Trademark informationMTS, Temposonics, FlexTest, and TestWare are registered trademarks of MTS
Systems Corporation within the United States; AeroPro, MPT, Station Builder,
Station Manager, and TestStar are trademarks of MTS Systems Corporation
within the United States. These trademarks may be protected in other countries.
Microsoft and Windows are registered trademarks of Microsoft Corporation. All
other trademarks or service marks are property of their respective owners.
The manuals supplied by MTS provide most of the information you need to use
and maintain your equipment. If your equipment includes software, look for
online help and README files that contain additional product information.
If you cannot find answers to your technical questions from these sources, you
can use the internet, e-mail, telephone, or fax to contact MTS for assistance.
MTS provides a full range of support services after your system is installed. If
you have any questions about a system or product, contact Technical Support in
one of the following ways.
www.mts.comThe web site provides access to our technical support staff by means of an online
form:
www.mts.com > Contact MTS > Service & Technical Support button
E-mailtech.support@mts.com
TelephoneMTS Call Center 800-328-2255
Weekdays 7:00 A.M. to 5:00 P.M., Central Time
Fax952-937-4515
Please include “Technical Support” in the subject line.
Outside the U.S.For technical support outside the United States, contact your local sales and
service office. For a list of worldwide sales and service locations and contact
information, use the Global MTS link at the MTS web site:
www.mts.com > Global MTS > (choose your region in the right-hand
column) > (choose the location closest to you)
MTS FlexTest® Models 40/60/100/200 Controller HardwareTechnical Support
7
Technical Support
Before You Contact MTS
MTS can help you more efficiently if you have the following information
available when you contact us for support.
Know your site
number and system
number
Know information from
prior technical
The site number contains your company number and identifies your equipment
type (such as material testing or simulation). The number is typically written on a
label on your equipment before the system leaves MTS. If you do not know your
MTS site number, contact your sales engineer.
Example site number: 571167
When you have more than one MTS system, the system job number identifies
your system. You can find your job number in your order paperwork.
Example system number: US1.42460
If you have contacted MTS about this problem before, we can recall your file
based on the:
assistance
•MTS notification number
•Name of the person who helped you
Identify the problemDescribe the problem and know the answers to the following questions:
•How long and how often has the problem occurred?
•Can you reproduce the problem?
•Were any hardware or software changes made to the system before the
For a computer problem, have the following information available:
•Manufacturer’s name and model number
•Operating software type and service patch information
•Amount of system memory
•Amount of free space on the hard drive where the application resides
•Current status of hard-drive fragmentation
•Connection status to a corporate network
For software application problems, have the following information available:
•The software application’s name, version number, build number, and (if
available) software patch number. This information can typically be found
in the About selection in the Help menu.
•The names of other applications on your computer, such as:
–Anti-virus software
–Screen savers
–Keyboard enhancers
–Print spoolers
–Messaging applications
If You Contact MTS by Phone
A Call Center agent registers your call before connecting you with a technical
support specialist. The agent asks you for your:
•Site number
•Name
•Company name
•Company address
•Phone number where you can be reached
If your issue has a notification number, please provide that number. A new issue
will be assigned a unique notification number.
MTS FlexTest® Models 40/60/100/200 Controller HardwareTechnical Support
9
Technical Support
Identify system typeTo enable the Call Center agent to connect you with the most qualified technical
support specialist available, identify your system as one of the following types:
•Electromechanical material test system
•Hydromechanical material test system
•Vehicle test system
•Vehicle component test system
•Aero test system
Be prepared to
troubleshoot
Write down relevant
information
After you callMTS logs and tracks all calls to ensure that you receive assistance for your
Prepare to perform troubleshooting while on the phone:
•Call from a telephone close to the system so that you can implement
suggestions made over the phone.
•Have the original operating and application software media available.
•If you are not familiar with all aspects of the equipment operation, have an
experienced user nearby to assist you.
In case Technical Support must call you:
•Verify the notification number.
•Record the name of the person who helped you.
•Write down any specific instructions.
problem or request. If you have questions about the status of your problem or
have additional information to report, please contact Technical Support again and
provide your original notification number.
Use the Problem Submittal Form to communicate problems with your software,
hardware, manuals, or service that are not resolved to your satisfaction through
the technical support process. The form includes check boxes that allow you to
indicate the urgency of your problem and your expectation of an acceptable
response time. We guarantee a timely response—your feedback is important to
us.
