Trademark informationMTS, Temposonics, FlexTest, and TestWare are registered trademarks of MTS
Systems Corporation within the United States; AeroPro, MPT, Station Builder,
Station Manager, and TestStar are trademarks of MTS Systems Corporation
within the United States. These trademarks may be protected in other countries.
Microsoft and Windows are registered trademarks of Microsoft Corporation. All
other trademarks or service marks are property of their respective owners.
The manuals supplied by MTS provide most of the information you need to use
and maintain your equipment. If your equipment includes software, look for
online help and README files that contain additional product information.
If you cannot find answers to your technical questions from these sources, you
can use the internet, e-mail, telephone, or fax to contact MTS for assistance.
MTS provides a full range of support services after your system is installed. If
you have any questions about a system or product, contact Technical Support in
one of the following ways.
www.mts.comThe web site provides access to our technical support staff by means of an online
form:
www.mts.com > Contact MTS > Service & Technical Support button
E-mailtech.support@mts.com
TelephoneMTS Call Center 800-328-2255
Weekdays 7:00 A.M. to 5:00 P.M., Central Time
Fax952-937-4515
Please include “Technical Support” in the subject line.
Outside the U.S.For technical support outside the United States, contact your local sales and
service office. For a list of worldwide sales and service locations and contact
information, use the Global MTS link at the MTS web site:
www.mts.com > Global MTS > (choose your region in the right-hand
column) > (choose the location closest to you)
MTS FlexTest® Models 40/60/100/200 Controller HardwareTechnical Support
7
Technical Support
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
number and system
number
Know information from
prior technical
The site number contains your company number and identifies your equipment
type (such as material testing or simulation). The number is typically written on a
label on your equipment before the system leaves MTS. If you do not know your
MTS site number, contact your sales engineer.
Example site number: 571167
When you have more than one MTS system, the system job number identifies
your system. You can find your job number in your order paperwork.
Example system number: US1.42460
If you have contacted MTS about this problem before, we can recall your file
based on the:
assistance
•MTS notification number
•Name of the person who helped you
Identify the problemDescribe the problem and know the answers to the following questions:
•How long and how often has the problem occurred?
•Can you reproduce the problem?
•Were any hardware or software changes made to the system before the
For a computer problem, have the following information available:
•Manufacturer’s name and model number
•Operating software type and service patch information
•Amount of system memory
•Amount of free space on the hard drive where the application resides
•Current status of hard-drive fragmentation
•Connection status to a corporate network
For software application problems, have the following information available:
•The software application’s name, version number, build number, and (if
available) software patch number. This information can typically be found
in the About selection in the Help menu.
•The names of other applications on your computer, such as:
–Anti-virus software
–Screen savers
–Keyboard enhancers
–Print spoolers
–Messaging applications
If You Contact MTS by Phone
A Call Center agent registers your call before connecting you with a technical
support specialist. The agent asks you for your:
•Site number
•Name
•Company name
•Company address
•Phone number where you can be reached
If your issue has a notification number, please provide that number. A new issue
will be assigned a unique notification number.
MTS FlexTest® Models 40/60/100/200 Controller HardwareTechnical Support
9
Technical Support
Identify system typeTo 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
•Hydromechanical material test system
•Vehicle test system
•Vehicle component test system
•Aero test system
Be prepared to
troubleshoot
Write down relevant
information
After you callMTS logs and tracks all calls to ensure that you receive assistance for your
Prepare to perform troubleshooting while on the phone:
•Call from a telephone close to the system so that you can implement
suggestions made over the phone.
•Have the original operating and application software media available.
•If you are not familiar with all aspects of the equipment operation, have an
experienced user nearby to assist you.
In case Technical Support must call you:
•Verify the notification number.
•Record the name of the person who helped you.
•Write down any specific instructions.
problem or request. If you have questions about the status of your problem or
have additional information to report, please contact Technical Support again and
provide your original notification number.
Use the Problem Submittal Form to communicate problems with your software,
hardware, manuals, or service that are not resolved to your satisfaction through
the technical support process. The form includes check boxes that allow you to
indicate the urgency of your problem and your expectation of an acceptable
response time. We guarantee a timely response—your feedback is important to
us.
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)
Technical Support
MTS FlexTest® Models 40/60/100/200 Controller HardwareTechnical Support
Safety first!Before you use your MTS product or system, read and understand the safety
information provided with your system. Improper installation, operation, or
maintenance can result in hazardous conditions that can cause severe personal
injury or death, or damage to your equipment and specimen. Again, read and
understand the safety information provided with your system before you
continue. It is very important that you remain aware of hazards that apply to your
system.
Other MTS manualsIn addition to this manual, you may receive additional manuals in paper or
electronic form.
You may also receive an MTS System Documentation CD. It contains an
electronic copy of the manuals that pertain to your test system, such as:
•Hydraulic and mechanical component manuals
•Assembly drawings
•Parts lists
•Operation manual
•Preventive maintenance manual
Controller and application software manuals are typically included on the
software CD distribution disc(s).
The following paragraphs describe some of the conventions that are used in your
MTS manuals.
Hazard conventionsHazard notices may be embedded in this manual. These notices contain safety
information that is specific to the activity to be performed. Hazard notices
immediately precede the step or procedure that may lead to an associated hazard.
Read all hazard notices carefully and follow all directions and recommendations.
Three different levels of hazard notices may appear in your manuals. Following
are examples of all three levels.
NoteFor general safety information, see the safety information provided with
your system.
Danger notices indicate the presence of a hazard with a high level of risk which,
if ignored, will result in death, severe personal injury, or substantial property
damage.
14
Warning notices indicate the presence of a hazard with a medium level of risk
which, if ignored, can result in death, severe personal injury, or substantial
property damage.
Caution notices indicate the presence of a hazard with a low level of risk which,
if ignored, could cause moderate or minor personal injury or equipment damage,
or could endanger test integrity.
NotesNotes provide additional information about operating your system or highlight
easily overlooked items. For example:
NoteResources that are put back on the hardware lists show up at the end of
the list.
Special termsThe first occurrence of special terms is shown in italics.
