MTS 200 User Manual

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

Service Information for Controllers Using Series 793 Software:

- Hardware Descriptions

- Specifications

- Installation

- Cabling

100-187-204 H

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

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

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

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

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

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

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

• 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

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

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

Technical Support

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

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.

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

Conventions

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)

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

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

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.

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

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

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

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.

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

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

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.

Safety Circuits

Safety Information

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

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

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

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

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)

FlexTest Controller Configurations

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

Installation

CAUTION

This section includes a number of installation requirements for Series 494 Controller Hardware.

Controller Installation Procedure

The following procedure provides a basic outline for the installation of FlexTest controllers.

1. Unpack the controller.

2. Inspect the controller for any damage.

Note Report any damage to the controller to the shipping agent and MTS.

Controller electronic components can be damaged during shipping.

Installation

Using a controller with damaged components can result in injury to personnel or equipment damage.

Do not attempt to use equipment that was damaged during shipping. Report any damaged components to the shipping agent and MTS.

3. Move the controller chassis to the desired location.

The Model 494.10 and 494.20 Chassis weighs approximately 45 kg (100 lb) and 60 kg (132 lb) respectively.

Improper lifting techniques can cause strained muscles and back injuries.

When lifting this chassis, take the appropriate precautions to prevent injuries to yourself.

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

Installation

CAUTION

WARNING

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

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.

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

Installation

WARNING

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.

• 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.

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

Installation

Installation Requirements–Series 494 Hardware

Software settings Software 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 panels To help ensure proper ventilation, each blank slot in a Series 494 Chassis must

have a blank chassis panel.

Chassis grounding The controller will not function correctly if the chassis is not grounded properly.

I/O carrier settings The 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 plugs Each 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 information For 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

Model 494.40 I/O Carrier Board” on page 121.

FlexTest Controller Configurations

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

Environmental Requirements—Series 494 Hardware

All Series 494 hardware components are intended for indoor use only. This indoor environment must conform to the following environmental specifications.

Note All Series 494 Controller must only be operated under the installation

and ambient conditions (such as, temperature, moisture, and EMC) specified.

PARAMETER SPECIFICATION

Temperature 5ºC–40ºC (41ºF–104ºF)

Humidity 5–85%, non-condensing

Altitude 3048 m (10,000 ft) maximum

Installation

Space Requirements

Note To 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.

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

Installation

Required

Clearance

51 mm (2 in.)

Required

Clearance

51 mm (2 in.)

102 mm

(4 in.)

100-240 VAC

50-60 Hz, 12/6A

9 8 7 6 5 4 3 2 1 B A

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

J49 AUX PWR

J3A STA

J3B STA

J28A HSM

J28B HSM

494.74

HSM

First

494.75

ANALOG

INPUT

CH 1 - 8

Last

J11

J12

First

494.76

ANALOG

OUTPUT

CH 1 - 8

Last

J11

J12

Power

Over

Temp

Power

J39 Power Monitor

J49 AUX PWR

J3A STA

J3B STA

J28A HSM

J28B HSM

494.74

HSM

J49 AUX PWR

J3A STA

J3B STA

J28A HSM

J28B HSM

494.74

HSM

100-240 VAC

50-60 Hz, 12/6A

9 8 7 6 5 4 3 2 1 B A

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

J49 AUX PWR

J3A STA

J3B STA

J28A HSM

J28B HSM

494.74

HSM

First

494.75

ANALOG INPUT

CH 1 - 8

Last

J11

J12

First

494.76

ANALOG OUTPUT CH 1 - 8

Last

J11

J12

Power

Over

Temp

Power

J39 Power Monitor

J49 AUX PWR

J3A STA

J3B STA

J28A HSM

J28B HSM

494.74

HSM

J49 AUX PWR

J3A STA

J3B STA

J28A HSM

J28B HSM

494.74

HSM

Required

Clearance

51 mm

(2 in.)

100-240 VAC 50-60 Hz, 12/6A

9 8 7 6 5 4 3 2 1 B A

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

J49 AUX PWR

J3A STA

J3B STA

J28A HSM

J28B HSM

494.74 HSM

First

494.75

ANALOG

INPUT CH 1 - 8

Last

J11

J12

First

494.76 ANALOG OUTPUT CH 1 - 8

Last

J11

J12

Power

Over Temp

Power

J39 Power Monitor

J49 AUX PWR

J3A STA

J3B STA

J28A HSM

J28B HSM

494.74 HSM

J49 AUX PWR

J3A STA

J3B STA

J28A HSM

J28B HSM

494.74 HSM

CAUTION

Ventilation Requirements–Series 494 Chassis

For proper ventilation for rack-mounted chassis, you must provide 51 mm (2 in) clearance on all sides of a Series 494 Chassis.

Note The rear of the chassis requires a minimum clearance of 15.24 cm (6 in)

for cable connections.

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.

FlexTest Controller Configurations

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

Rack-Mounting Requirements–Series 494 Chassis

Shorting Bar

Signal

Common

Chassis

Ground

To install a Series 494 Chassis in most 19-inch consoles you will need a console mounting kit.

OUNTING KIT PART NUMBER

494.04 Chassis Console Mounting Kit 100-152-784

494.06 Chassis Console Mounting Kit 100-174-282

494.10 Chassis Console Mounting Kit 100-183-825

Installation

494.20 Chassis Console Mounting Kit (Vertical Console)

494.20 Chassis Console Mounting Kit (Half-Height Console)

Grounding Requirements–Series 494 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.

56-819-501

56-781-303

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

Installation

WARNING

100-240 VAC 50-60 Hz, 12/6A

9 8 7 6 5 4 3 2 1 B A

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

J49 AUX PWR

J3A STA

J3B STA

J28A HSM

J28B HSM

494.74 HSM

First

494.75

ANALOG

INPUT

CH 1 - 8

Last

J11

J12

First

494.76

ANALOG

OUTPUT CH 1 - 8

Last

J11

J12

Power

Over Temp

Power

J39 Power Monitor

J49 AUX PWR

J3A STA

J3B STA

J28A HSM

J28B HSM

494.74 HSM

J49 AUX PWR

J3A STA

J3B STA

J28A HSM

J28B HSM

494.74 HSM

Series 494 Chassis (Rear)

Shorting Bar

Required

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

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.

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

Ground Rail

Console Power Panel

The System Ground cable (PN 376-999-xx) connects to the test frame and other equipment.

Use a cabinet ground cable (PN 569-278-xx) to connect each controllers Chassis Ground lug to the vertical ground rail.

A System Ground cable (PN

376-999-xx) connects each

ground lug on the power panel

to the ground rail.

Series 494

Chassis

Series 494

Chassis

ATTENTION:

RECEPTACLE FOR CONSOLE EQUIPMENT ONLY.

Receptacle Output:

System Ground

cable (PN 376-999-01)

connects the cabinet

ground stud to the

Ground Rail.

Cabinet Ground

Stud

Cabinet

Wall

Ground

Rail

ATTENTION:

RECEPTACLE FOR CONSOLE EQUIPMENT ONLY.

Receptacle Output:

System Ground

Connect all Signal Common cables here.

Connect all Chassis Ground cables here.

Shorting Bar

Removed

Installation

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

Installation

Outlet Strip

with circuit breaker

Outlet Strip

(printer, etc.)

Dedicated Circuit

Locking Connector

100-240 VAC 50-60 Hz, 12/6A

9 8 7 6 5 4 3 2 1 B A

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

J49 AUX PWR

J3A STA

J3B STA

J28A HSM

J28B HSM

494.74 HSM

First

494.75 ANALOG INPUT CH 1 - 8

Last

J11

J12

First

494.76

ANALOG

OUTPUT CH 1 - 8

Last

J11

J12

Power

Over Temp

Power

J39 Power Monitor

J49 AUX PWR

J3A STA

J3B STA

J28A HSM

J28B HSM

494.74 HSM

J49 AUX PWR

J3A STA

J3B STA

J28A HSM

J28B HSM

494.74 HSM

Self-Standing Enclosure

ATTENTION:

RECEPTACLE FOR CONSOLE EQUIPMENT ONLY.

