock cable (PN 056-455-0xx) to make these connections for each Model 407 Controller station.
  • Page 159 Connecting Interlock Signals to 407 Controllers How to connect The following figure shows how to cable hydraulic terminals on multiple station Model 407 Controllers, where each Model 407 Controller can run an independent hydraulic terminals on test program. Repeat this scheme for each additional Model 407 Controller. multiple station 407 Controllers 407 Controller...
  • Page 160 Connecting Interlock Signals to 407 Controllers Interlock connections The following figure shows how to cable interlocks when a master Model 407 for master/dependent Controller is daisy-chained with three other dependent Model 407 Controllers to 407 Controllers run a single test program on a FlexTest GT Controller (via its Model 493.74 HSM transition module).
  • Page 161 Connecting Interlock Signals to 407 Controllers 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 last dependent hydraulic terminals on controller in any daisy-chain must have jumper plugs installed in its Hyd Out master-dependent 407 and Intlk In terminals.

  • Page 162: Sending And Receiving Signals To A Model 407 Controller

    Sending and Receiving Signals to a Model 407 Sending and Receiving Signals to a Model 407 Controller After cabling the Model 407 Controller, you must configure it to receive and send signals from the FlexTest GT Controller. The tables below list typical menu settings.
  • Page 163 Sending and Receiving Signals to a Model 407 407 Amplitude Control Menu ARAMETER ETTING Ampl Cntrl Fdback — Mean — — Ampl AMC Gain — 407 Digital I/O Menu ARAMETER ETTING Din1 Definition Program in RUN RUN/STOP Din1 Din1Pol ACT HI Din2 Definition Hydraulic Interlock Din2...

  • Page 164: Connecting Interlock Signals To 458 Controllers

    Connecting Interlock Signals to 458 Controllers Connecting Interlock Signals to 458 Controllers FlexTest GT Controllers monitor digital I/O interlock signals through the Model 493.74 HSM transition module. Jumper Jumper 493.74 458.XX Transition Controller Jumper Run/Stop Program Interlock Cable (PN 056-455-2xx) Jumper 458.XX Controller...

  • Page 165: Eurotherm Temperature Controller Connection

    Eurotherm Temperature Controller Connection Eurotherm Temperature Controller Connection When equipped with a Model 498.71B GRES III plug-in module, your controller can program and control one or more Series 2200/2400 Eurotherm Temperature Controllers via the J50 serial connectors on a Model 493.71 Serial Interface transition module.
  • Page 166 Eurotherm Temperature Controller Connection Program the Use the Station Builder application to configure a Eurotherm temperature temperature controller controller. 498.71B 493.71 GRES III Serial Interface +12V J50A Use Jumper Plug 055-634-101 CLOCK OUT in these connectors. EVENT OUT EVENT IN J50B J3 IN J4 OUT...

  • Page 167: Miscellaneous Conditioner Output Connections

    Miscellaneous Conditioner Output Connections Miscellaneous Conditioner Output Connections The following table shows connector assignments for various MTS products you can use with your the Model 493.10 Chassis. Conditioning Sensors with Other MTS Products MTS P RODUCT ENSOR UTPUT Model 408.81 Testing Panel/ Sensor output is available at the rear-panel connector J201 Model 408.82 DC Conditioner or J202.

  • Page 168: Cabling For External Command Inputs

    Cabling for External Command Inputs Cabling for External Command Inputs Cabled properly, Model 793 Controllers can receive programming from an external controller. How to Enable and Run External Command Inputs 1. Cable the controllers. Cable the external programmer analog out connector to a Model 493.75 Analog In module BNC connector.