IllustrationsIllustrations 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
conventions
This manual is available as an electronic document in the Portable Document
File (PDF) format. It can be viewed on any computer that has Adobe Acrobat
Reader installed.
Hypertext linksThe electronic document has many hypertext links displayed in a blue font. All
blue words in the body text, along with all contents entries and index page
numbers, are hypertext links. When you click a hypertext link, the application
jumps to the corresponding topic.
ContentsIntended Use of MTS Series 494 Controllers 18
EC Declaration of Conformity for MTS Models 494.04 (FlexTest 40),
494.06 (FlexTest 60), 494.10 (FlexTest 100) and 494.20 (FlexTest 200)
19
Waste Electrical and Electronic Equipment (WEEE) Considerations 20
E-Stop Circuits 22
Hardware Interlocks 24
E-Stop and Hardware Interlocks 25
Safety Information
MTS FlexTest® Models 40/60/100/200 Controller HardwareSafety Information
17
Safety Information
Intended Use of MTS Series 494 Controllers
MTS Series 494 Controllers vary from single-channel, single-station systems to
multichannel, multistation systems. This increased flexibility of Series 494
Controllers permits their use in several industrial testing applications.
MTS Series 494 Controllers are typically used in the following testing markets:
•Materials
•Automobile
•Tire and Wheel
•Aircraft
Before you attempt to use your MTS product, read and understand the manuals
that accompany this product. Improper installation or operation of this product
can result in hazardous conditions that can cause severe personal injury or death,
and damage to your equipment and test specimen.
EC Declaration of Conformity for MTS Models 494.04 (FlexTest 40),
494.06 (FlexTest 60), 494.10 (FlexTest 100) and 494.20 (FlexTest 200
)
Description of ModelsThe MTS Series 494 Electronics Control Chassis’ are VMEbus chassis’ that can
house up to twenty VMEbus modules in the front of the chassis and up to twenty
MTS Systems Corporation transition modules in the rear panel of the chassis.
The chassis can be configured with a variety of MTS VMEbus plug-in modules
and related transition modules.
ManufacturerMTS Systems Corporation
14000 Technology Drive
Eden Prairie, MN, USA 55344-2290
Phone: 952-937-4000
DirectivesLow Voltage directive 2006/95/EEC and the EMC directive 2004/108/EC.
StandardsEN 61010-1: Safety requirements for electrical equipment for measurement,
control and laboratory use, Part 1: General requirements
EN 61000-6-2: Electromagnetic Compatibility, Generic Standards - Immunity for
Industrial Environments.
EN 61000-6-4: Electromagnetic Compatibility, Generic Standards - Emission
standard for Industrial Environments.
Radio frequency electromagnetic
field, amplitude modulated
Electrical fast transientEN 61000-4-42 kV mains
MTS FlexTest® Models 40/60/100/200 Controller HardwareSafety Information
EN 61000-3-2Class A
EN 61000-3-3Class A
+/- 8 kV air discharge
Performance Criteria B
EN 61000-4-310 V/m
Performance Criteria A
2 kV control and signal
Performance Criteria B
19
Safety Information
DESCRIPTIONBASIC STANDARDTEST SPECIFICATION
Electrical surge immunity testEN 61000-4-52 kV mains line to earth
1 kV mains line to line
.5 / 1 kV cables >30 meters line to earth
Performance Criteria B
Radio frequency common mode,
amplitude modulated
Power frequency magnetic fieldEN 61000-4-830 A (rms)/m 50 and 60 Hz
Voltage dips, short interruptions,
and voltage variations
Radiated emissions EN 55011Class A
Conducted emissionsEN 55011Class A
EN 61000-4-610 V (rms)
Performance Criteria A
Performance Criteria B
EN 61000-4-111 cycle and 0% amplitude of cycle
Performance Criteria B
10 cycle and 40% amplitude of cycle
25 cycle and 70% amplitude of cycle
250 cycle and 0% amplitude of cycle
Performance Criteria C
Name:Rich Baker
Title:Vice President of Engineering
Date:01 November 2007
Waste Electrical and Electronic Equipment (WEEE) Considerations
The Waste Electrical and Electronic Equipment (WEEE) symbol ()
indicates that the controller and its electronic parts must not be disposed of as
unsorted municipal waste. Proper disposal is required by approved electronic
waste collection agencies. Customers in the EC region who desire to return an
end-of-life controller and its electronic parts are encouraged to contact your local
MTS Systems Sales/Service Offices for instructions.
Series 494 hardware includes a number of safety circuits that monitor and
respond to potentially unsafe conditions.
To avoid shock hazards, users should not attempt to service any parts located
inside any Series 494 Controller chassis.
Controllers contain components that operate at hazardous voltage levels.
Hazardous voltage levels inside the controller pose a danger. Contact with
high-voltage electricity can result in injury or death.
Do not remove any panel, cover, or door on any Series 494 Controller chassis. Do
not attempt to service any Series 494 Controller chassis. There are no userserviceable parts or fuses in any Series 494 Controller chassis.
MTS FlexTest® Models 40/60/100/200 Controller HardwareSafety Information
21
Safety Circuits
WARNING
Input/Output Verification
Relay outputsIf necessary, you can use an external device to monitor both NO and NC contacts
There are a number of ways that you can verify the integrity of controller input
and output circuits.
Improper use of controller outputs can result in damage to the controller
and unexpected actuator movement.
Unexpected actuator movement can result in injury to personnel or damage
to the equipment.
Outputs should be used to monitor controller functions within the specifications
included in the MTS Series 494 Controller Hardware Manual.
to detect state changes and verify relay integrity. You can also provide a
redundant set of contacts to an external device.
Digital inputsIf necessary, you can set up the controller to monitor redundant digital input
Digital outputsIf necessary, you can provide redundant output signals to external systems.
E-Stop Circuits
signals and use the controller software to verify input circuit integrity and take
action if a problem is identified.
Emergency stop (E-stop) circuits include an electro-mechanical switch that when
pressed, removes power from the HPU E-stop relay and forces a global interlock.
Most Series 494 Controllers include E-Stop outputs that are intended to be
monitored by external devices. If necessary, an external device can monitor
multiple E-stop output contacts to detect state changes and verify relay integrity.