Receptacle Output:

System Ground

100-240 VAC

50-60 Hz, 12/6A

9 8 7 6 5 4 3 2 1 B A

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

J49 AUX PWR

J3A STA

J3B STA

J28A HSM

J28B HSM

494.74

HSM

First

494.75

ANALOG INPUT

CH 1 - 8

Last

J11

J12

First

494.76

ANALOG OUTPUT CH 1 - 8

Last

J11

J12

Power

Over

Temp

Power

J39 Power Monitor

J49 AUX PWR

J3A STA

J3B STA

J28A HSM

J28B HSM

494.74

HSM

J49 AUX PWR

J3A STA

J3B STA

J28A HSM

J28B HSM

494.74

HSM

100-240 VAC

50-60 Hz, 12/6A

9 8 7 6 5 4 3 2 1 B A

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

J49 AUX PWR

J3A STA

J3B STA

J28A HSM

J28B HSM

494.74

HSM

First

494.75

ANALOG INPUT

CH 1 - 8

Last

J11

J12

First

494.76

ANALOG OUTPUT CH 1 - 8

Last

J11

J12

Power

Over

Temp

Power

J39 Power Monitor

J49 AUX PWR

J3A STA

J3B STA

J28A HSM

J28B HSM

494.74

HSM

J49 AUX PWR

J3A STA

J3B STA

J28A HSM

J28B HSM

494.74

HSM

Outlet Strip

Dedicated Circuit

Power Panel

Internal

Power

Strip

Locking Connectors

Chassis

Power Cords

Console Mounting

AC Power Disconnect Requirements–Series 494 Chassis

The Series 494 Chassis and the computer workstation should both be powered from the same electrical circuit.

Note Be sure to locate the chassis so that you have adequate access to

disconnect the power cord from the chassis.

FlexTest Controller Configurations

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

Cable Requirements–Series 494 Hardware

WARNING

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.

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

Installation

FlexTest Controller Configurations

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

UPS System Requirements

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.

Battery power

considerations

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

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.

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.

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.

Note FT40 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.)

FlexTest Controller Configurations

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

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

TEM REQUIREMENT

Operating temperature 5–40 deg C

Operating humidity 5–85% 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

ONTROLLER TYPE CONTROLLER CHASSIS UPS POWER REQUIRED

FlexTest SE 493.02 1200 watt

FlexTest GT 493.10 2500 watt

Aero ST 493.20 3500 watt

Flextest 40 494.04 1200 watt

FlexTest 60 494.06 1800 watt

FlexTest 100 494.10 2500 watt

FlexTest 200 494.20 3500 watt

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

UPS System Requirements

Controller P0 Interlock Check Utility

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.

FlexTest Controller Configurations

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

FlexTest 40 Controller Configuration

FlexTest 40

Digital Controller

About the FlexTest 40 Controller

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).

FlexTest 40 Controller Configuration

Controller capabilities

PARAMETER FLEXTEST 40

Test Stations 1

Control Channels Up to 4

Conditioned Transducer Inputs Up to 12

Auxiliary Data Inputs Up to 16

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

FlexTest 40 Controller Configuration

Power

100-240 VAC 50-60 Hz, 1-2 A

DA Output

J24

1234567

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 T 10/100 BASE T

SCSI BUSY

PIB

BUSY

PCI MEZZANINE CARD

About the Model 494.04 Chassis

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 cards Two 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)

Hydraulic control The system board provides control of the test system hydraulics, including

hydraulic power unit (HPU) and hydraulic service manifold (HSM) control.

Interlocks The 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 board The 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.

FlexTest Controller Configurations

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

Specifications–Model 494.04 Chassis

All equipment related to the controller should be connected to the same fused power circuit.

Note Electrical connections must be made by qualified personnel and conform

to local codes and regulations. Local electrical codes supersede any information found here.

Model 494.04 Chassis Specifications

ARAMETER SPECIFICATION

Input Voltage 100–240 V AC (single phase)

Input Frequency 50–60 Hz

Input Current 5 A at 100 V AC

Facility Power Requirements Provide a dedicated circuit for the

Input Surge <40 A

FlexTest 40 Controller Configuration

power factor corrected universal input

3 A at 240 V AC

chassis, computer, and monitor.

Insulation Over Voltage Category I

Pollution Degree 2

Weight Approximately 8.6 kg (19 lb)

Dimensions Width: 43 cm (17 in)

Height: 14 cm (5.5 in) Depth: 44.5 cm (17.5 in)

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

FlexTest 40 Controller Configuration

Power

100-240 VAC 50-60 Hz, 4-2 A

DA Output

J24

1234567

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 T 10/100 BASE T

SCSI

BUSY

PIB

BUSY

PCI MEZZANINE CARD

Slot 4-5 - 494.41 System I/O

Slot 3 - 494.40 I/O Carrier

Slot 2 - 494.40 I/O Carrier

Slot 1 - Processor Board

Model 494.04 Chassis Boards

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

LOT BOARD NAME FUNCTION

Slot 1 Processor Board Provides PIDF processing and an interface between the

controller and the computer workstation.

Slots 2, 3 Model 494. 40 I/O Carrier Supports 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, 5 System Board Provides 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.

FlexTest Controller Configurations

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

Typical Model 494.04 Chassis Connections

HPU

Power

100-240 VAC 50-60 Hz, 1-2 A

DA Output

J24

1234567

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 T 10/100 BASE T

SCSI

BUSY

PIB

BUSY

PCI MEZZANINE CARD

Slot 3 - 494.40 I/O Carrier

Slot 2 - 494.40 I/O Carrier

Slot 1 - Processor Board

Force Transducer

Hydraulic

Service

Manifold

(HSM)

Hydraulic

Power Unit

(HPU)

Computer Workstation

Load Frame E-Stop

Servovalve

J49 AUX PWR

Auxilliary DC supply voltages for external devices. + 5 V DC, +15 V DC,

-15 V DC, +24 V DC

Slot 4-5

494.41 System I/O

J43 Interlock Input/Output

J55

Digital

Outputs

J54

Digital

Inputs (3)

Analog

Outputs (2)

J24 Remote E-Stop

To Digital Universal Conditioner (DUC) Card in 494.40 I/O Carrier

LVDT

To Valve Driver

Card in 494.40

I/O Carrier

FlexTest 40 Controller Configuration

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

J54 Dig In

J49 Aux Pwr

J25 Hpu

Dig Out J55

Intlk J43

E-stop J29

J28 HSM

Power

100-240 VAC 50-60 Hz, 1-2 A

DA Output

J24

1234567

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

J49 AUX PWR

Auxiliary DC supply voltages for external devices. + 5 V DC, +15 V DC,

-15 V DC, +24 V DC

J28 HSM

24-volt control for HSM off/low/high or proportional solenoids

J43

Interlock input Interlock output

J29

Load Frame E-Stop

J25

24 V DC HPU control

J54

Digital inputs (3)

J55

Digital outputs (3)

494.04

Chassis

J24

Remote E-Stop

Output

(2)

Model 494.41 Single-Station System Board

About the Model 494.41 Single-Station System Board

The Model 494.41 System board is a twoslot board that is only used in the Model

494.04 Chassis. This board provides analog and digital I/O, E-Stop, HSM, and HPU control for one station.

Board features

External Interfaces

• Three digital inputs (J54)

• Three digital outputs (J55)

• Auxiliary power outputs for external

devices (J49)

• Two analog outputs (DA Output

connector located on the 494.04 chassis)

Hydraulic Control

• 24-volt HPU control (J25)

• 24-volt HSM control (Off/Low/High

or proportional) (J28)

• E-Stop/Interlock Control

• Load-frame E-Stop control (J29)

• Optional E-Stop control (J24-located

on the 494.04 chassis)

• One interlock input and one interlock

output (J43)

FlexTest Controller Configurations

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

Model 494.41 System Board Specifications

Model 494.41 Specifications (part 1 of 3)

ARAMETER SPECIFICATION

Model 494.41 Single-Station System Board

HSM Control*

Off/Low/High Control

Low Output

High Output

Proportional Control

Signal Output

Solenoid Impedance

Ramp Time (0 to full scale)

Interlock Output Relay

Volta ge

Current

Connector J28 (CPC-4S)

+24 V DC, 1.0 A maximum

0–0.78 A

20–25 Ω

2.1 s or 4.2 s (software selectable)

* The type of HSM control (off/low/high or proportional) is software configurable.