  • Page 169: Cabling And Using External Readout Devices

    Cabling and Using External Readout Devices Cabling and Using External Readout Devices Cabled appropriately, your controller can send station signals to external readout devices such as oscilloscopes and digital-volt-meters. You define which signal is sent to the readout device using the Station Setup window’s Readout panel. For more information, see “Working with Readout Devices”...
  • Page 170 Cabling and Using External Readout Devices 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 171: How To Send Signals To External Readout Devices

    How to Send Signals to External Readout Devices How to Send Signals to External Readout Devices 1. Cable your controller to the readout device. Cable your FlexTest IIm analog output connector to the readout device. Analog I/O connectors are located on the rear of the test processor chassis. Connect an external readout device analog input to a BNC connector on a Model 493.76 Analog Out module.

  • Page 172: Multi-Box I/O Module

    Multi-Box I/O Module Multi-Box I/O Module The optional Model 493.43 Multi-Box I/O module allows multiple controllers to share a master hardware synchronization clock and pass station interlock state information between each other. In addition, this front panel module also provides user station interlock inputs and outputs. Module features •...

  • Page 173: J9 Interlock Out

    J9 Interlock OUT 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. J9 Interlock OUT Connector J9 Interlock OUT provides four station interlock outputs that can be connected to a multiple MTS controller box interlock chain.

  • Page 174: J51 Box In

    J51 Box In J51 Box In The J51 Box In connector provides an interface for connecting multiple MTS controller boxes together to allow sharing of station interlock status and a master synchronization clock. Box In +clk in /intlk in 1 /intlk in 2 signal return /intlk in 3...

  • Page 175: J52 Box Out

    J52 Box Out J52 Box Out The J52 Box Out connector provides an interface for connecting multiple MTS controller boxes together to allow sharing of station interlock status and a master synchronization clock. J52 Box Out +clk in /intlk out 1 /intlk out 2 /intlk out 3 /intlk out 4...
  • Page 176 J52 Box Out Models FlexTest® IIm/GT/SE Controller Hardware FlexTest GT Controller Connections...

  • Page 177: Flextest Iim Controller Connections

    Chapter 4 FlexTest IIm Controller Connections Note For information on connecting power cables, see “Connecting the Console and Chassis Power” on page 61. Note For information about CE compliance, see “CE EMC Compliant Cabling” on page 83. Contents Workstation Connection Sensor and Valve Connections ADDA Module Connections Hydraulic Connections...

  • Page 178: Workstation Connection

    Workstation Connection Workstation Connection Connect the computer’s network interface card to the 10/100 BaseT connector on the front panel of the processor installed in slot 1. Processor 24x1 Processor PN 051-996-803 Models FlexTest® IIm/GT/SE Controller Hardware FlexTest IIm Controller Connections...

  • Page 179: Sensor And Valve Connections

    Sensor and Valve Connections Sensor and Valve Connections The Model 497.01 Analog Chassis connectors J101 through J1601 are 15-pin D- type connectors located on the chassis rear panel. They connect either a valve driver to a servovalve or a conditioner to a transducer. Connectors J102 through J1602 provide a second connection for dual conditioners, dual valve drivers, or three-stage valve drivers.
  • Page 180 Sensor and Valve Connections AC sensor connection AC Sensor (LVDT) Inner Guard DC sensor connection 4-wire connections are the Drain Outer most common. An 8-wire Shield Braid connection is typically used Inner for long cables. Guard The additional wires for an DC Sensor 8-wire connection are -FBR...
  • Page 181 Sensor and Valve Connections Single-valve connection + Valve Command 1 – Valve Command 1 Dual-valve connection Shown for valves phased the same hydraulically. For valves phased opposite hydraulically, reverse A and D on P2. + Valve Command 1 – Valve Command 1 Models FlexTest®...
  • Page 182 Sensor and Valve Connections Sample control The following figure illustrates sample connections to a sensor and a servovalve. channel DC Conditioner Valve Driver AC Conditioner Signals Signals Signals J1401 J1301 J601 J501 J201 J101 Force Force (load sensor) Valve Valve LVDT LVDT (displacement sensor) Model 497.01 Analog Chassis Rear Panel...