Access the Problem Submittal Form:
•In the back of many MTS manuals (postage paid form to be mailed to MTS)
•www.mts.com > Contact Us > Problem Submittal Form button (electronic
form to be e-mailed to MTS)
Technical Support
MTS FlexTest® Models 40/60/100/200 Controller HardwareTechnical Support
Safety first!Before you use your MTS product or system, read and understand the safety
information provided with your system. Improper installation, operation, or
maintenance can result in hazardous conditions that can cause severe personal
injury or death, or damage to your equipment and specimen. Again, read and
understand the safety information provided with your system before you
continue. It is very important that you remain aware of hazards that apply to your
system.
Other MTS manualsIn addition to this manual, you may receive additional manuals in paper or
electronic form.
You may also receive an MTS System Documentation CD. It contains an
electronic copy of the manuals that pertain to your test system, such as:
•Hydraulic and mechanical component manuals
•Assembly drawings
•Parts lists
•Operation manual
•Preventive maintenance manual
Controller and application software manuals are typically included on the
software CD distribution disc(s).
The following paragraphs describe some of the conventions that are used in your
MTS manuals.
Hazard conventionsHazard notices may be embedded in this manual. These notices contain safety
information that is specific to the activity to be performed. Hazard notices
immediately precede the step or procedure that may lead to an associated hazard.
Read all hazard notices carefully and follow all directions and recommendations.
Three different levels of hazard notices may appear in your manuals. Following
are examples of all three levels.
NoteFor general safety information, see the safety information provided with
your system.
Danger notices indicate the presence of a hazard with a high level of risk which,
if ignored, will result in death, severe personal injury, or substantial property
damage.
14
Warning notices indicate the presence of a hazard with a medium level of risk
which, if ignored, can result in death, severe personal injury, or substantial
property damage.
Caution notices indicate the presence of a hazard with a low level of risk which,
if ignored, could cause moderate or minor personal injury or equipment damage,
or could endanger test integrity.
NotesNotes provide additional information about operating your system or highlight
easily overlooked items. For example:
NoteResources that are put back on the hardware lists show up at the end of
the list.
Special termsThe first occurrence of special terms is shown in italics.
IllustrationsIllustrations appear in this manual to clarify text. They are examples only and do
not necessarily represent your actual system configuration, test application, or
software.
Electronic manual
conventions
This manual is available as an electronic document in the Portable Document
File (PDF) format. It can be viewed on any computer that has Adobe Acrobat
Reader installed.
Hypertext linksThe electronic document has many hypertext links displayed in a blue font. All
blue words in the body text, along with all contents entries and index page
numbers, are hypertext links. When you click a hypertext link, the application
jumps to the corresponding topic.
ContentsIntended Use of MTS Series 494 Controllers 18
EC Declaration of Conformity for MTS Models 494.04 (FlexTest 40),
494.06 (FlexTest 60), 494.10 (FlexTest 100) and 494.20 (FlexTest 200)
19
Waste Electrical and Electronic Equipment (WEEE) Considerations 20
E-Stop Circuits 22
Hardware Interlocks 24
E-Stop and Hardware Interlocks 25
Safety Information
MTS FlexTest® Models 40/60/100/200 Controller HardwareSafety Information
17
Safety Information
Intended Use of MTS Series 494 Controllers
MTS Series 494 Controllers vary from single-channel, single-station systems to
multichannel, multistation systems. This increased flexibility of Series 494
Controllers permits their use in several industrial testing applications.
MTS Series 494 Controllers are typically used in the following testing markets:
•Materials
•Automobile
•Tire and Wheel
•Aircraft
Before you attempt to use your MTS product, read and understand the manuals
that accompany this product. Improper installation or operation of this product
can result in hazardous conditions that can cause severe personal injury or death,
and damage to your equipment and test specimen.
EC Declaration of Conformity for MTS Models 494.04 (FlexTest 40),
494.06 (FlexTest 60), 494.10 (FlexTest 100) and 494.20 (FlexTest 200
)
Description of ModelsThe MTS Series 494 Electronics Control Chassis’ are VMEbus chassis’ that can
house up to twenty VMEbus modules in the front of the chassis and up to twenty
MTS Systems Corporation transition modules in the rear panel of the chassis.
The chassis can be configured with a variety of MTS VMEbus plug-in modules
and related transition modules.
ManufacturerMTS Systems Corporation
14000 Technology Drive
Eden Prairie, MN, USA 55344-2290
Phone: 952-937-4000
DirectivesLow Voltage directive 2006/95/EEC and the EMC directive 2004/108/EC.
StandardsEN 61010-1: Safety requirements for electrical equipment for measurement,
control and laboratory use, Part 1: General requirements
EN 61000-6-2: Electromagnetic Compatibility, Generic Standards - Immunity for
Industrial Environments.
EN 61000-6-4: Electromagnetic Compatibility, Generic Standards - Emission
standard for Industrial Environments.