The E-Stop circuit should be tested periodically to help ensure that the system
shuts down safely when the E-Stop button(s) is pressed.
NoteMTS recommends testing the E-Stop circuit at least once per month.
1. Remove any specimens from each station.
2. Apply power to the controller.
3. Start the HPU and each HSM associated with your test station(s).
4. Press the E-Stop button and ensure that the following global-interlock
actions occur:
•Power is removed from each HPU.
•Power is removed from each HSM.
•If valve clamping is enabled, the actuator should move to the
predetermined position defined in software.
•Any external I/O device that is monitoring the E-Stop circuit should
acknowledge the E-Stop state and take appropriate action.
5. Twist the switch clockwise to release it.
6. Repeat this procedure for each E-Stop button used with your controller.
MTS FlexTest® Models 40/60/100/200 Controller HardwareSafety Information
23
Safety Circuits
Hardware Interlocks
Global interlocksGlobal interlocks detect controller chassis conditions (such as watchdog timers
Station interlocksStation interlocks are associated with a specific test station and will force the
A Series 494 controller running Series 793 Control Software can have up to eight
separate hardware interlock chains. Each test station configuration that you open
must be assigned to a unique hardware interlock chain. This allows one controller
to run up to eight test stations, each with its own hardware interlock chain.
NoteSome test configurations may only use one station that is assigned to a
single hardware interlock chain.
The controller can generate two type of hardware interlocks, global interlocks,
and station interlocks:
and undervoltage conditions) that can affect any station running on the controller.
A global interlock forces all eight hardware interlock chains to an active state.
hardware interlock chain assigned to that station to an active interlock state.
Series 494 controllers include interlock output contacts (NO/NC) that are
intended to provide hardware interlock status to external systems.
Safety Information
24
NoteIf necessary for critical applications, you can use an external I/O
monitoring device to monitor both NC and NO contacts to detect state
changes and verify relay integrity.
The following table shows E-stop/interlock operation for a typical system that
uses Series 793 Control Software. Interlock and E-stop operation on some test
systems may vary.
E-stop and Hardware Interlock Events/Actions (Series 793 Control Software)
E-S
TOPGLOBAL (CONTROLLER) INTERLOCKSTATION INTERLOCK
Safety Circuits
An E-stop occurs when the
operator presses an electromechanical E-stop switch.
An active E-stop causes the
following actions:
•Physically removes power
from the HPU CRM E-stop
relay.
NoteThe CRM E-stop relay is
located in the HPU.
•Forces a global interlock.
Any of the following events results
in a global interlock:
•Undervoltage conditions on
auxiliary power outputs.
•Controller conditions such as
watchdog timers and
backplane monitoring.
•E-stop button pressed.
A global interlock applies the
following actions to each of the
hardware interlock chains:
•Sets the controller HPU
commands to off.
•Sets each controller HSM
command to off.
•Sets the controller function
generator/program (for all
stations) to off.
•If enabled, the valve driver
current is clamped to a
predefined value/polarity.
Any of the following events results
in a station interlock:
•Software events (such as
limits).
•External interlock input
active.
•Station Stop button pressed.
A station interlock applies the
following actions to the single
hardware interlock chain where
that station is assigned:
•Sets the station HSM
command to off.
•Sets the controller function
generator/program (for that
station only) to off.
•If enabled, the valve driver
current is clamped to a
predefined value/polarity.
E-Stop outputs are intended to be
monitored by external devices.
NoteIf necessary, an external I/O monitoring device can monitor multiple E-stop/Interlock output contacts to
detect state changes and verify relay integrity.
MTS FlexTest® Models 40/60/100/200 Controller HardwareSafety Information
Interlock outputs are intended to be
monitored by external devices.
Interlock outputs are intended to be
monitored by external devices.
About MTS FlexTest Models 40/60/100/200 Controllers
MTS FlexTest Models 40/60/100/200 Controllers are generally used in
servohydraulic test systems. They provide real-time closed-loop control, with
transducer conditioning and function generation to drive various types of servoactuators.
A FlexTest Controller consists of:
•One or more Series 494 Hardware chassis that contain controller hardware.
•A computer workstation that runs MTS controller applications.
Controller capabilities
PARAMETERFLEXTEST40FLEXTEST 60FLEXTEST
Test Stations2Up to 6*Up to 8Up to 8
Control ChannelsUp to 4Up to 8Up to 16Up to 40
100
FLEXTEST
200
FlexTest Controller Configurations
28
Conditioned
Transducer Inputs
Auxiliary Data InputsUp to 16Up to 32Up to 64Up to 96
The Model 494.06 Chassis has a removable front cover that could loosen
when attempting to lift the chassis.
Lifting the Model 494.06 Chassis without first removing the front cover can
result in injury to personnel or equipment damage.
Remove the front cover on the Model 494.06 Chassis before attempting to lift the
Model 494.06 Chassis.
4. Connect power and cables as required.
If you attempt to change a cable connection while the system is in
operation, an open control loop condition can result.
An open control loop condition can cause a rapid, unexpected system
response which can result in severe personal injury, death, or damage to
equipment.
FlexTest Controller Configurations
32
Do not change any cable connections when the system is capable of motion
(electric drives are enabled, hydraulic pressure is applied, etc.). Ensure that all
cables are connected after you make any changes in the system configuration.
Also, ensure that all cables are properly connected after you make any changes in
the system configuration.
Software settingsSoftware is used to define the location (address) of each board used in the
system. Controller software uses this information to locate and communicate
with each board. In addition, there are other software settings that define
hardware parameters.
Blank chassis panelsTo help ensure proper ventilation, each blank slot in a Series 494 Chassis must
have a blank chassis panel.
Chassis groundingThe controller will not function correctly if the chassis is not grounded properly.
I/O carrier settingsThe Model 494.40 I/O Carrier board has a number of hardware settings that must
be set before you install the board. These settings include:
•Address switch settings (required)
•The installation of bridge-completion resistors (optional)
•The installation of shunt-calibration resistors (optional)
Interlock jumper plugsEach system includes a system jumper plug kit. If interlock/E-Stop inputs are not
used, you must install a jumper plug to maintain the integrity of those interlocks.