  • Page 183: Adda Module Connections

    ADDA Module Connections ADDA Module Connections In order to process A/D and D/A signal conversion, you must connect your Model 497.01 Analog Chassis to your Model 498.65 ADDA plug-in module. The following graphic illustrates the connections for a Model 497.01 Analog Chassis containing four AC conditioners, dual DC conditioners, and valve drivers.

  • Page 184: Adda Ii Connections

    ADDA II Connections ADDA II Connections Each optional Model 493.50 ADDA II module supports up to four mezzanine cards. Each installed mezzanine card is assigned a specific ADDA II module front panel connector (J11–J18). A hardware interface file (.hwi) defines each type of module (and their associated mezzanine cards) and maps each module location for the system software.
  • Page 185 ADDA II Connections Note The external analog source can be a stand-alone function generator, another controller, or a computer controlled analog output. External Analog Source Select Waveform Breakpt +100% FS 5 - 05% Normal Full Scale 410.81 Invert Function +100% FS Generator Control Mode Output Mode...
  • Page 186 ADDA II Connections Analog inputs The analog-to-digital mezzanine cards accommodate up to eight analog input signals. Each A/D input signal must be within ±10 volts. • Analog inputs can be connected at the BNC connectors of a Model 493.81 Analog In transition module and the outputs from this module are connected to the Model 493.50 ADDA II module.
  • Page 187 ADDA II Connections D/A connections Digital-to-analog mezzanine cards support up to eight program or readout signals to external devices. Each D/A signal is an analog output within ±10 volts. • Each readout signal is from a 16 bit digital to analog converter. •...
  • Page 188 ADDA II Connections Up to sixteen encoders can be connected to the Model 493.80 ADDA II Encoder Transition module when the Model 493.50 ADDA II module is fully populated with Universal Encoder cards. To/From Encoder Transition Module Return Gnd Index Ser Clk Input 4 B/Interrogate A/Serial Dat a...

  • Page 189: Hydraulic Connections

    Hydraulic Connections Hydraulic Connections You must connect your external hydraulic equipment to the Model 497.05 Hydraulic Control Panel. The FlexTest IIm hardware supports control of up to four hydraulic stations simultaneously. Hydraulic Power Unit J28C J28B J28D J28A FlexTest IIm Hydraulic Connections Models FlexTest®...

  • Page 190: Hpu Connections

    HPU Connections HPU Connections T o/From To/From Connector J25 497.05 controls the hydraulic power unit. Interlock 1 Interlock 2 HPS Ground Hyd Interlock Reset HPU Interlock Common HPU Power HPU Start Interlock 3 HPU High + Defeat HPU Common Voltage (Common) HPU Defeat +24 V Cable specification...

  • Page 191: Hsm Connections

    HSM Connections HSM Connections The outputs provide 24 V DC to turn on the HSM solenoids. Connector J28 controls the From To HSM low-pressure and high- Hydraulic I/O Solenoids pressure solenoids of a hydraulic service manifold. Low Pressure DC Common High Pressure Cable specification •...

  • Page 192: Interlock Connections

    Interlock Connections Interlock Connections Remote Interlock J52 (Jumper Plug, Inputs (3 for each 497.05 Hydraulic (046-350-701) hydraulic channel) Control Panel E-Stop 047-807-8xx 046-350-602 497.01 Analog Chassis 051-074-601 051-074-501 498.71B 24X1 24X1 498.65 System GLOBAL Digital DIGITAL I/O Processor Processor RESOURCES ADDA TRANSITION MODULE...

  • Page 193: Interlock Jumper Plugs

    Interlock Jumper Plugs Interlock Jumper Plugs Several jumper plugs must be installed to maintain the integrity of the interlock chain. Each jumper plug represents a place where you can add a custom connection to the interlock chain. Model 497.05 Any interlocks connected to the hydraulic control panel will generate a hydraulic Hydraulic Control interlock which shuts down the hydraulic power supply.
  • Page 194 Interlock Jumper Plugs The interlock connectors require jumpers under the following conditions: • If you do not use the external hydraulic/program interlocks on any of the D- 15S connectors (J3A Sta 1, J3B Sta 2, J3C Sta 3, and J3D Sta 4). Use an external jumper plug (PN 052-750-501) on each connector not used.