Connector J43 (D9S)

30 V DC/AC maximum

1 A maximum

Normally Open Relay Contacts: Open = Interlock

Normally Closed Relay Contacts: Closed = Interlock

Interlock Input

Interlock Trip Volta ge

Maximum Input Volta ge

Input Resistance

Interlock Power Output

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

Connector J43 (D9S)

0.8 V minimum, 3 V maximum

+26 V DC

2700 Ω

+24 V DC (current limited by a 6.6-KΩ resistor)

Model 494.41 Single-Station System Board

ARAMETER SPECIFICATION

Model 494.41 Specifications (part 2 of 3)

Program Interlock Input

Input Logic

HPU Outputs (Start/Low/High)

HPU Output

HPU ON Input

HPU Interlock Inputs (Low Level and Overtemp)

Trip-point Voltage

Auxiliary Power Outputs

Connector J29 (D15S)

Switch Contact Closed = no program interlock Switch Contact Open = program interlock

Connector J25 (D15P)

Output Voltage: 24 V DC at 10 mA

Trip Voltage: 0.9–5.5 V DC

Maximum Input Voltage: +26 V DC

Connector J25 (D15P)

18–23 V DC Maximum Input Voltage: +26 V DC

Connector J49 (D9S)

FlexTest Controller Configurations

+5 V DC

+15 V DC

-15 V DC

+24 V DC

0.75 A at 40ºC (104ºF)

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

Model 494.41 Specifications (part 3 of 3)

ARAMETER SPECIFICATION

Model 494.41 Single-Station System Board

Digital Output Relays

Volta ge

Current

Output logic

Aux. Voltage

Digital Inputs

Input ON/OFF Trip Volta ge

Maximum Input Volta ge

Input Resistance

Connector J55 (D9S)

30 V AC/DC maximum

1 A maximum

Output 1: One normally open (NO) contact Open = Output is OFF

Output 2: One normally open (NO) contact and one normally closed (NC) contact NO Contact: Open = Output is OFF NC Contact: Closed = Output is OFF

Output 3: One normally open (NO) contact Open = Output is OFF

24 V DC, 0.75 A at 40ºC

Connector J54 (D9P)

0.8–3 V DC

+ 26 V DC

2.7 KΩ

Digital Input Power Output

D/A Outputs

Resolution

Output Type

Output Voltage

Output Current

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

+ 24 V DC (current limited by 6.6-KΩ resistor)

Connector "D/A Output" (D9P)

16 bit

Single ended

+/- 10 V full scale

5.0 mA maximum

Note This connector is located on the rear panel

of the 494.04 chassis.

Model 494.41 Single-Station System Board

Power

100-240 VAC 50-60 Hz, 1-2 A

DA Output

J24

1234567

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

494.04 Chassis

494.41 System Board

J24 E-Stop

J24

E-Stop Box

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 specification To 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 required If 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.

FlexTest Controller Configurations

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

Model 494.41 Single-Station System Board

Power

100-240 VAC 50-60 Hz, 1-2 A

DA Output

J24

1234567

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

ON = Normal

ON = HPU ON

Controller 24 V DC

HPU

Sense

24 V DC (from HPU)

Start

High

HPU Over Temp Open = Interlock Active

494.41 System Board

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

+24 V DC (from HPU)

HPU E-Stop Out 1

Open = HPU E Stop

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.

Note Other 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.

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

Model 494.41 Single-Station System Board

CAU TION

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 specification To maintain EMC compliance, J25 HPU cables must comply with the following

specifications:

Connector—15-contact, type-D, female EMI connector.

Backshell–EMI metallized plastic or metal.

Cable—22 AWG, 10-conductor with braided shield with the shield connected to

metallized plastic or metal backshell to the chassis.

Jumper plug required If connector J25 HPU is not used, you must install a jumper plug to maintain the

integrity of the interlocks. Use jumper plug part number 039-713-301 or jumper pins 1–7, 2–3–5, 6–9, 8–10–11–12.

FlexTest Controller Configurations

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

Model 494.41 Single-Station System Board

494.41 System I/O Board

J28 HSM

+24V

HSM Low

Solenoid

HSM High

Solenoid

High

Low

494.41 System I/O Board

J28 HSM

HSM Proportional

Control

Current Amplifier

Power

100-240 VAC 50-60 Hz, 1-2 A

DA Output

J24

1234567

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

(Off/Low/High HSM Control)

(Proportional HSM Control)

J28 HSM

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.

Note The 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 specification To 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.

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

Model 494.41 Single-Station System Board

Controller Interlock

Open = Controller Interlock

494.41 System Board

Power

100-240 VAC 50-60 Hz, 1-2 A

DA Output

J24

1234567

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

Fused 24 V DC to Crosshead

J29

E Stop

Crosshead Interlock Common

+24V

External Program Interlock Source

Open=Program Interlock

HPU E Stop

+24V

HSM High

Crosshead Unlock Power

Crosshead Unlock Power Common

J29 E-Stop

To HPU E Stop Chain

* MTS Model 505 Pumps and older do not use the

HPU E-Stop 2 signal.

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 specification To 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 required If 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

FlexTest Controller Configurations

pins 3-4, 5-7, 8-13, and 11-15.

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

Model 494.41 Single-Station System Board

+24V

Interlock Disabled

+24V

Switch Contact

(Open = Interlock)

+24V

Logic Input

(0=Interlock)

Interlock In (Gnd)

Interlock Out (NO)

Interlock = Open

Interlock Out (NC) Interlock = Closed

Common

- Interlock In

+ Interlock In

Interlock In (Pwr)

+24V

J43

Intlk

494.41 System Board

Interlock

Output

Interlock

Input

Power

100-240 VAC 50-60 Hz, 1-2 A

DA Output

J24

1234567

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

J43 Interlock

J43 Interlock Connections for the Model 494.41 System Board

Connector J43 Interlock provides one optically isolated interlock input and a relay-contact interlock output.

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

Cable specification To maintain EMC compliance, the J43 Interlock 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.

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 part number 100-057-245, or jumper pins 1-2, 3-4, and 5-9.

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

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

+24 V

-15V

+ 15 V

+24 V

Gnd (+24 V)

+5V

J49 Aux Pwr

Gnd (+/- 15 V)

- 15 V

+15V

Gnd (+5 V)

+ 5 V

+ 15 V

J49 Auxiliary Power

J49 Auxiliary Power Connections for the Model 494.41 System Board

The J49 Aux Pwr connector provides fused (self resetting) auxiliary power outputs for: +5 V DC, +15 V DC, -15 V DC, and +24 V DC.

Cable specification To maintain EMC compliance, the J49 Auxiliary Power cable must comply with

the following specifications:

Connector type–9-pin, type D, male EMI connector.

Backshell–EMI metallized plastic or metal.

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

FlexTest Controller Configurations

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

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

J54 Digital Input

Logic Input Wiring

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

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 specification To maintain EMC compliance, the J54 Digital Input cable must comply with the

following specifications:

Connector type–9-pin, type D, male EMI connector.

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

Cable–AWG and number of conductors as required. Braided shield with the shield connected to the metallized backshell at the chassis.

Back shell–EMI metallized plastic or metal.

Model 494.41 Single-Station System Board

Relay Contact

494.41 System Board

Power

100-240 VAC 50-60 Hz, 1-2 A

DA Output

J24

1234567

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

J55

Output 1

Output 3

+24 V

Output 2

Aux Power

J55 Digital Output

J55 Digital Output Connections for the Model 494.41 System Board

Connector J55 Dig Out provides three general-purpose digital outputs that can send digital-logic signals to external switches or logic devices.

Cable specification To maintain EMC compliance, the J55 Digital Output cable must comply with

the following specifications:

Connector–9-pin, type D, male EMI connector.

