MTS 200 User Manual

m
be certain.
MTS FlexTest® Models 40/60/100/200 Controller Hardware
Service Information for Controllers Using Series 793 Software:
- Specifications
- Installation
- Cabling
100-187-204 H
Copyright information © 2014 MTS Systems Corporation. All rights reserved.
Trademark information MTS, 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.
Publication information
MANUAL PART NUMBER PUBLICATION DATE
100-187-204 A November 2007
100-187-204 B May 2008
100-187-204 C September 2008
100-187-204 D August 2009
100-187-204 E September 2010
100-187-204 F July 2011
100-187-204 G December 2013
100-187-204 H February 2014
2
MTS FlexTest® Models 40/60/100/200 Controller Hardware

Contents

Contents 3
Technical Support 7
Preface 13
Conventions 14
Chapter 1 Safety Information 17
Safety Circuits 21
Chapter 2 FlexTest Controller Configurations 27
FlexTest Controller Overview 28
Installation 31
UPS System Requirements 43
FlexTest 40 Controller Configuration 47
Model 494.41 Single-Station System Board 52
Model 494.42 Single-Station System Board 67
Model 494.44 Two-Station System Board 84
FlexTest 60 Controller Configuration 101
FlexTest 100 Controller Configuration 104
FlexTest 200 Controller Configuration 107
MTS FlexTest® Models 40/60/100/200 Controller Hardware Contents
3
Chapter 3 VME Bus Boards 113
VME Bus Board Overview 114
Processor Connections 118
Model 494.40 I/O Carrier Board 120
Model 494.43 Multibox Board 126
Chapter 4 Mezzanine Cards 133
Digital Universal Conditioner Mezzanine Cards 143
Model 494.25 Single DUC Card 154
Model 494.26 Dual DUC Card 157
Model 494.16 VD/DUC Mezzanine Card 160
Model 494.21 Multi-Range DUC with Acceleration Compensation Card 168
Model 494.45 8-Input A/D Converter Card 176
Model 494.46 8-Output D/A Card 179
Model 494.47 Dual UART/Encoder Interface Card 183
Model 494.49 Quad Encoder Interface Card 195
TEDS Transducer ID Module 206
Chapter 5 Digital I/O and Transition Boards 207
Digital I/O Hardware Devices 208
Model 493.72 Digital I/O Board 209
Model 493.31 16-Channel Low-Current DI/O Breakout Box 212
Model 494.31 16-Channel High-Current DI/O Breakout Box 216
Model 494.32 8-Channel DI/O Breakout Box 221
Model 494.33 Digital I/O Power Supply 227
Transition Boards 237
Model 493.73 HPU Interface Board 238
Model 493.74 Two-Station HSM Interface Board 246
Model 493.80 Encoder Interface Board 256
Model 494.74 Two-Station HSM Interface Board 261
Model 494.75 8-Input BNC Transition Board 269
4
Contents
MTS FlexTest® Models 40/60/100/200 Controller Hardware
Model 494.76 8-Output BNC Transition Board 270
Model 494.79 8-Channel Valve Driver Board 271
Model 493.07 HPU Converter Box 275
Chapter 6 Cables 281
Appendix A Troubleshooting and Maintenance 285
Chassis Troubleshooting 285
Service Connections 288
Chassis Maintenance 289
Appendix B Optional Station Configurations 291
Appendix C Aero Multibox Systems 293
Aero Multibox Overview 294
Appendix D Model 793 Multibox Systems 331
Index 339
MTS FlexTest® Models 40/60/100/200 Controller Hardware Contents
5
6
Contents
MTS FlexTest® Models 40/60/100/200 Controller Hardware