  • Page 195: Serial Communications

    Serial Communications Serial Communications Each chassis communicates with each other through a serial communications cable. Model 497.05 Hydraulic Control Panel 046-350-902 Model 497.01 Analog Chassis Debug 498.71B 498.65 24X1 24X1 GLOBAL 056-027-101 ADDA Processor Processor RESOURCES Model 498.22 Test Processor MOTOROLA Models FlexTest®...

  • Page 196: Digital I/O Connections

    Digital I/O Connections Digital I/O Connections Digital I/O hardware enables two-way communication between your test and external logic devices. This transition module This transition module provides user DIGITAL I/O reserves system DIO. digital I/O the built-in digital I/O System TRANSITION Digital MODULE +5V +12V...
  • Page 197 Digital I/O Connections Digital inputs • Digital inputs can be wired to allow the input from a switch contact, a relay contact, or a logic signal. • All digital inputs are optically isolated at the Series 498 Digital I/O transition module. •...
  • Page 198 Digital I/O Connections This shows how to Digital I/O 498 Digital I/O connect an external Access Panel Transition Module switch or a set of relay +12 VDC contacts to channel 1 of J1 - 2 the digital inputs. Opto- Coupler +CH1 External Device -CH1...

  • Page 199: Connector Pinouts

    Digital I/O Connections Digital outputs • Digital outputs provide an optically isolated open collector/open emitter output. • The digital outputs are controlled by the Digital Output process in the MultiPurpose TestWare application. They can also be controlled manually in the Station Manager application. •...

  • Page 200: Encoder/Temposonics Connections

    Encoder/Temposonics Connections Encoder/Temposonics Connections Encoders and Temposonics sensors are connected to the FlexTest IIm controller in a similar way. Each type of sensor requires a different jumper configuration on the Model 498.65 Transition Module and a different mezzanine card for the 498.65 ADDA Module.

  • Page 201: Jumper Configurations

    Encoder/Temposonics Connections Jumper configurations The Series 498 transition module can be configured for a Temposonics sensor, a 5 V DC encoder, a 12 V DC encoder, a 24 V DC encoder. The following is a list of the configuration drawings: •...
  • Page 202 Encoder/Temposonics Connections The Model 493.80 Encoder Transition module provides up to four channels of encoder interface between the Model 493.50 ADDA II module and various incremental, Temposonics, or other digital and serial data transducers. Daughter Board 1 Daughter Board 2 Daughter Board 3 Daughter...

  • Page 203: Remote Station Controller (Rsc) Connections

    Remote Station Controller (RSC) Connections Remote Station Controller (RSC) Connections When equipped with a GRES III plug-in module and a corresponding Series 498 RS-485 transition module, your FlexTest IIm controller can accommodate up to four remote station controllers (one RSC for each station).

  • Page 204: Cabling And Programming External Controllers

    Cabling and Programming External Controllers Cabling and Programming External Controllers Cabled properly, you can use your FlexTest controller to send test commands to another controller. For detailed setup information, see “How to Program an External Controller” on page 204. When programming Series 2200 and 2400 Eurotherm temperature controllers, the FlexTest IIm controller supports a special serial connection and software setup.
  • Page 205 How to Program an External Controller 2. If you will monitor sensor feedback for data acquisition or control feedback, connect the external conditioner output to a Series 498 Input Filter connector. For conditioner output locations on various MTS devices, see “Sample conditioner output connections”...
  • Page 206 How to Program an External Controller Note Analog I/O connectors are located on the rear panel of the Series 498 test processor chassis. 1. Connect a 493.82 Analog Out BNC connector to the external controller program (analog) input. 2. If you will monitor sensor feedback for data acquisition or control feedback, connect the external conditioner output to a 493.83 Filtered Analog Input BNC connector.
  • Page 207 How to Program an External Controller Sample conditioner This table shows connector assignments for various MTS products you can use output connections 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 J201 Model 408.82 DC Conditioner or J202.
  • Page 208 How to Program an External Controller For mroe information, see “How to Configure an Externally Conditioned Feedback Signal” in the MTS 793 Control Software manual. Task 3 Set up your program. Define a program with the Function Generator, Basic TestWare, or Multipurpose TestWare applications.