For more informationFor detailed descriptions of software settings, see the controller software manuals
delivered with your system.
For detailed descriptions of I/O Carrier board settings, see “How to Set Up a
All Series 494 hardware components are intended for indoor use only. This
indoor environment must conform to the following environmental specifications.
NoteAll Series 494 Controller must only be operated under the installation
and ambient conditions (such as, temperature, moisture, and EMC)
specified.
PARAMETERSPECIFICATION
Temperature5ºC–40ºC (41ºF–104ºF)
Humidity5–85%, non-condensing
Altitude3048 m (10,000 ft) maximum
Installation
Space
Requirements
NoteTo maintain EMC compliance, the controller must be installed in a
location that does not exceed the EN 61000-6-4 emission standard for
industrial environments.
For proper ventilation, allow 51 mm (2 in) clearance
on all sides of the chassis.
The rear of the chassis requires a minimum
clearance of 15.24 cm (6 in) for cable connections.
For proper ventilation for rack-mounted chassis, you must provide 51 mm (2 in)
clearance on all sides of a Series 494 Chassis.
NoteThe rear of the chassis requires a minimum clearance of 15.24 cm (6 in)
for cable connections.
36
The chassis Over Temp indicator (located on the front of the Model 494.06
chassis and on the back of the Models 494.10 and 494.20 chassis) turns on
when the chassis temperature is too hot–over 50ºC (122ºF).
Failure to take immediate action to correct the overtemperature condition
can result in irreparable damage to components.
Do not operate the system when the chassis Over Temp indicator is on. Shut
down the system and check the airflow through the chassis. Check for blocked
filters and damaged fans in the chassis. If the chassis is installed in a console,
check for blocked filters and damaged fans in the console. Also, make sure that
the ambient air temperature is less than 40ºC (104ºF) and that there is at least 51
mm (2 in) clearance on all sides of the chassis.
The controller will not function correctly if the chassis is not grounded as shown.
Make sure that your power source is also properly grounded.
The chassis includes two grounds: a chassis ground and a signal common. During
manufacturing, the two grounding lugs are connected together with an external
shorting bar.
Signal common cable (part number 376999-xx) connected to other components.
Chassis ground connects to
AC power ground through the
power cord.
Improper grounding can result in unexpected actuator movement and
failure to meet EMC emission and susceptibility requirements.
Unexpected actuator movement can result in injury or death and/or damage
to the equipment.
Ensure that each controller chassis is properly grounded.
Stand-alone ground
connections
Console ground
connections
For stand-alone mounting, connect the shorting bar to both ground lugs. Tighten
the two nuts that secure the shorting bar to the ground lugs.
If you mount a Series 494 Chassis in a console, remove the shorting bar from the
chassis ground lugs and connect the chassis ground to the console rail as shown.
FlexTest Controller Configurations
38
The chassis ground connects to the AC power ground through the power cord.
The power cord must be plugged into both the chassis and the power source for
proper grounding.
To maintain EMC compliance and help ensure optimal performance, MTS
recommends ordering all system cables from MTS. Cables should be installed so
that they are protected from conditions that could damage the cable.
Unprotected cables can be damaged by hydraulic fluid, excessive
temperature, excessive strain, and contact with sharp, abrasive, or heavy
objects.
A damaged cable can cause a rapid, unexpected system response which
can result in severe personal injury, death, or damage to equipment.
Protect all system cables as described below:
•Protect electrical cables from spilled hydraulic fluid and from excessive
temperatures that can cause the cables to harden and eventually fail.
•Ensure that all cables have strain-relief devices installed at the cable and
near the connector plug. Do not use the connector plug as a strain relief.
Installation
•Protect all system cables from sharp or abrasive objects that can cause the
cable to fail.
•Use a cable cover or cable tray where cables are in traffic locations. Never
walk on cables or move heavy objects over them.
•Route cables away from areas that expose them to possible damage.
If you attempt to change a cable connection while the system is in
operation, an open control loop condition can result.
An open control loop condition can cause a rapid, unexpected system
response which can result in severe personal injury, death, or damage to
equipment.
Do not change any cable connections when the system is capable of motion
(electric drives are enabled, hydraulic pressure is applied, etc.). Also, ensure that
all cables are properly connected after you make any changes in the system
configuration.
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.
It is important to note that the UPS will not prevent any unexpected motion if the
controller, or any other electrical subsystem required for control of the system
has an internal failure, including a HPU or a Motor Drive.
UPS requirements•The UPS must be wired to provide power to the controller and any
peripheral equipment that is instrumental in safe system operation and shutdown. In some cases it may be feasible and appropriate to provide UPS
power to the Hydraulic Power Unit (HPU).
•The UPS must be sized to provide adequate electrical power for a period of
three minutes after loss of input power.
•The controller must be configured to take appropriate actions for safe shut-
down of hydraulic equipment being controlled. (Appropriate actions depend
on the particular system.)
•Both UPS input power and UPS output power connections must include
strain relief and a twist-lock plug or equivalent.
•UPS systems used in the European Union must be CE marked.
•The UPS must have input power-loss (AC Fail) alarm relay contact out and
a low battery alarm relay contact out, both of which must be wired to the
controller's UPS monitoring interface.
A UPS with an AC Fail relay contact wired to the controller provides a
mechanism for the controller to identify that the UPS has switched over to
battery power due to a detected AC power failure condition from the facility's
power grid. This fault signal from the UPS can be used by the controller to start a
safe shutdown sequence, ramp command(s) to a safe state(s), and then shut off
the power source.
The addition of a low battery warning relay contact out from the UPS will
provide additional system safety protection by letting the controller know that the
UPS battery is low.
43
UPS System Requirements
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.
It is important to note that the UPS will not prevent any unexpected motion if the
controller, or any other electrical subsystem required for control of the system
has an internal failure, including a HPU or a motor drive.
UPS requirements•The UPS must be wired to provide power to the servocontroller and any
peripheral equipment that is instrumental in safe system operation and shutdown. In some cases it may be feasible and appropriate to provide UPS
power to the hydraulic power unit (HPU).