Technical Support

How to Get Technical Support

Technical Support
Start with your
manuals
Technical support
methods
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.com The 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-mail tech.support@mts.com
Telephone MTS Call Center 800-328-2255
Weekdays 7:00 A.M. to 5:00 P.M., Central Time
Fax 952-937-4515
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 Hardware Technical 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 problem Describe 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
problem started?
Technical Support
8
What are the equipment model numbers?
What is the controller model (if applicable)?
What is the system configuration?
MTS FlexTest® Models 40/60/100/200 Controller Hardware
Technical Support
Know relevant
computer information
Know relevant
software information
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 Hardware Technical Support
9
Technical Support
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
Hydromechanical material test system
Vehicle test system
Vehicle component test system
Aero test system
Be prepared to
troubleshoot
Write down relevant
information
After you call MTS 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.
Technical Support
10
MTS FlexTest® Models 40/60/100/200 Controller Hardware

Problem Submittal Form in MTS Manuals

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 Hardware Technical Support
11
Technical Support
Technical Support
12
MTS FlexTest® Models 40/60/100/200 Controller Hardware

Preface

Before You Begin

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 manuals In 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).
MTS FlexTest® Models 40/60/100/200 Controller Hardware Preface
13

Conventions

DANGER
WARNING
CAUTION
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. 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.
Note For 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.
Notes Notes provide additional information about operating your system or highlight
easily overlooked items. For example:
Note Resources that are put back on the hardware lists show up at the end of
the list.
Special terms The first occurrence of special terms is shown in italics.
Preface
MTS FlexTest® Models 40/60/100/200 Controller Hardware
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
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 links The 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.
MTS FlexTest® Models 40/60/100/200 Controller Hardware Preface
15
Conventions
16
Preface
MTS FlexTest® Models 40/60/100/200 Controller Hardware
Chapter 1

Safety Information

Contents Intended 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 Hardware Safety 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.
Safety Information
18
MTS FlexTest® Models 40/60/100/200 Controller Hardware
Safety Information
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 Models The 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.
Manufacturer MTS Systems Corporation
14000 Technology Drive Eden Prairie, MN, USA 55344-2290 Phone: 952-937-4000
Directives Low Voltage directive 2006/95/EEC and the EMC directive 2004/108/EC.
Standards EN 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.
D
ESCRIPTION BASIC STANDARD TEST SPECIFICATION
Limits for harmonic current emissions
Limits for voltage fluctuations and flicker
Electrostatic discharge EN 61000-4-2 +/- 4 kV contact discharge
Radio frequency electromagnetic field, amplitude modulated
Electrical fast transient EN 61000-4-4 2 kV mains
MTS FlexTest® Models 40/60/100/200 Controller Hardware Safety Information
EN 61000-3-2 Class A
EN 61000-3-3 Class A
+/- 8 kV air discharge Performance Criteria B
EN 61000-4-3 10 V/m
Performance Criteria A
2 kV control and signal Performance Criteria B
19
Safety Information
DESCRIPTION BASIC STANDARD TEST SPECIFICATION
Electrical surge immunity test EN 61000-4-5 2 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 field EN 61000-4-8 30 A (rms)/m 50 and 60 Hz
Voltage dips, short interruptions, and voltage variations
Radiated emissions EN 55011 Class A
Conducted emissions EN 55011 Class A
EN 61000-4-6 10 V (rms)
Performance Criteria A
Performance Criteria B
EN 61000-4-11 1 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.
Safety Information
20
MTS FlexTest® Models 40/60/100/200 Controller Hardware

Safety Circuits

WARNING

Shock Hazards

Safety Circuits
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 Hardware Safety Information
21
Safety Circuits
WARNING

Input/Output Verification

Relay outputs If 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 inputs If necessary, you can set up the controller to monitor redundant digital input
Digital outputs If 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.
22
Safety Information
MTS FlexTest® Models 40/60/100/200 Controller Hardware

E-Stop Circuit Testing

Safety Circuits
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.
Note MTS 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 Hardware Safety Information
23
Safety Circuits