  • Page 209: Programming Eurotherm Temperature Controllers

    Programming Eurotherm Temperature Controllers Programming Eurotherm Temperature Controllers When equipped with a GRES III plug-in module, your FlexTest IIm controller can program and control one or more Series 2200/2400 Eurotherm Temperature Controllers via the J50 serial connectors on the Series 498 RS-485 transition module.

  • Page 210: Cabling For External Command Inputs

    Cabling for External Command Inputs Cabling for External Command Inputs Cabled properly, your FlexTest controller can receive programming from an external controller. How to Enable and Run External Command Inputs To enable an external command source, perform the following: “Cable the controllers.” on page 211.
  • Page 211 How to Enable and Run External Command Inputs Task 1 Cable the controllers. Cable the external programmer analog out connector to a Series 498 Input Filter connector. Analog I/O connectors are located on the rear of the test processor chassis. Note If you cable the hardware before you create a station configuration file, note the connector you use on the FlexTest IIm rear console.
  • Page 212 How to Enable and Run External Command Inputs Task 3 Adjust the command signal with Station Manager. For more information, see “How to Enable and Run External Command Inputs” in the MTS 793 Control Software manual. Task 4 Start the External Command. For more information, see “How to Enable and Run External Command Inputs”...

  • Page 213: Cabling And Using External Readout Devices

    Cabling and Using External Readout Devices Cabling and Using External Readout Devices Cabled appropriately, your FlexTest controller can send station signals to external readout devices such as oscilloscopes and digital-volt-meters. You define which signal is sent to the readout device with the Adjust Readouts window. For a diagram and description of signals available to the station, refer to “Station signal descriptions”...
  • Page 214 How to Send Signals to External Readout Devices Task 1 Cable your controller to the readout device. Cable your FlexTest IIm analog output connector to the readout device. Analog I/ O connectors are located on the rear of the test processor chassis. Connect a Series 498 Analog Out connector to the external readout device analog input.
  • Page 215 How to Send Signals to External Readout Devices Task 2 Create a readout channel with Station Builder. For more information, see “How to Create a Readout” in the MTS 793 Control Software manual. Task 3 Adjust the readout signal in Station Manager. Use the Station Manager application to adjust the readout signal.

  • Page 216: Cable Part Numbers

    Cable Part Numbers Cable Part Numbers Refer to the following table for cable part numbers used to connect test hardware to the Model 497.01 Analog Chassis rear-panel connectors. ESCRIPTION ABLE UMBER Load cell, 661.xx w/MS connector 046-440-6XX Load cell, 661.xx w/PT connector 046-440-2XX Strain w/PT connector 050-120-0XX...

  • Page 217: Flextest Se Controller Connections

    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 53. Note For information about CE compliance, see “CE EMC Compliant Cabling” on page 83.

  • Page 218: Stand-Alone Cabling Overview

    Stand-alone Cabling Overview Stand-alone Cabling Overview Models FlexTest® IIm/GT/SE Controller Hardware FlexTest SE Controller Connections...

  • Page 219: Automated Cabling Overview

    Automated Cabling Overview Automated Cabling Overview Models FlexTest® IIm/GT/SE Controller Hardware FlexTest SE Controller Connections...

  • Page 220: Multiple Controller Connections

    Multiple Controller Connections 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 PC. •...
  • Page 221 Multiple Controller Connections Note The indicated cables on each controller must be connected before the controllers are turned on. Master 056-316-0xx Dependent 1 Box Out 056-316-0xx Jumper Plug 100-057-246 Dependent 2 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 222: Interlock Function

    Multiple Controller Connections Interlock function Power must be applied to all controllers in the chain for proper interlock operation. If power is not applied to any one of the controllers, you will not be able to clear an interlock condition in any of the controllers. Also, if a cable becomes disconnected from a dependent controller’s Box In connector, or if a cable is inadvertently connected to the Box In connector on the master controller, an interlock is set which cannot be reset until all controllers are...