•The UPS must be sized to provide adequate electrical power for a period of
three minutes after loss of input power.
•The controller must be configured to take appropriate actions for safe shut-
down of hydraulic equipment being controlled. (Appropriate actions depend
on the particular system.)
Battery power
considerations
•Both UPS input power and UPS output power connections must include
strain relief and a twist-lock plug or equivalent.
•UPS systems used in the European Union must be CE marked.
•FT40 (with Model 494.41 System board) and FTSE controllers do not have
dedicated UPS monitoring inputs.The UPS must have input power-loss (AC
Fail) alarm relay contact out and a low battery alarm relay contact out, both
of which must be wired to two of the digital inputs that are part of generaluse DI/O in the FT40 or FTSE controllers.
NoteFT40 controllers that include a Model 494.44 or a Model 494.42 system
board have dedicated UPS inputs.
•The controller’s “Event Action” feature must be configured to take
appropriate actions for safe shut-down of hydraulic equipment being
controlled. (Appropriate actions depend on the particular system.)
A UPS with an AC Fail relay contact wired to the controller provides a
mechanism for the controller to identify that the UPS has switched over to
battery power due to a detected AC power failure condition from the facility's
power grid. This fault signal from the UPS can be used by the controller to start a
safe shutdown sequence, ramp command(s) to a safe state(s), and then shut off
the power source.
The addition of a low battery warning relay contact out from the UPS will
provide additional system safety protection by letting the controller know that the
UPS battery is low.
Specifications–UPS Systems Used with MTS Controllers
Any UPS used with an MTS system must comply with these specifications.
UPS Specifications
I
TEMREQUIREMENT
Operating temperature5–40 deg C
Operating humidity5–85% non-condensing
UPS System Requirements
UPS power
requirements
Supported UPS output
voltage range
Input/output frequency
range
Output load regulation-/+5% nominal operating voltage (both in
Switch-over time to battery
on power loss
100–240 V AC nominal, single phase,
sine-wave output
50–60 Hz
battery and normal operation modes)
0 s (recommended), < 6 ms (required)
The following UPS power requirements include power for the PC, MTS
Controller (one chassis), and 25% capability for other subsystems.
UPS Power Requirements
C
ONTROLLER TYPECONTROLLER CHASSISUPS POWER REQUIRED
793-based systems include a utility that uses Telnet commands to set and clear
interlocks on various boards to identify boards that cannot set or clear interlocks.
This is often the result of a bent P0 pin on the board connector.
During normal startup, sysload will run this utility. If a problem is identified,
1. Sysload will not complete.
2. A results window lists the problem boards and the location of the log file
that contains the results.
You can also run this utility using the P0interlockcheck command line, before
sysload runs.
The FlexTest 40 Controller is a fully digital proportional, integral, derivative,
feed forward (PIDF) servocontroller that provides complete control of one station
in a test system.
A FlexTest 40 Controller consists of:
•One Model 494.04 Chassis that contains controller hardware.
•A computer workstation that runs MTS controller software applications.
For a detailed listing of configuration options, see the FlexTest 40 Configuration
engineering drawing (Part number 700-003-810).
The Model 494.04 Chassis is a four-slot VME chassis that you can rack mount or
place on a desktop. All cabling is accessed through the rear panel.
Mezzanine cardsTwo slots are reserved for Model 494.40 I/O Carrier boards. Each I/O carrier
board can contain up to four mezzanine cards. You can use mezzanine cards to
condition transducers, drive servovalves, provide A-to-D inputs, and interface to
various digital transducers (such as encoders and Temposonics transducers).
Model 494.04 Chassis (rear view)
48
Hydraulic controlThe system board provides control of the test system hydraulics, including
hydraulic power unit (HPU) and hydraulic service manifold (HSM) control.
InterlocksThe system board provides interlock inputs and outputs.
•You can use interlock-output contacts to control external devices.
•You can use interlock inputs from external devices to initiate station and
program interlocks.
System boardThe system board provides three optically isolated digital inputs and three relay-
contact digital outputs.
•You can use digital-input signals to trigger test events in your controller
software.
•You can use digital-output signals to control external devices.
The Model 494.04 Chassis includes three VME bus slots that contain the boards
listed in the following table.
Rear View of the Model 494.04 Chassis
S
LOTBOARD NAMEFUNCTION
Slot 1Processor BoardProvides PIDF processing and an interface between the
controller and the computer workstation.
Slots 2, 3Model 494. 40 I/O CarrierSupports up to four mezzanine cards that can condition
transducers, drive servovalves, provide A-to-D inputs, and
interface to various digital transducers (such as encoders and
Temposonics transducers).
Slots 4, 5System BoardProvides digital I/O, E-Stop, and HSM/HPU control.
Compatible system boards include: the Model 494.41 SingleStation System Board, the Model 494.42 Single-Station
System Board, and the Model 494.44 Two-Station System
Board.
J24 Emergency Stop Connections for the Model 494.41 System Board
The Model 494.41 System board provides two E-Stop inputs that are available on
the J24 E Stop connector (located on the rear panel of the Model 494.04
Chassis).
Cable specificationTo maintain EMC compliance, the J24 E-Stop cable must comply with the
following specifications:
Connector type–15-pin, type D, male EMI connector.
Backshell–EMI metallized plastic or metal.
Cable–24 AWG, four-conductor with braided shield, with the braid connected to
a metallized plastic backshell at the chassis and to ground at the emergency stop
(E-Stop) box.
Jumper plug requiredIf connector J24 is not used, you must install a jumper plug to maintain the
integrity of the interlocks. Use jumper plug part number 039-713-201 or jumper
pins 5-7 and 8-13.
J25 Hydraulic Power Unit Connections for the Model 494.41 System Board
Connector J25 HPU provides 24-volt logic signals that control the hydraulic
power unit (HPU). The connector can be connected directly to MTS Series 505
HPUs and similar HPUs with low-current, 24-volt input controls.
NoteOther MTS HPUs require the Model 493.07 HPU Converter Box to
convert the low-current HPU output signal to a signal that can drive the
HPU relay.