Hardware Interlocks

Global interlocks Global interlocks detect controller chassis conditions (such as watchdog timers
Station interlocks Station 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.
Note Some 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
Note If 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.
MTS FlexTest® Models 40/60/100/200 Controller Hardware

E-Stop and Hardware Interlocks

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
TOP GLOBAL (CONTROLLER) INTERLOCK STATION 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.
Note The 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.
Note If 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 Hardware Safety Information
Interlock outputs are intended to be monitored by external devices.
Interlock outputs are intended to be monitored by external devices.
25
Safety Circuits
Safety Information
26
MTS FlexTest® Models 40/60/100/200 Controller Hardware

FlexTest Controller Configurations

Chapter 2
FlexTest Controller Configurations
This chapter describes the various components, specifications, and installation requirements for MTS FlexTest Controller hardware.
Contents About MTS FlexTest Models 40/60/100/200 Controllers 28
Typical Series 494 Chassis Connections (FT60, FT100, FT200) 30
Controller Installation Procedure 31
Installation Requirements–Series 494 Hardware 34
Environmental Requirements—Series 494 Hardware 35
Ventilation Requirements–Series 494 Chassis 36
Rack-Mounting Requirements–Series 494 Chassis 37
Grounding Requirements–Series 494 Chassis 37
AC Power Disconnect Requirements–Series 494 Chassis 40
UPS System Requirements 43
UPS System Requirements 43
Specifications–UPS Systems Used with MTS Controllers 45
FlexTest 40 Controller Configuration 47
About the Model 494.41 Single-Station System Board 52
Model 494.42 System Board Specifications 68
About the Model 494.44 Two-Station System Board 84
FlexTest 60 Controller Configuration 101
FlexTest 100 Controller Configuration 104
FlexTest 200 Controller Configuration 107
MTS FlexTest® Models 40/60/100/200 Controller Hardware FlexTest Controller Configurations
27

FlexTest Controller Overview

FlexTest Controller Overview

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
PARAMETER FLEXTEST 40FLEXTEST 60FLEXTEST
Test Stations 2 Up to 6* Up to 8 Up to 8
Control Channels Up to 4 Up to 8 Up to 16 Up to 40
100
FLEXTEST
200
FlexTest Controller Configurations
28
Conditioned Transducer Inputs
Auxiliary Data Inputs Up to 16 Up to 32 Up to 64 Up to 96
*With On/Off Hydraulic Service Manifolds only
MTS FlexTest® Models 40/60/100/200 Controller Hardware
Up to 12 Up to 24 Up to 40 Up to 80
FlexTest 40 FlexTest 60
FlexTest 100
FlexTest 200
Front
(6 VME slots)
Back
(8 transition slots,
7 powered)
Back
(12 transition slots, 10 powered)
Back
(3 VME slots)
Front
(10 VME slots)
Front
(20 VME slots)
Back
(20 transition slots, 19 powered)
FlexTest Controller Overview
FlexTest Models 40/60/100/200 Controllers
MTS FlexTest® Models 40/60/100/200 Controller Hardware FlexTest Controller Configurations
29
FlexTest Controller Overview
HPU
Force Transducer
Hydraulic
Service
Manifold
(HSM)
Hydraulic
Power Unit (HPU)
Servovalve
LVDT
1 2 3 4 5 6 7 8
SERVICE
493.73 HPU
J23 E-STOP OUT
J24 E-STOP IN
J25 HPU
J54 SYS D I/O
J49 AUX PWR
J3A STA
J3B STA
J28A HSM
J28B HSM
494.74 HSM
VME Bus
Transition Bus
494.26 Dual
DUC
494.40
I/O Carrier
Station A
E-Stop
494.16
VD/DUC
494.16
VD/DUC
Force Transducer
Hydraulic
Service
Manifold
(HSM)
Servovalve
LVDT
Station B

Typical Series 494 Chassis Connections (FT60, FT100, FT200)

30
FlexTest Controller Configurations
MTS FlexTest® Models 40/60/100/200 Controller Hardware
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