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

FlexTest Controller Configurations

Back shell–EMI metallized plastic.

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

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

494.04 Chassis

494.41 System Board

D/A Output

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 specification To 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.

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

Model 494.41 Single-Station System Board

494.41 System I/O Board

Power

100-240 VAC 50-60 Hz, 1-2 A

DA Output

J24

1234567

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

J54 Digital Input

+24 V DC

UPS

AC Fail Contacts

Open = Logic 0

J54

Dig In

Digital Input 1

Low Battery Contacts

Open = Logic 0

Digital Input 2

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.

Note See your controller software user guide for information on how digital

inputs are assigned and used.

Cable specification To maintain EMC compliance, the J54 Digital Input cable must comply with the

following specifications:

FlexTest Controller Configurations

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

connected to the backshell at the chassis.

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

Power

100-240 VAC 50-60 Hz, 1-2 A

DA Output

J24

1234567

LAN 2 LAN 1

DEBUG

MOTOROLA

10/100 BASE T10/100 BASE T

SCSI BUSY

PIB

BUSY

PCI MEZZANINE CARD

J54 Dig InJ55 Dig Out

J43 INTLKJ56 UPS

J49 Aux Pwr J23 Estop/Run

J29 Load FrameJ25 HPU

J28 HSM

J54 Dig In J55 Dig Out

J43 INTLK J56 UPS

J49 Aux Pwr J23 Estop/Run

J29 Load Frame J25 HPU

J28 HSM

J49 AUX PWR

Auxiliary DC supply voltages for external devices: + 5 V DC, +15 V DC,

-15 V DC, +24 V DC

J28 HSM

24-volt control for HSM off/low/high or proportional solenoid plus an HSM Estop input

J43 Intlk

Interlock input Interlock output Event input

J29 Load Frame

Load Frame E-Stop

J25 HPU

24 V DC HPU control for one HPU channel

J54 Dig In

Digital inputs (3)

J55 Dig Out

Digital outputs (3)

Model

494.04

Chassis

J23 Estop/Run

2 Estop NO outputs 1 set of Run NO/NC outputs

DA Output (2))

J24 E-Stop

(Optional)

J56 UPS

UPS digital inputs ACFail, Low battery

Model 494.42 Single-Station System Board

About the Model 494.42 Single-Station System Board

The Model 494.42 System Board is a twoslot board that is only used in the Model

494.04 Chassis. This board provides analog and digital I/O, E-Stop, HSM, UPS, and HPU control for one station.

Board features

External Interfaces

• Three digital inputs (J54)

• Three digital outputs (J55)

• Auxiliary power outputs for external

devices (J49)

• UPS inputs (J56) ACFail and low

battery inputs (switch contacts)

Hydraulic Control

• Two analog outputs (DA Output

• 24-volt HPU control (J25)

• 24-volt HSM control (Off/Low/High or

E-Stop/Interlock Control

• Load-frame E-Stop and crosshead

• Optional E-Stop inputs (J24-located on

• Interlock (J43) provides one interlock

• E-Stop/Run outputs (J23)

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

connector on the 494.04 chassis)

proportional) for one HSM (J28)

control for one load frame (J29)

the 494.04 chassis)

input, one interlock output, and a software-defined event input

Model 494.42 Single-Station System Board

Model 494.42 System Board Specifications

Model 494.42 Specifications (part 1 of 4)

ARAMETER SPECIFICATION

E-Stop/Run Output Relay Contacts

Vol tage

Current

HPU Outputs (Start/Low/High)

HPU Outputs (start, low, high)

HPU ON Input

HPU Interlock Inputs (Low Level and Overtemp)

Connector J23 (D9S)

30 V DC/AC maximum

1 A maximum

Two (2) Normally Open Estop Relay Contacts: HPU E-Stop = Open

Set of NO/NC Prog. Run Relay Contacts:

Normally Open Contacts: Prog. Run = Closed Normally Closed Contacts: Prog. Run = Open

Connector J25 (D15P)

Output Voltage: 24 V DC at 250 mA

Trip Voltage: 0.8–10.0 V DC

Maximum Input Voltage: +26 V DC

Connector J25 (D15P)

FlexTest Controller Configurations

Trip-point Voltage

0.8–10.0 V DC Maximum Input Voltage: +26 V DC

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

Model 494.42 Specifications (part 2 of 4)

ARAMETER SPECIFICATION

Model 494.42 Single-Station System Board

HSM Control*

Off/Low/High Control

Low Output

High Output

Proportional Control

Signal Output

Solenoid Impedance

Ramp Time (0 to full scale)

Load Frame E-Stop

Crosshead Unlock Output

Program Interlock Input

Connector J28 (D-9S)

+24 V DC, 1.0 A maximum

0–0.78 A

20–25 Ω

2.1 s or 4.2 s (software selectable)

* The type of HSM control (off/low/high or proportional) is software configurable.

Connector J29 (D15S)

24 V DC at 1 A

Switch Contact Closed = no program interlock Switch Contact Open = program interlock

Interlock Output Relay

Vol tage

Current

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

Connector J43 (D9S)

30 V DC/AC maximum

1 A maximum

Normally Open Relay Contacts: Open = Interlock

Normally Closed Relay Contacts: Closed = Interlock

Model 494.42 Single-Station System Board

ARAMETER SPECIFICATION

Model 494.42 Specifications (part 3 of 4)

Interlock Input

Interlock Trip Vol tage

Maximum Input Vol tage

Input Resistance

Interlock Power Output

Event SwitchContact Input

Auxiliary Power Outputs

+5 V DC

+15 V DC

-15 V DC

+24 V DC

Connector J43 (D9S)

0.8 V minimum, 3 V maximum

+26 V DC

2700 Ω

+24 V DC (current limited by a 15-KΩ resistor)

Connector J43 (D9S)

Event contacts open= Active event

Event contacts closed= Inactive event

Connector J49 (D9S)

0.75 A maximum

FlexTest Controller Configurations

Digital Inputs

Input ON/OFF Trip Vol tage

Maximum Input Vol tage

Input Resistance

Digital Input Power Output

Connector J54 (D9P)

0.8–3 V DC

+ 26 V DC

2.7 KΩ

+ 24 V DC (current limited by 2.7-KΩ resistor)

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

Model 494.42 Specifications (part 4 of 4)

ARAMETER SPECIFICATION

Model 494.42 Single-Station System Board

Digital Output Relays

Vol tage

Current

Output logic

Aux. Voltage

UPS Alarm Inputs Connector J56 (D9S)

Connector J55 (D9S)

30 V AC/DC maximum

1 A maximum

Output 1: One normally open (NO) contact Open = Output is OFF

Output 2: One normally open (NO) contact and one normally closed (NC) contact NO Contact: Open = Output is OFF NC Contact: Closed = Output is OFF

Output 3: One normally open (NO) contact Open = Output is OFF

24 V DC, 0.75 A

UPS ACFAIL Alarm Input (switch contact):

Open=UPS ACFAIL active (logic 1) Closed= UPS ACFAIL not active (logic 0)

UPS Low Battery Alarm Input (switch contact):

Open=UPS Low Battery active (logic 1) Closed= UPS Low Battery not active (logic 0)

D/A Outputs

Resolution

Output Type

Output Voltage

Output Current

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

Connector "D/A Output" (D9P)

16 bit

Single ended

+/- 10 V full scale

5.0 mA maximum

Note This connector is located on the rear panel

of the Model 494.04 Chassis.

Model 494.42 Single-Station System Board

E-Stop 1 Output (NO)

HPU E-Stop = Open

494.42 System Board

J23 Estop/Run

E-Stop 2 Output (NO)

HPU E-Stop = Open

Program Run 1 Output (NC)

Program Run = Open

Program Run 2 Output (NO)

Program Run = Closed

Reserved

J23

Estop/Run

Power

100-240 VAC 50-60 Hz, 1-2 A

DA Output

J24

1234567

LAN 2 LAN 1

DEBUG

MOTOROLA

10/100 BASE T10/100 BASE T

SCSI BUSY

PIB BUSY

PCI MEZZANINE CARD

J54 Dig InJ55 Dig Out

J43 INTLKJ56 UPS

J49 Aux Pwr J23 Estop/Run

J29 Load FrameJ25 HPU

J28 HSM

Reserved

J23 E-Stop/Run Output Connections for the Model 494.42 System Board

The Model 494.42 System Board provides E-Stop/Program Run outputs that are available on the J23 E-Stop/Run connector.