Control voltages for hydraulic power units vary between models. The
interface between the Model 494.41 System board and an HPU consists of
24-volt logic signals.
Connecting J25 to a non-compliant HPU can damage the board.
Do not connect 24 V DC relay circuitry or 115 V AC circuitry to connector J25 on
the Model 494.41 System board.
Cable specificationTo maintain EMC compliance, J25 HPU cables must comply with the following
J28 HSM Connections for the Model 494.41 System Board
HSM control (off/low/high or proportional) is software configurable. The Model
494.41 Board provides separate 24-volt, low-pressure and high-pressure outputs
that drive the HSM low- and high-pressure solenoids. Proportional control
provides a current output from 0 to 0.78 A.
NoteThe Model 494.41 Board cannot be used with 115 V AC HSMs.
Applications that use 115 V AC HSMs require an external converter box
(such as a Model 413.08), which is used with this board.
Cable specificationTo maintain EMC compliance, J25 HPU cables must comply with the following
specifications:
Connector—4-contact, CPC-4P, male EMI connector.
Proportional Control Cable—18 AWG, 2-conductor with foil shield with the
drain wire connected to pin 3 of the CPC connector.
Off/low/high Control Cable—18 AWG, 3-conductor with foil shield with the
drain wire connected to pin 3 of the CPC connector.
J29 Emergency Stop Connections for the Model 494.41 System Board
Connector J29 E-STOP provides an output to external devices when an
emergency stop signal is generated. You can also connect an external E-Stop to
the J29 connector.
Cable specificationTo maintain EMC compliance, the J29 E-STOP cable must comply with the
following specifications:
Connector type–15-pin, type D, male EMI connector.
Backshell–EMI metallized plastic or metal.
Cable–18 AWG, 8-conductor with foil shield, with the drain wire connected to a
metallized plastic backshell at the chassis.
Jumper plug requiredIf connector J29 is not used, you must install a jumper plug to maintain the
integrity of the interlocks. Use jumper plug part number 100-007-947 or jumper
Cable–AWG and number of conductors as required. Braided shield with the
shield connected to the metallized backshell at the chassis.
Model 494.41 Single-Station System Board
494.41 System Board
Power
100-240 VAC
50-60 Hz, 1-2 A
DA Output
J24
1234567
8
1234567
8
J54 Dig In
J49 Aux Pwr
J25 Hpu
Dig Out J55
Intlk J43
E-stop J29
J28 HSM
LAN 2 LAN 1
DEBUG
MOTOROLA
10/100 BASE T10/100 BASE T
SCSI
BUSY
PIB
BUSY
PCI MEZZANINE CARD
PCI MEZZANINE CARD
J54 Digital Input
Logic Input Wiring
1
2
3
4
5
6
7
8
9
J54
Dig In
Input 1
+24 V
Low side of Opto
Inputs must be
jumpered to
ground. Use 22
AWG Jumper Wire.
Switch
or dry
contacts
Input 3
Input 2
+24 V DC
Opto-
Coupler
1
2
3
J54
External
Device
J54 Digital Input Connections for the Model 494.41 System Board
Connector J54 Dig In accepts up to three optically isolated digital-input signals
from external devices. You can use these digital input signals to trigger test
events in controller applications.
Cable specificationTo maintain EMC compliance, the J54 Digital Input cable must comply with the
Cable–AWG and number of conductors as required. Braided shield with the
shield connected to the metallized backshell at the chassis.
Model 494.41 Single-Station System Board
Power
100-240 VAC
50-60 Hz, 1-2 A
DA Output
J24
1234567
8
1234567
8
J54 Dig In
J49 Aux Pwr
J25 Hpu
Dig Out J55
Intlk J43
E-stop J29
J28 HSM
LAN 2 LAN 1
DEBUG
MOTOROLA
10/100 BASE T10/100 BASE T
SCSI
BUSY
PIB
BUSY
PCI MEZZANINE CARD
PCI MEZZANINE CARD
494.04 Chassis
494.41 System
Board
D/A Output
D/A Output
2
6
4
9
Monitor 1
Monitor 2
-
+
D/A Output 1
D/A Output 2
-
+
Twisted
Pairs
Analog Output Connections for the Model 494.41 System Board
The Model 494.41 System board provides two analog output signals that are
available on the D/A Output connector (located on the rear panel of the Model
494.04 Chassis). Each D/A output is software defined.
Cable specificationTo maintain EMC compliance, the D/A Output cable must comply with the
following specifications:
Connector type–9-pin, type D, male EMI connector.
Backshell–EMI metallized plastic or metal.
Cable–shielded twisted pairs (24 AWG minimum), braided shield with the shield
connected to the metallized backshell at the chassis.
UPS Connections for the Model 494.41 System Board (FT40)
The following drawing shows UPS connections for the Model 494.41 System
board. Once connected, use your controller software to add the digital input
resources and configure the digital inputs to perform various actions in response
to the UPS signals.
NoteSee your controller software user guide for information on how digital
inputs are assigned and used.
Cable specificationTo maintain EMC compliance, the J54 Digital Input cable must comply with the
following specifications:
FlexTest Controller Configurations
66
Connector type–9-pin contact, type D, male EMI connector.
Back shell–EMI metallized plastic or metal.
Cable—26 to 22 AWG, 4-conductor with an overall braided shield that is
J24 Emergency Stop Connections for the Model 494.42 System Board
The Model 494.42 System Board provides two optional E-Stop inputs that are
available on the J24 E Stop connector (located on the rear panel of the Model
494.04 Chassis).
Jumper plug requiredIf connector J24 is not used, you must install a jumper plug to maintain the
Cable specificationTo maintain EMC compliance, the J24 E-Stop cable must comply with the
following specifications:
Connector type–15-pin, type D, male EMI connector.
Backshell–EMI metallized plastic or metal.
Cable–24 AWG 4-conductor with braided shield, with the braid connected to a
metallized plastic backshell at the chassis and to ground at the emergency stop
(E-Stop) box.
integrity of the interlocks. Use jumper plug part number 039-713-201 or jumper
pins 5-7 and 8-13.