  • Page 223: Cable Part Numbers

    Cable Part Numbers Cable Part Numbers System cables The following is a list of the most common cables, see the System Cable/Jumper Plug 493 Package Selection drawing (MTS PN 700-000-656) for the most current and additional cable part numbers. Model 493.02 Chassis Cables †...
  • Page 224 Cable Part Numbers -XX specifies cable length. –01 through –09 represent 10–50 ft. in 5 ft. increments. Higher numbers represent custom cable lengths † Jumper plugs are required if a cable is not installed. ‡ The connector is the 10/100 BaseT connector on the power PC module. Sensor cables “Sensor Cables”...

  • Page 225: Model 493.40 I/O Carrier Connections

    Model 493.40 I/O Carrier Connections Model 493.40 I/O Carrier Connections For more information, see “Model 493.40 I/O Carrier Connections” on page 87. Automated option Automated FlexTest SE Controllers are designed to be used with a PC, MTS 793 software, and various types of support files, including a hardware interface file (.hwi) file.

  • Page 226: Sensor Connections

    Sensor Connections Sensor Connections “Sensor Connections” on page 88. “Sensor Cables” on page 100. “Shunt Calibration/Bridge Completion Resistor Installation” on page 103. “Transducer Identification Modules” on page 106. Valve Connections “Valve Connections” on page 108. “Series 252 Servovalve connections” on page 109. “Series 256 Servovalve connections”...
  • Page 227 Analog I/O Connections A/D connections The analog-to-digital mezzanine cards accommodate up to six analog input signals. • Each A/D input signal must be within ±10 volts. From J4 - J7 Input 1 Analog Ground Input 2 Analog Ground Input 3 Input 4 Input 5 Input 6...

  • Page 228: Cable Specification

    Encoder Connections D/A connections Digital-to-analog mezzanine cards support up to six program or readout signals to external devices. • Each D/A signal is an analog output within ±10 volts. From External J4 - J7 Device Output 1 Output 2 Output 3 Output 4 Output 5 Output 6...

  • Page 229: Workstation Connection

    Workstation Connection Workstation Connection The workstation computer is connected to the processor module installed in the VMEbus of the chassis. It is an Ethernet 10/100 Base-T connection. The workstation computer must have an Ethernet compatible connector. RUN 6TS BFL TYPE E PC-MIP DEBUG TYPE E PC-MIP PCI MEZZANNE CARD...

  • Page 230: 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 Model 493.02 Chassis. • Provides box-in and box-out, analog and digital I/O, E-Stop, and HSM and HPU control.

  • Page 231: J28 Hydraulic Service Manifold Connector

    J28 Hydraulic Service Manifold Connector Cable specification The J25 HPU and J51 Box In connectors are 15 pin type D male connectors. • 15 contact type D female EMI connector. • Cable—24 AWG, 10 conductor with braided shield with drain wire connected to metallized plastic backshell to the chassis.

  • Page 232: J29 Emergency Stop Connections

    J29 Emergency Stop Connections J29 Emergency Stop Connections Connector J29 E-STOP provides an output to external devices when an emergency stop signal is generated. This connector may also be used with an external E-stop. J29 Connector Pin Assignments UNCTION xhead 24V Fused +24V xhead intlk com 24V common...

  • Page 233: J43 Interlock

    J43 Interlock Jumper plug required If connector J29 is not used, you must install a jumper plug to maintain the integrity of the interlocks. Use jumper plug PN 100-007-947B or jumper pins: 3- 4, 5-7, 8-13. J43 Interlock Connector J43 Interlock contains one optically isolated interlock input and one relay contact interlock output.