Cable specification To maintain EMC compliance, the J23 E-Stop/Run cable must comply with the

FlexTest Controller Configurations

following specifications:

Connector type–9-pin, type D, male EMI connector.

Backshell–EMI metallized plastic or metal.

Cable–4-conductor with braided shield, with the braid connected to a metallized

plastic backshell at the chassis.

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

Model 494.42 Single-Station System Board

494.04 Chassis

494.42 System Board

J24 E-Stop

Power

100-240 VAC 50-60 Hz, 1-2 A

DA Output

J24

1234567

LAN 2 LAN 1

DEBUG

MOTOROLA

10/100 BASE T10/100 BASE T

SCSI BUSY

PIB BUSY

PCI MEZZANINE CARD

J54 Dig InJ55 Dig Out

J43 INTLKJ56 UPS

J49 Aux Pwr J23 Estop/Run

J29 Load FrameJ25 HPU

J28 HSM

J24

E-Stop Box

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 required If connector J24 is not used, you must install a jumper plug to maintain the

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

Cable specification To 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.

Model 494.42 Single-Station System Board

ON = Normal

ON = HPU ON

Power

100-240 VAC 50-60 Hz, 1-2 A

DA Output

J24

1234567

LAN 2 LAN 1

DEBUG

MOTOROLA

10/100 BASE T10/100 BASE T

SCSI BUSY

PIB

BUSY

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

Sense

24 V DC (from HPU)

Start

High

HPU Over Temp Open = Interlock Active

494.42 System Board

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.

Note Other 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.

FlexTest Controller Configurations

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

Model 494.42 Single-Station System Board

CAU TION

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 specification To maintain EMC compliance, J25 HPU cables must comply with the following

specifications:

Connector—15-contact, type-D, female EMI connector.

Backshell–EMI metallized plastic or metal.

Cable—22 AWG, 10-conductor with braided shield with the shield connected to

metallized plastic or metal backshell to the chassis.

Jumper plug required If connector J25 HPU is not used, you must install a jumper plug to maintain the

integrity of the interlocks. Use jumper plug PN 039-713-301 or jumper pins 1–7, 2–3–5, 6–9, 8–10–11–12.

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

Model 494.42 Single-Station System Board

Current Amplifier

494.42 System Board

+24V

HSM Low

Solenoid

HSM High

Solenoid

High

Low

J28 (D9S)

HSM Proportional

Control

J28 HSM

Power

100-240 VAC 50-60 Hz, 1-2 A

DA Output

J24

1234567

LAN 2 LAN 1

DEBUG

MOTOROLA

10/100 BASE T10/100 BASE T

SCSI BUSY

PIB BUSY

PCI MEZZANINE CARD

J54 Dig InJ55 Dig Out

J43 INTLKJ56 UPS

J49 Aux Pwr J23 Estop/Run

J29 Load FrameJ25 HPU

J28 HSM

Reserved

2,3

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.

Note The 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 specification To maintain EMC compliance, J28 HSM cables must comply with the following

FlexTest Controller Configurations

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.

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

Model 494.42 Single-Station System Board

HPU E Stop 2*

To HPU E Stop Chain

Controller Interlock

Open = Controller Interlock

494.42 System Board

Fused 24 V DC to Crosshead

J29

Crosshead Interlock Common

+24V

External Program Interlock Source

Open=Program Interlock

To HPU E Stop Chain

HPU E Stop 1

+24V

HSM High

Crosshead Unlock Power

Crosshead Unlock Power Common

Load Frame

J29

Pins 6,9,10 Reserved

Power

100-240 VAC 50-60 Hz, 1-2 A

DA Output

J24

1234567

LAN 2 LAN 1

DEBUG

MOTOROLA

10/100 BASE T10/100 BASE T

SCSI BUSY

PIB

BUSY

PCI MEZZANINE CARD

J54 Dig InJ55 Dig Out

J43 INTLKJ56 UPS

J49 Aux Pwr J23 Estop/Run

J29 Load FrameJ25 HPU

J28 HSM

* MTS Model 505 Pumps and older do not use the

HPU E-Stop 2 signal.

J29 Load Frame Connections for the Model 494.42 System Board

Connector J29 Load Frame provides an interface to connect one load frame.

Cable specification To maintain EMC compliance, the J29 Load Frame cable must comply with the

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

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.

Model 494.42 Single-Station System Board

Event Input

+24V

Interlock Disabled

+24V

Switch Contact

(Open = Interlock)

+24V

Logic Input

(0=Interlock)

Interlock In (Gnd)

Interlock Out (NO)

Interlock = Open

Interlock Out (NC) Interlock = Closed

Common

- Interlock In

+ Interlock In

Interlock In (Pwr)

+24V

J43

Intlk

494.42 System Board

Interlock

Output

Interlock

Input

Interlock

J43

Software Defined

Power

100-240 VAC 50-60 Hz, 1-2 A

DA Output

J24

1234567

LAN 2 LAN 1

DEBUG

MOTOROLA

10/100 BASE T10/100 BASE T

SCSI BUSY

PIB

BUSY

PCI MEZZANINE CARD

J54 Dig InJ55 Dig Out

J43 INTLKJ56 UPS

J49 Aux Pwr J23 Estop/Run

J29 Load FrameJ25 HPU

J28 HSM

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 part number 100-007-947 or jumper pins: 3-4, 5-7, 8-13, and 11-15.

J43 Interlock Connections for the Model 494.42 System Board

Connector J43 Intlk provides one optically isolated interlock input and a relaycontact interlock output per connector.

Cable specification To maintain EMC compliance, the J43 Intlk 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 shield

connected to the metallized backshell at the chassis.

FlexTest Controller Configurations

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

Model 494.42 Single-Station System Board

494.42 System Board

+24 V

-15V

+ 15 V

+24 V

Gnd (+24 V)

+5V

J49 Aux Pwr

Gnd (+/- 15 V)

- 15 V

+15V

Gnd (+5 V)

+ 5 V

+ 15 V

J49 Auxiliary Power

Power

100-240 VAC 50-60 Hz, 1-2 A

DA Output

J24

1234567

LAN 2 LAN 1

DEBUG

MOTOROLA

10/100 BASE T10/100 BASE T

SCSI

BUSY

PIB

BUSY

PCI MEZZANINE CARD

J55 Dig Out Dig In J54

J43A J43B

J49 Aux PwrEstop/Run J23

Interlock

J29A J29B

Load Frame

J28 HSM A-B

HPU J25

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 part number 100-057-245, or jumper pins: 1-2, 3-4, and 5-9.

J49 Auxiliary Power Connections for the Model 494.42 System Board

The J49 Aux Pwr connector provides fused (self resetting) auxiliary power outputs for: +5 V DC, +15 V DC, -15 V DC, and +24 V DC.

Cable specification To maintain EMC compliance, the J49 Auxiliary Power cable must comply with

the following specifications:

Connector type–9-pin, type D, male EMI connector.

Backshell–EMI metallized plastic or metal.

Cable–AWG and number of conductors as required. Braided shield with shield

connected to the metallized backshell at the chassis.

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

Model 494.42 Single-Station System Board

494.42 System Board

J54 Digital Input

Logic Input Wiring

Power

100-240 VAC 50-60 Hz, 1-2 A

DA Output

J24

1234567

LAN 2 LAN 1

DEBUG

MOTOROLA

10/100 BASE T10/100 BASE T

SCSI BUSY

PIB BUSY

PCI MEZZANINE CARD

J54 Dig InJ55 Dig Out

J43 INTLKJ56 UPS

J49 Aux Pwr J23 Estop/Run

J29 Load FrameJ25 HPU

J28 HSM

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

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 specification To 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

Cable–AWG and number of conductors as required. Braided shield with the shield connected to the metallized backshell at the chassis.