73
Model 494.42 Single-Station System Board
ON = Normal
ON = Normal
ON = HPU ON
Power
100-240 VAC
50-60 Hz, 1-2 A
DA Output
J24
1234567
8
1234567
8
LAN 2 LAN 1
DEBUG
MOTOROLA
10/100 BASE T10/100 BASE T
SCSI
BUSY
PIB
BUSY
PCI MEZZANINE CARD
PCI MEZZANINE CARD
J54 Dig InJ55 Dig Out
J43 INTLKJ56 UPS
J49 Aux Pwr J23 Estop/Run
J29 Load FrameJ25 HPU
J28 HSM
Controller 24 Vdc
+24 V DC (from HPU)
HPU
ON
Sense
24 V DC (from HPU)
Start
Lo
High
HPU Over Temp
Open = Interlock Active
494.42 System Board
9
10
11
12
1
2
3
4
5
6
15
7
8
J25
HPU
HPU Low Level
Open = Interlock Active
Start
SSR
Low
SSR
High
SSR
24 V DC (from HPU)
HPU ON
Series 505 HPU or Equivalent
J25
HPU
HPU E-Stop Out 1
* MTS Model 505 Pumps and older do not use the
HPU E-Stop 2 signal.
HPU E-Stop Out 2*
Open = HPU E Stop
J25 Hydraulic Power Unit Connections for the Model 494.42 System I/O Board
Connector J25 HPU provides 24-volt logic signals that control the hydraulic
power unit (HPU). The connector may be connected directly to MTS Series 505
HPUs and similar HPUs that use low-current, 24-volt input controls.
NoteOther MTS HPUs require the Model 493.07 HPU Converter Box to
convert the low-current HPU output signal to a signal that can drive the
HPU relay.
Control voltages for hydraulic power units vary between models
The HPU interface between the Model 494.42 System I/O board and an HPU
is 24-volt logic signals. Connecting J25 to a non-compliant HPU can damage
the board.
Do not connect 24 V DC relay circuitry or 115 V AC circuitry to connector J25 on
the Model 494.42 System I/O board.
Cable specificationTo maintain EMC compliance, J25 HPU cables must comply with the following
J28 HSM Connections for the Model 494.42 System Board
HSM control (off/low/high or proportional) is software configurable. The Model
494.42 board provides separate 24-volt, low-pressure and high-pressure outputs
that drive the HSM low- and high-pressure solenoids. Proportional solenoid
control provides a current output from 0 to 0.78 A.
NoteThe Model 494.42 board can not be used with 115 V AC HSMs.
Applications that use 115 V AC HSMs require an external converter box
(such as a Model 413.08), which is used with this board.
Cable specificationTo maintain EMC compliance, J28 HSM cables must comply with the following
FlexTest Controller Configurations
76
specifications:
Connector—9-pin type D male EMI connector.
Backshell—EMI metallized plastic or metal.
Proportional Control Cable—18 AWG, 2-conductor with foil shield drain wire
connected to conductive backshell.
Off/low/high Control Cable—18 AWG, 3-conductor with foil shield drain wire
connected to conductive backshell.
Low side of Opto
Inputs must be
jumpered to
ground. Use 22
AWG Jumper Wire.
Switch
or dry
contacts
Input 3
Input 2
+24 V DC
Opto-
Coupler
1
2
3
J54
External
Device
J54 Digital Input Connections for the Model 494.42 System Board
Connector J54 Dig In accepts up to three optically isolated digital-input signals
from external devices. You can use these digital input signals to trigger test
events in controller applications.
Cable specificationTo maintain EMC compliance, the J54 Digital Input cable must comply with the
following specifications:
Connector type–9-pin, type D, male EMI connector.
Back shell–EMI metallized plastic or metal.
FlexTest Controller Configurations
80
Cable–AWG and number of conductors as required. Braided shield with the
shield connected to the metallized backshell at the chassis.
Analog Output Connections for the Model 494.42 System Board
The Model 494.42 System Board provides two analog output signals that are
available on the D/A Output connector (located on the rear panel of the 494.04
chassis). Each D/A output is software defined.
Cable specificationTo maintain EMC compliance, the D/A Output cable must comply with the
following specifications:
Connector type–9-pin, type D, male EMI connector.
Backshell–EMI metallized plastic or metal.
Cable–shielded twisted pairs (24 AWG minimum), braided shield with the shield
connected to the metallized backshell at the chassis.
J24 Emergency Stop Connections for the Model 494.44 System Board
The Model 494.44 System Board provides two optional E-Stop inputs that are
available on the J24 E Stop connector (located on the rear panel of the Model
494.04 Chassis).
Jumper plug requiredIf connector J24 is not used, you must install a jumper plug to maintain the
Cable specificationTo maintain EMC compliance, the J24 E-Stop cable must comply with the
following specifications:
Connector type–15-pin, type D, male EMI connector.
Backshell–EMI metallized plastic or metal.
Cable–24 AWG 4-conductor with braided shield, with the braid connected to a
metallized plastic backshell at the chassis and to ground at the emergency stop
(E-Stop) box.
integrity of the interlocks. Use jumper plug part number 039-713-201 or jumper
pins 5-7 and 8-13.
89
Model 494.44 Two-Station System Board
ON = Normal
ON = Normal
ON = HPU ON
Power
100-240 VAC
50-60 Hz, 1-2 A
DA Output
J24
1234567
8
1234567
8
LAN 2 LAN 1
DEBUG
MOTOROLA
10/100 BASE T10/100 BASE T
SCSI
BUSY
PIB
BUSY
PCI MEZZANINE CARD
PCI MEZZANINE CARD
J55 Dig Out Dig In J54
J43AJ43B
J49 Aux PwrEstop/Run J23
Interlock
J29AJ29B
Load Frame
J28 HSM A-B
HPU J25
J25
HPU
Controller 24 Vdc
+24 V DC (from HPU)
HPU
ON
Sense
24 V DC (from HPU)
Start
Lo
High
HPU Over Temp
Open = Interlock Active
494.44 System Board
9
10
11
12
1
2
3
4
5
6
15
7
8
J25
HPU
HPU Low Level
Open = Interlock Active
Start
SSR
Low
SSR
High
SSR
24 V DC (from HPU)
HPU ON
Series 505 HPU or Equivalent
HPU E-Stop Out 1
* MTS Model 505 Pumps and older do not use the
HPU E-Stop 2 signal.