  • Page 234: J49 Auxiliary Power

    J49 Auxiliary Power Jumper plug required If connector J43 is not used, you must install a jumper plug to maintain the integrity of the interlocks. Use jumper plug PN 100-057-245, or jumper pins: 1-2, 3-4. J49 Auxiliary Power “J49 Auxiliary Power” on page 140.

  • Page 235: J52 Box Out

    J52 Box Out J52 Box Out Connector J52 Box Out allows the Model 493.02 Chassis to send clock, hydraulic, and interlock signals to another Model 493.02 Chassis. J52 Connector Pin Assignments UNCTION +clk in +External clock output hyd high out Hydraulic high output reset out Interlock reset request output...

  • Page 236: J54 Digital Inputs

    J54 Digital Inputs J54 Digital Inputs Connector J54 Dig In accommodates up to three digital signals from external devices. You can use digital input signals to trigger test events with your controller applications. • All of the inputs are optically isolated. •...

  • Page 237: J55 Digital Outputs

    J55 Digital Outputs J55 Digital Outputs Connector J55 Dig Out provides three general purpose digital outputs that can send digital logic signals to external switches or logic devices. • The digital output relays are rated for a maximum of 1 Amp max, 30 V DC/ AC max.
  • Page 238 J55 Digital Outputs Stand-alone mode 1. Press Setup on the console front panel menu. 2. Scroll down the Setup menu to Digital Output 1. 3. Press the button next to Digital Output 1. 4. Press the button next to Assignment until the state Run/Stop is shown. 5.

  • Page 239: Eurotherm Temperature Controller Connection

    Eurotherm Temperature Controller Connection Eurotherm Temperature Controller Connection Automated FlexTest SE Controllers can program and control a single Eurotherm temperature controller. Note Stand-alone FlexTest SE Controllers are not equipped for use with temperature controllers. To use a temperature controller with a FlexTest SE Controller: 1.
  • Page 240 Eurotherm Temperature Controller Connection Cabling the Two cables and an RS 232/RS 485 converter are required to connect the FlexTest temperature controller SE Controller to a temperature controller, as shown. Debug Serial Port 100-112-652 Eurotherm Temperature RS232/RS485 Controller Converter 056-719-6xx (651 Chamber) (100-112-820) 409.83...

  • Page 241: Debug Serial Port

    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.) Models FlexTest®...
  • Page 242 Eurotherm Temperature Controller Connection To add the resource, select the Miscellaneous tab and select 1 for temperature controllers, then save the file. The application automatically adds the required information in the proper syntax to the text in the hardware interface file. Adding a temperature After updating the hardware interface file, you must add a temperature control control channel to the...

  • Page 243: Hydraulic Configurations

    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 For jumpering information, see Appendix B: Model 493.07 Converter Box...
  • Page 244 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 245: Compatible Controllers

    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 246: Model 493.02 Chassis Multiple Controller Interconnections

    Model 493.02 Chassis Multiple Controller Model 493.02 Chassis Multiple Controller Interconnections FlexTest SE Controllers support the following hydraulic interconnections for multiple controller configurations: • Independent HSM control with no HPU • Independent HSM control with a shared HPU • Shared HSM with an HPU •...

  • Page 247: Independent Hsm (Shared Hpu)

    Independent HSM (shared HPU) Independent HSM (shared HPU) Power Type = HPU/HSM Power Type = HPU/HSM FlexTest SE FlexTest SE Interlock/Hydraulics reset reset 056-316-0xx Emergency Stop enter Emergency Stop enter cancel cancel Monitor 1 Monitor 2 Monitor 1 Monitor 2 J28 HSM J25 HPU 056-126-4xx...

  • Page 248: Shared Hsm (No Hpu)

    Shared HSM (no HPU) For this multiple controller configuration: • The HSM and HPU are connected to one controller only. • Select HPU/HSM for Power Type on the controller to which the HSM and HPU is connected. Path: Config > Edit Hardware > Power Options > Power Type > HPU/ •...