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

Model 494.42 Single-Station System Board

Relay Contact

494.42 System Board

Power

100-240 VAC 50-60 Hz, 1-2 A

DA Output

J24

1234567

LAN 2 LAN 1

DEBUG

MOTOROLA

10/100 BASE T10/100 BASE T

SCSI

BUSY

PIB

BUSY

PCI MEZZANINE CARD

J54 Dig InJ55 Dig Out

J43 INTLKJ56 UPS

J49 Aux Pwr J23 Estop/Run

J29 Load FrameJ25 HPU

J28 HSM

J55

Output 1

Output 3

+24 V

Output 2

Aux Power

J55 Digital Output

J55 Digital Output Connections for the Model 494.42 System Board

Connector J55 Dig Out provides three general-purpose digital outputs that can send digital-logic signals to external switches or logic devices.

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

Cable specification To maintain EMC compliance, the J55 Digital Output cable must comply with

the following specifications:

Connector–9-pin, type D, male EMI connector.

Back shell–EMI metallized plastic.

Cable–AWG and number of conductors as required. Braided shield with the

shield connected to the metallized backshell at the chassis.

Model 494.42 Single-Station System Board

494.42 System Board

J56

UPS

J56

Reserved

AC Fail

UPS

Open=Logic1=Active

UPS Battery Low

Reserved

UPS AC Fail

Battery Low

Power

100-240 VAC 50-60 Hz, 1-2 A

DA Output

J24

1234567

LAN 2 LAN 1

DEBUG

MOTOROLA

10/100 BASE T10/100 BASE T

SCSI BUSY

PIB

BUSY

PCI MEZZANINE CARD

J54 Dig InJ55 Dig Out

J43 INTLKJ56 UPS

J49 Aux Pwr J23 Estop/Run

J29 Load FrameJ25 HPU

J28 HSM

J56 UPS Input Connections for the Model 494.42 System Board

Connector J56 UPS provides dedicated inputs for an uninterruptible power supply (UPS).

Cable specification To maintain EMC compliance, the J56 UPS cable must comply with the

FlexTest Controller Configurations

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.

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

Model 494.42 Single-Station System Board

494.04 Chassis

494.42 System I/O Board

D/A Output

Power

100-240 VAC 50-60 Hz, 1-2 A

DA Output

J24

1234567

LAN 2 LAN 1

DEBUG

MOTOROLA

10/100 BASE T10/100 BASE T

SCSI BUSY

PIB BUSY

PCI MEZZANINE CARD

J54 Dig InJ55 Dig Out

J43 INTLKJ56 UPS

J49 Aux Pwr J23 Estop/Run

J29 Load FrameJ25 HPU

J28 HSM

D/A Output

Monitor 1

Monitor 2

D/A Output 1

D/A Output 2

Twisted

Pairs

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 specification To 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.

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

Model 494.44 Two-Station System Board

J55 Dig Out Dig In J54

J43A J43B

J49 Aux Pwr Estop/Run J23

Interlock

J29A J29B

Load Frame

J28 HSM A-B

HPU J25

Power

100-240 VAC 50-60 Hz, 1-2 A

DA Output

J24

1234567

LAN 2 LAN 1

DEBUG

MOTOROLA

10/100 BASE T10/100 BASE T

SCSI BUSY

PIB

BUSY

PCI MEZZANINE CARD

J55 Dig Out Dig In J54

J43A J43B

J49 Aux PwrEstop/Run J23

Interlock

J29A J29B

Load Frame

J28 HSM A-B

HPU J25

J49 AUX PWR

Auxiliary DC supply voltages for external devices. + 5 V DC, +15 V DC,

-15 V DC, +24 V DC

J28 HSM

24-volt control for HSM off/low/high or proportional solenoids

J43

Interlock input Interlock output Event input

J29

Load Frame E-Stop

J25

24 V DC HPU control

J54*

Digital inputs (8)

J55*

Digital outputs (8)

Model

494.04

Chassis

J23

Estop/Run 2 Estop outputs 2 Run outputs

DA Output (2))

J24 E-Stop

(Optional)

* Digital inputs (J54)

and digital outputs (J55) require a Model 494.32 DI/O Breakout Box.

* Digital input and output signals must be routed through a Model 494.32 DI/O Breakout Box that includes drivers and connections for external devices.

Model 494.44 Two-Station System Board

About the Model 494.44 Two-Station System Board

The Model 494.44 System Board is a twoslot board that is only used in the Model

494.04 Chassis. This board provides analog and digital I/O, E-Stop, HSM, and HPU control for two stations.

Board features

External Interfaces

• Eight digital inputs (J54*)

• Eight digital outputs (J55*)

• Auxiliary power outputs for external

devices (J49)

• Two analog outputs (DA Output

connector on the 494.04 chassis)

Hydraulic Control

• 24-volt HPU control (J25)

• 24-volt HSM control (Off/Low/High

or proportional) for two HSMs (J28)

E-Stop/Interlock Control

• Load-frame E-Stop and crosshead

control for two load frames (J29A and J29B)

• Optional E-Stop inputs (J24-located

on the 494.04 chassis)

• Two connectors (J43 A and J43B)

each provides one interlock input, one interlock output, and a softwaredefined event input

• E-Stop/Run outputs (J23)

FlexTest Controller Configurations

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

Model 494.44 System Board Specifications

Model 494.44 Specifications (part 1 of 3)

ARAMETER SPECIFICATION

Model 494.44 Two-Station System Board

HSM Control*

Off/Low/High Control

Low Output

High Output

Proportional Control

Signal Output

Solenoid Impedance

Ramp Time (0 to full scale)

E-Stop/Run Output Relay

Volta ge

Current

Connector J28A and 28B (D-15S)

+24 V DC, 1.0 A maximum

0–0.78 A

20–25 Ω

2.1 s or 4.2 s (software selectable)

* The type of HSM control (off/low/high or proportional) is software configurable.

Connector J23 (D9S)

30 V DC/AC maximum

1 A maximum

Two (2) Normally Open Relay Contacts: HPU E-Stop = Open

Normally Open Relay Contacts: Prog. Run = Closed

Interlock Output Relay

Volta ge

Current

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

Connector J43 A/B(D9S) (one per J43 connector)

30 V DC/AC maximum

1 A maximum

Normally Open Relay Contacts: Open = Interlock

Normally Closed Relay Contacts: Closed = Interlock

Model 494.44 Two-Station System Board

ARAMETER SPECIFICATION

Model 494.44 Specifications (part 2 of 3)

Interlock Input

Interlock Trip Volta ge

Maximum Input Volta ge

Input Resistance

Interlock Power Output

Load Frame E-Stop

Crosshead Unlock Output

Program Interlock Input

HPU Outputs (Start/Low/High)

HPU Outputs (start, low, high)

Connector J43 A/B (D9S) (one per J43 connector)

0.8 V minimum, 3 V maximum

+26 V DC

2700 Ω

+24 V DC (current limited by a 15-KΩ resistor)

Connector J29A and J29B (D15S)

24 V DC at 1 A

Switch Contact Closed = no program interlock Switch Contact Open = program interlock

Connector J25 (D15P)

Output Voltage: 24 V DC at 250 mA

FlexTest Controller Configurations

HPU ON Input

HPU Interlock Inputs (Low Level and Overtemp)

Trip-point Voltage

Trip Voltage: 0.8–10.0 V DC

Maximum Input Voltage: +26 V DC

Connector J25 (D15P)

0.8–10.0 V DC Maximum Input Voltage: +26 V DC

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

Model 494.44 Specifications (part 3 of 3)

ARAMETER SPECIFICATION

Model 494.44 Two-Station System Board

Auxiliary Power Outputs

+5 V DC

+15 V DC

-15 V DC

+24 V DC

Digital Outputs Connector J55 (D9S)

Digital Inputs Connector J54 (D9P)

D/A Outputs

Resolution

Connector J49 (D9S)

0.75 A maximum

Note Digital output signals must be routed

through a Model 494.32 DI/O Breakout Box that includes drivers and connections for external devices.