HPU E-Stop Out 2*
Open = HPU E Stop
J25 Hydraulic Power Unit Connections for the Model 494.44 System I/O Board
Connector J25 HPU provides 24-volt logic signals that control the hydraulic
power unit (HPU). The connector may be connected directly to MTS Series 505
HPUs and similar HPUs that use low-current, 24-volt input controls.
NoteOther MTS HPUs require the Model 493.07 HPU Converter Box to
convert the low-current HPU output signal to a signal that can drive the
HPU relay.
Control voltages for hydraulic power units vary between models
The HPU interface between the Model 494.44 System I/O board and an HPU
is 24-volt logic signals. Connecting J25 to a non-compliant HPU can damage
the board.
Do not connect 24 V DC relay circuitry or 115 V AC circuitry to connector J25 on
the Model 494.44 System I/O board.
Cable specificationTo maintain EMC compliance, J25 HPU cables must comply with the following
Note: A custom Y Cable
and individual HSM
cables are required.
To
494.44
J28
Custom J28 Y Cable
(PN 100-185-473)
D9S
D9S
D15P
HSM A
HSM B
J28 HSM Connections for the Model 494.44 System Board
HSM control (off/low/high or proportional) for both HSMs is software
configurable. The Model 494.44 board provides separate 24-volt, low-pressure
and high-pressure outputs that drive the HSM low- and high-pressure solenoids.
Proportional solenoid control provides a current output from 0 to 0.78 A.
NoteThe Model 494.44 board can not be used with 115 V AC HSMs.
Applications that use 115 V AC HSMs require an external converter box
(such as a Model 413.08), which is used with this board.
Cable–AWG and number of conductors as required. Braided shield with shield
connected to the metallized backshell at the chassis.
Model 494.44 Two-Station System Board
DI 2
DI 1
DI 3
DI 4
DI 5
DI 6
DI 7
DI 8
494.44 System Board
J54 Dig In
Power
100-240 VAC
50-60 Hz, 1-2 A
DA Output
J24
1234567
8
1234567
8
LAN 2 LAN 1
DEBUG
MOTOROLA
10/100 BASE T10/100 BASE T
SCSI
BUSY
PIB
BUSY
PCI MEZZANINE CARD
PCI MEZZANINE CARD
J55 Dig Out Dig In J54
J43A J43B
J49 Aux PwrEstop/Run J23
Interlock
J29AJ29B
Load Frame
J28 HSM A-B
HPU J25
494.32 DIO Breakout Box
J54 Dig In
J10 Inputs
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
J54 Digital Input Connections for the Model 494.44 System Board
Connector J54 Dig In accepts up to eight optically isolated digital-input signals
from the Model 494.32 8-Channel DI/O Breakout Box. You can use these digital
input signals to trigger test events in controller applications.
NoteDigital input power for the breakout box is brought in through breakout-
box connector J19.
Cable specificationTo maintain EMC compliance, the J54 Digital Input cable must comply with the
following specifications:
Connector type–9-pin, D type, female EMI connector.
Cable–AWG and number of conductors as required. Braided shield with shield
connected to the metallized backshell at the chassis and at the DI/O Breakout
box.
97
Model 494.44 Two-Station System Board
DO 1
DO 1
DO 1
DO 1
DO 1
DO 1
DO 1
DO 1
DO 1
494.44 System Board494.32 Breakout Box
J55 Dig OutJ20 Outputs
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
Power
100-240 VAC
50-60 Hz, 1-2 A
DA Output
J24
1234567
8
1234567
8
LAN 2 LAN 1
DEBUG
MOTOROLA
10/100 BASE T10/100 BASE T
SCSI
BUSY
PIB
BUSY
PCI MEZZANINE CARD
PCI MEZZANINE CARD
J55 Dig Out Dig In J54
J43A J43B
J49 Aux PwrEstop/Run J23
Interlock
J29AJ29B
Load Frame
J28 HSM A-B
HPU J25
J55 Dig Out
J55 Digital Output Connections for the Model 494.44 System Board
Connector J55 Dig Out provides eight digital outputs that must be used with the
Model 494.32 8-Channel High-Current DI/O Breakout Box. The breakout box
provides high-current switching/isolation and device connections for each of the
eight J55 outputs.
NoteExternal power for the output devices is brought into the breakout box
through breakout-box connector J29.
Cable specificationTo maintain EMC compliance, the J55 Digital Output cable must comply with
FlexTest Controller Configurations
98
the following specifications:
Connector–9-pin contact type D male EMI connector
Back shell–EMI metallized plastic
Cable–AWG and number of conductors as required. Braided shield with shield
connected to the metallized backshell at the chassis.
Analog Output Connections for the Model 494.44 System Board
The Model 494.44 System Board provides two analog output signals that are
available on the D/A Output connector (located on the rear panel of the 494.04
chassis). Each D/A output is software defined.
Cable specificationTo maintain EMC compliance, the D/A Output cable must comply with the
following specifications:
Connector type–9-pin, type D, male EMI connector.
Backshell–EMI metallized plastic or metal.
Cable–shielded twisted pairs (24 AWG minimum), braided shield with the shield
connected to the metallized backshell at the chassis.
Custom J29 Y Cable
(PN 100-197-651)
required for UPS systems.
D9S
2
7
8
4
D9P
2
7
8
4
D15S
UPS
Battery Low
D15P
UPS Cable
Load
Frame
Cable
D15P
UPS Connections for the Model 494.44 System Board (FT40)
The following drawing shows UPS connections for the Model 494.44 System
Board. Once connected, you must use your controller software to configure the
various UPS options.
Cable specificationTo maintain EMC compliance, the UPS cable that connects to the load frame Y
100
FlexTest Controller Configurations
cable must comply with the following specifications:
Connector type–9-pin, type D, male EMI connector.
Backshell–EMI metallized plastic or metal.
Cable–26–22 AWG, four-conductor with overall braided shield, with the braided
shield connected to the metallized backshell at the chassis.