  • Page 249: Independent Hsm With Hpu (First On-Last Off)

    Independent HSM with HPU (First On-Last Off) Independent HSM with HPU (First On-Last Off) Note This interconnect option is only available for controllers on the same interlock. Power Type = Auto. HPU/HSM Power Type = HSM Only Interlock/Hydraulics FlexTest SE FlexTest SE reset reset...
  • Page 250 Independent HSM with HPU (First On-Last Off) Models FlexTest® IIm/GT/SE Controller Hardware Hydraulic Configurations...

  • Page 251: Appendix B Model 493.07 Converter Box

    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 252 Note If the Model 493.10 Chassis is the only device connected to the HPU, the jumper settings do not matter. OMPATIBLE WITH UMPERS Model 458.05/.10/.20/.40 Standard jumper setting: Model 490.01 E10–E11install Model 497.05 E12–E13 install E14–E15 install E16–E17 install E10–E13 remove E14–E17 remove Model 413.05 Jumper change required:...

  • Page 253: Chassis Maintenance

    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 254 Chassis Maintenance Models FlexTest® IIm/GT/SE Controller Hardware...

  • Page 255: Optional Station Configurations

    6-Station Configuration Appendix D Optional Station Configurations This section describes how to configure your Model 493.10 Chassis (FlexTest GT Controllers) to support an optional six or eight stations. When configuring your system for a six or eight stations you must consider the following: •...

  • Page 256: 8-Station Configuration

    8-Station Configuration 8-Station Configuration The 8-Station configuration can provide eight channels of control. A typical 8-Channel/8-Station configuration requires 16 Digital Universal Conditioners and 8 two-stage valve drivers. HSM power limits 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 257: Index

    Index Numerics ADDA cabling connections daughter boards 252 servovalve,I/O carrier connection 109, 226, analog chassis (497.01) 256 servovalve,I/O carrier connection adding to console 257 servovalve,I/O carrier module connection chassis slots 407 controller,programming to receive, send signals modules 493.07 HPU Converter analog I/O 493.10 chassis cable specifications 118,...
  • Page 258 cables conditioner jumpers (DUC) CE ECM compliant ± shunt cal E-stop 4/8 wire sensor cable 93, 95, fabrication active guard 92, 94, HPU connector 131, bridge balance 93, 96, part number list 85, excitation sense 94, 96, sensor single-ended excitation 94, 96, system conditioners cabling...
  • Page 259 digital I/O connections digital I/O access panel digital I/O connections force/strain sensor digital I/O transition module I/O carrier connection J3 In connector front panel J4 out connector function generation digital inputs cable specification J3 In connector J54 Dig In connector digital inputs, connections digital outputs cable specification 143,...
  • Page 260 I/O carrier module jumpers 252 servovalve connection 109, 226, ± shunt cal 256 servovalve connection 4/8 wire sensor cable 93, 95, 257 servovalve connection 498 System Digital I/O accelerometer connection 119, active guard 92, 94, analog I/O cable specifications 118, bridge balance 93, 96, analog I/O connection 114, digital I/O transition module...
  • Page 261 power specifications UPS requirements 493.10 chassis 23, 27, power cabling 53, sensor cables power connections 493.10 chassis stand alone configuration pressure control standard configurations, FlexTest IIm Controller programming station connections Eurotherm temperature controller station signals receiving from external controllers available for monitoring 169, sending to external controllers descriptions external readout of 171,...
  • Page 262 valve dual-valve connection single-valve connection VME bus VMEbus installing modules VMEbus modules description descriptions installing 43, workstation connection 145, Index Models FlexTest® IIm/GT/SE Controller Hardware...
  • Page 264 MTS Systems Corporation 14000 Technology Drive Eden Prairie, Minnesota 55344-2290 USA Toll Free Phone: 800-328-2255 (within the U.S. or Canada) Phone: 952-937-4000 (outside the U.S. or Canada) Fax: 952-937-4515 E-mail: info@mts.com Internet: www.mts.com ISO 9001 Certified QMS...
Save PDF