Note Digital input signals must be routed through

a Model 494.32 DI/O Breakout Box that includes opto-isolators and connections for external devices.

Connector "D/A Output" (D9P)

16 bit

Output Type

Output Voltage

Output Current

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

Single ended

+/- 10 V full scale

5.0 mA maximum

Note This connector is located on the rear panel

of the Model 494.04 Chassis.

Model 494.44 Two-Station System Board

E-Stop 1 Output (NO)

HPU E-Stop = Open

494.44 System Board

J23 Estop/Run

E-Stop 2 Output (NO)

HPU E-Stop = Open

Program Run 1 Output (NO)

Program Run = Closed

Program Run 2 Output (NO)

Program Run = Closed

Reserved

J23

Estop/Run

Power

100-240 VAC 50-60 Hz, 1-2 A

DA Output

J24

1234567

LAN 2 LAN 1

DEBUG

MOTOROLA

10/100 BASE T10/100 BASE T

SCSI BUSY

PIB

BUSY

PCI MEZZANINE CARD

J55 Dig Out Dig In J54

J43A J43B

J49 Aux PwrEstop/Run J23

Interlock

J29A J29B

Load Frame

J28 HSM A-B

HPU J25

J23 E-Stop/Run Output Connections for the Model 494.44 System Board

The Model 494.44 System Board provides E-Stop/Program Run outputs that are available on the J23 E-Stop/Run connector.

Cable specification To maintain EMC compliance, the J23 E-Stop/Run cable must comply with the

FlexTest Controller Configurations

following specifications:

Connector type–9-pin, type D, male EMI connector.

Backshell–EMI metallized plastic or metal.

Cable–4-conductor with braided shield, with the braid connected to a metallized

plastic backshell at the chassis.

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

Model 494.44 Two-Station System Board

494.04 Chassis

494.44 System Board

J24 E-Stop

Power

100-240 VAC 50-60 Hz, 1-2 A

DA Output

J24

1234567

LAN 2 LAN 1

DEBUG

MOTOROLA

10/100 BASE T10/100 BASE T

SCSI BUSY

PIB BUSY

PCI MEZZANINE CARD

J54 Dig InJ55 Dig Out

J43 INTLKJ56 UPS

J49 Aux Pwr J23 Estop/Run

J29 Load FrameJ25 HPU

J28 HSM

J24

E-Stop Box

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 required If connector J24 is not used, you must install a jumper plug to maintain the

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

Cable specification To 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.

Model 494.44 Two-Station System Board

ON = Normal

ON = HPU ON

Power

100-240 VAC 50-60 Hz, 1-2 A

DA Output

J24

1234567

LAN 2 LAN 1

DEBUG

MOTOROLA

10/100 BASE T10/100 BASE T

SCSI BUSY

PIB BUSY

PCI MEZZANINE CARD

J55 Dig Out Dig In J54

J43A J43B

J49 Aux PwrEstop/Run J23

Interlock

J29A J29B

Load Frame

J28 HSM A-B

HPU J25

J25

HPU

Controller 24 Vdc

+24 V DC (from HPU)

HPU

Sense

24 V DC (from HPU)

Start

High

HPU Over Temp Open = Interlock Active

494.44 System Board

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

Note Other 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.

FlexTest Controller Configurations

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

Model 494.44 Two-Station System Board

CAU TION

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 specification To maintain EMC compliance, J25 HPU cables must comply with the following

specifications:

Connector—15-contact, type-D, female EMI connector.

Backshell–EMI metallized plastic or metal.

Cable—22 AWG, 10-conductor with braided shield with the shield connected to

metallized plastic or metal backshell to the chassis.

Jumper plug required If connector J25 HPU is not used, you must install a jumper plug to maintain the

integrity of the interlocks. Use jumper plug PN 039-713-301 or jumper pins 1–7, 2–3–5, 6–9, 8–10–11–12.

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

Model 494.44 Two-Station System Board

Current Amplifier

HSM B Proportional

Control

+24V

High

Low

Reserved

HSM B (D9S)

Current Amplifier

Reserved

HSM A (D9S)

494.44 System Board

+24V

HSM A Low

Solenoid

HSM A High

Solenoid

High

Low

J28

(D15P)

HSM A Proportional

Control

HSM B Low

Solenoid

HSM B High

Solenoid

HSM

J28 HSM

Power

100-240 VAC 50-60 Hz, 1-2 A

DA Output

J24

1234567

LAN 2 LAN 1

DEBUG

MOTOROLA

10/100 BASE T10/100 BASE T

SCSI BUSY

PIB

BUSY

PCI MEZZANINE CARD

J55 Dig Out Dig In J54

J43A J43B

J49 Aux PwrEstop/Run J23

Interlock

J29A J29B

Load Frame

J28 HSM A-B

HPU J25

Note: A custom Y Cable and individual HSM cables are required.

494.44 J28

Custom J28 Y Cable (PN 100-185-473)

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.

Note The 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.

FlexTest Controller Configurations

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

Model 494.44 Two-Station System Board

Cable specification To maintain EMC compliance, J28 A/B HSM cables must comply with the

following 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.

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

Model 494.44 Two-Station System Board

HPU E Stop 2**

To HPU E Stop Chain

Controller Interlock

Open = Controller Interlock

494.44 System Board

Fused 24 V DC to Crosshead

J29 A/B

L Frame

Crosshead Interlock Common

+24V

External Program Interlock Source

Open=Program Interlock

HPU E Stop 1

+24V

HSM High

Crosshead Unlock Power

Crosshead Unlock Power Common

Load Frame

J29A J29B

Power

100-240 VAC 50-60 Hz, 1-2 A

DA Output

J24

1234567

LAN 2 LAN 1

DEBUG

MOTOROLA

10/100 BASE T10/100 BASE T

SCSI BUSY

PIB BUSY

PCI MEZZANINE CARD

J55 Dig Out Dig In J54

J43A J43B

J49 Aux PwrEstop/Run J23

Interlock

J29A J29B

Load Frame

J28 HSM A-B

HPU J25

UPS AC Fail*

UPS

Open=Logic1=Active

UPS Battery Low*

* UPS Inputs

are only available

on connector J29A

Load

Frame

Note: A custom Y Cable (PN 100-197-651) is required for UPS systems.

To HPU E Stop Chain

** MTS Model 505 Pumps and older

do not use the HPU E-Stop 2 signal.

J29 A/B Load Frame Connections for the Model 494.44 System Board

Connector J29 A/B Load Frame provides interfaces to connect up to two load frames and optional UPS (J29A only).

Cable specification To maintain EMC compliance, the J29 A/B Load Frame cable must comply

FlexTest Controller Configurations

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.

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

Model 494.44 Two-Station System Board

Event Input

+24V

Interlock Disabled

+24V

Switch Contact

(Open = Interlock)

+24V

Logic Input

(0=Interlock)

Interlock In (Gnd)

Interlock Out (NO)

Interlock = Open

Interlock Out (NC) Interlock = Closed

Common

- Interlock In

+ Interlock In

Interlock In (Pwr)

+24V

J43

Intlk

494.44 System Board

Interlock

Output

Interlock

Input

Interlock

J43A J43B

Power

100-240 VAC 50-60 Hz, 1-2 A

DA Output

J24

1234567

LAN 2 LAN 1

DEBUG

MOTOROLA

10/100 BASE T10/100 BASE T

SCSI BUSY

PIB BUSY

PCI MEZZANINE CARD

J55 Dig Out Dig In J54

J43A J43B

J49 Aux PwrEstop/Run J23

Interlock

J29A J29B

Load Frame

J28 HSM A-B

HPU J25

Software Defined

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 part number 100-007-947 or jumper pins: 3-4, 5-7, 8-13, and 11-15.

J43 A/B Interlock Connections for the Model 494.44 System Board

Connector J43 A/B Interlock provides one optically isolated interlock input and a relay-contact interlock output per connector.

Cable specification To maintain EMC compliance, the J43 Interlock 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 shield

connected to the metallized backshell at the chassis.

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

Model 494.44 Two-Station System Board

494.44 System Board

+24 V

-15V

+ 15 V

+24 V

Gnd (+24 V)

+5V

J49 Aux Pwr

Gnd (+/- 15 V)

- 15 V

+15V

Gnd (+5 V)

+ 5 V

+ 15 V

J49 Auxiliary Power

Power

100-240 VAC 50-60 Hz, 1-2 A

DA Output

J24

1234567

LAN 2 LAN 1

DEBUG

MOTOROLA

10/100 BASE T10/100 BASE T

SCSI

BUSY

PIB

BUSY

PCI MEZZANINE CARD

J55 Dig Out Dig In J54

J43A J43B

J49 Aux PwrEstop/Run J23

Interlock

J29A J29B

Load Frame

J28 HSM A-B

HPU J25

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 part number 100-057-245, or jumper pins: 1-2, 3-4, and 5-9.

J49 Auxiliary Power Connections for the Model 494.44 System Board

The J49 Aux Pwr connector provides fused (self resetting) auxiliary power outputs for: +5 V DC, +15 V DC, -15 V DC, and +24 V DC.

Cable specification To maintain EMC compliance, the J49 Auxiliary Power cable must comply with

the following specifications:

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

FlexTest Controller Configurations

Connector type–9-pin, type D, male EMI connector.

Backshell–EMI metallized plastic or metal.

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

LAN 2 LAN 1

DEBUG

MOTOROLA

10/100 BASE T10/100 BASE T

SCSI BUSY

PIB BUSY

PCI MEZZANINE CARD

J55 Dig Out Dig In J54

J43A J43B

J49 Aux PwrEstop/Run J23

Interlock

J29A J29B

Load Frame

J28 HSM A-B

HPU J25

494.32 DIO Breakout Box

J54 Dig In

J10 Inputs

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.

Note Digital input power for the breakout box is brought in through breakout-

box connector J19.

Cable specification To maintain EMC compliance, the J54 Digital Input cable must comply with the

following specifications:

Connector type–9-pin, D type, female EMI connector.

Back shell–EMI metallized plastic or metal.

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

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.

Model 494.44 Two-Station System Board

DO 1

494.44 System Board 494.32 Breakout Box

J55 Dig Out J20 Outputs

Power

100-240 VAC 50-60 Hz, 1-2 A

DA Output

J24

1234567

LAN 2 LAN 1

DEBUG

MOTOROLA

10/100 BASE T10/100 BASE T

SCSI BUSY

PIB BUSY

PCI MEZZANINE CARD

J55 Dig Out Dig In J54

J43A J43B

J49 Aux PwrEstop/Run J23

Interlock

J29A J29B

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.

Note External power for the output devices is brought into the breakout box

through breakout-box connector J29.

Cable specification To maintain EMC compliance, the J55 Digital Output cable must comply with

FlexTest Controller Configurations

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.

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

Model 494.44 Two-Station System Board

494.04 Chassis

494.44 System I/O Board

D/A Output

Power

100-240 VAC 50-60 Hz, 1-2 A

DA Output

J24

1234567

LAN 2 LAN 1

DEBUG

MOTOROLA

10/100 BASE T10/100 BASE T

SCSI BUSY

PIB

BUSY

PCI MEZZANINE CARD

J55 Dig Out Dig In J54

J43A J43B

J49 Aux PwrEstop/Run J23

Interlock

J29A J29B

Load Frame

J28 HSM A-B

HPU J25

D/A Output

Monitor 1

Monitor 2

D/A Output 1

D/A Output 2

Twisted

Pairs

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 specification To 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.

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

Model 494.44 Two-Station System Board

Controller Interlock

Open = Controller Interlock

494.44 System I/O Board

Fused 24 V DC to Crosshead

J29A

L Frame

Crosshead Interlock Common

+24V

External Program Interlock Source

Open=Program Interlock

To J25 HPU

J25

HPU

HPU E Stop

+24V

HSM High

Crosshead Unlock Power

Crosshead Unlock Power Common

Load Frame

J29A

Reserved

Power

100-240 VAC 50-60 Hz, 1-2 A

DA Output

J24

1234567

LAN 2 LAN 1

DEBUG

MOTOROLA

10/100 BASE T10/100 BASE T

SCSI BUSY

PIB

BUSY

PCI MEZZANINE CARD

J55 Dig Out Dig In J54

J43A J43B

J49 Aux PwrEstop/Run J23

Interlock

J29A J29B

Load Frame

J28 HSM A-B

HPU J25

UPS AC Fail*

UPS

UPS AC Fail

Active Alarm: Open=Logic1

UPS Battery Low*

* UPS Inputs

are only available

on connector J29A

Load

Frame

UPS

494.44 J29A

Custom J29 Y Cable (PN 100-197-651) required for UPS systems.

D9S

D9P

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 specification To 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.

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

MTS 200 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents

Technical Support

How to Get Technical Support

Before You Contact MTS

If You Contact MTS by Phone

Problem Submittal Form in MTS Manuals

Preface

Before You Begin

Conventions

Documentation Conventions

Safety Information

Intended Use of MTS Series 494 Controllers

Waste Electrical and Electronic Equipment (WEEE) Considerations

Safety Circuits

Shock Hazards

Input/Output Verification

E-Stop Circuits

E-Stop Circuit Testing

Hardware Interlocks

E-Stop and Hardware Interlocks

FlexTest Controller Configurations

FlexTest Controller Overview

About MTS FlexTest Models 40/60/100/200 Controllers

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

Installation

Controller Installation Procedure

Installation Requirements–Series 494 Hardware

Environmental Requirements—Series 494 Hardware

Ventilation Requirements–Series 494 Chassis

Rack-Mounting Requirements–Series 494 Chassis

Grounding Requirements–Series 494 Chassis

AC Power Disconnect Requirements–Series 494 Chassis

Cable Requirements–Series 494 Hardware

UPS System Requirements

UPS Systems for FlexTest 60, 100, 200, and GT Controllers

UPS Systems for FlexTest 40 and FlexTest SE Servocontrollers

Specifications–UPS Systems Used with MTS Controllers

Controller P0 Interlock Check Utility

FlexTest 40 Controller Configuration

About the FlexTest 40 Controller

About the Model 494.04 Chassis

Specifications–Model 494.04 Chassis

Model 494.04 Chassis Boards

Typical Model 494.04 Chassis Connections

Model 494.41 Single-Station System Board

About the Model 494.41 Single-Station System Board

Model 494.41 System Board Specifications

J24 Emergency Stop Connections for the Model 494.41 System Board

J25 Hydraulic Power Unit Connections for the Model 494.41 System Board

J28 HSM Connections for the Model 494.41 System Board

J29 Emergency Stop Connections for the Model 494.41 System Board

J43 Interlock Connections for the Model 494.41 System Board

J49 Auxiliary Power Connections for the Model 494.41 System Board

J54 Digital Input Connections for the Model 494.41 System Board

J55 Digital Output Connections for the Model 494.41 System Board

Analog Output Connections for the Model 494.41 System Board

UPS Connections for the Model 494.41 System Board (FT40)

Model 494.42 Single-Station System Board

About the Model 494.42 Single-Station System Board

Model 494.42 System Board Specifications

J23 E-Stop/Run Output Connections for the Model 494.42 System Board

J24 Emergency Stop Connections for the Model 494.42 System Board

J25 Hydraulic Power Unit Connections for the Model 494.42 System I/O Board

J28 HSM Connections for the Model 494.42 System Board

J29 Load Frame Connections for the Model 494.42 System Board

J43 Interlock Connections for the Model 494.42 System Board

J49 Auxiliary Power Connections for the Model 494.42 System Board

J54 Digital Input Connections for the Model 494.42 System Board

J55 Digital Output Connections for the Model 494.42 System Board

J56 UPS Input Connections for the Model 494.42 System Board

Analog Output Connections for the Model 494.42 System Board

Model 494.44 Two-Station System Board

About the Model 494.44 Two-Station System Board

Model 494.44 System Board Specifications

J23 E-Stop/Run Output Connections for the Model 494.44 System Board

J24 Emergency Stop Connections for the Model 494.44 System Board