Radio frequency electromagnetic
field, amplitude modulated
Electrical fast transientEN 61000-4-42 kV mains
MTS FlexTest® Models 40/60/100/200 Controller HardwareSafety Information
EN 61000-3-2Class A
EN 61000-3-3Class A
+/- 8 kV air discharge
Performance Criteria B
EN 61000-4-310 V/m
Performance Criteria A
2 kV control and signal
Performance Criteria B
19
Safety Information
DESCRIPTIONBASIC STANDARDTEST SPECIFICATION
Electrical surge immunity testEN 61000-4-52 kV mains line to earth
1 kV mains line to line
.5 / 1 kV cables >30 meters line to earth
Performance Criteria B
Radio frequency common mode,
amplitude modulated
Power frequency magnetic fieldEN 61000-4-830 A (rms)/m 50 and 60 Hz
Voltage dips, short interruptions,
and voltage variations
Radiated emissions EN 55011Class A
Conducted emissionsEN 55011Class A
EN 61000-4-610 V (rms)
Performance Criteria A
Performance Criteria B
EN 61000-4-111 cycle and 0% amplitude of cycle
Performance Criteria B
10 cycle and 40% amplitude of cycle
25 cycle and 70% amplitude of cycle
250 cycle and 0% amplitude of cycle
Performance Criteria C
Name:Rich Baker
Title:Vice President of Engineering
Date:01 November 2007
Waste Electrical and Electronic Equipment (WEEE) Considerations
The Waste Electrical and Electronic Equipment (WEEE) symbol ()
indicates that the controller and its electronic parts must not be disposed of as
unsorted municipal waste. Proper disposal is required by approved electronic
waste collection agencies. Customers in the EC region who desire to return an
end-of-life controller and its electronic parts are encouraged to contact your local
MTS Systems Sales/Service Offices for instructions.
Series 494 hardware includes a number of safety circuits that monitor and
respond to potentially unsafe conditions.
To avoid shock hazards, users should not attempt to service any parts located
inside any Series 494 Controller chassis.
Controllers contain components that operate at hazardous voltage levels.
Hazardous voltage levels inside the controller pose a danger. Contact with
high-voltage electricity can result in injury or death.
Do not remove any panel, cover, or door on any Series 494 Controller chassis. Do
not attempt to service any Series 494 Controller chassis. There are no userserviceable parts or fuses in any Series 494 Controller chassis.
MTS FlexTest® Models 40/60/100/200 Controller HardwareSafety Information
21
Safety Circuits
WARNING
Input/Output Verification
Relay outputsIf necessary, you can use an external device to monitor both NO and NC contacts
There are a number of ways that you can verify the integrity of controller input
and output circuits.
Improper use of controller outputs can result in damage to the controller
and unexpected actuator movement.
Unexpected actuator movement can result in injury to personnel or damage
to the equipment.
Outputs should be used to monitor controller functions within the specifications
included in the MTS Series 494 Controller Hardware Manual.
to detect state changes and verify relay integrity. You can also provide a
redundant set of contacts to an external device.
Digital inputsIf necessary, you can set up the controller to monitor redundant digital input
Digital outputsIf necessary, you can provide redundant output signals to external systems.
E-Stop Circuits
signals and use the controller software to verify input circuit integrity and take
action if a problem is identified.
Emergency stop (E-stop) circuits include an electro-mechanical switch that when
pressed, removes power from the HPU E-stop relay and forces a global interlock.
Most Series 494 Controllers include E-Stop outputs that are intended to be
monitored by external devices. If necessary, an external device can monitor
multiple E-stop output contacts to detect state changes and verify relay integrity.
The E-Stop circuit should be tested periodically to help ensure that the system
shuts down safely when the E-Stop button(s) is pressed.
NoteMTS recommends testing the E-Stop circuit at least once per month.
1. Remove any specimens from each station.
2. Apply power to the controller.
3. Start the HPU and each HSM associated with your test station(s).
4. Press the E-Stop button and ensure that the following global-interlock
actions occur:
•Power is removed from each HPU.
•Power is removed from each HSM.
•If valve clamping is enabled, the actuator should move to the
predetermined position defined in software.
•Any external I/O device that is monitoring the E-Stop circuit should
acknowledge the E-Stop state and take appropriate action.
5. Twist the switch clockwise to release it.
6. Repeat this procedure for each E-Stop button used with your controller.
MTS FlexTest® Models 40/60/100/200 Controller HardwareSafety Information
23
Safety Circuits
Hardware Interlocks
Global interlocksGlobal interlocks detect controller chassis conditions (such as watchdog timers
Station interlocksStation interlocks are associated with a specific test station and will force the
A Series 494 controller running Series 793 Control Software can have up to eight
separate hardware interlock chains. Each test station configuration that you open
must be assigned to a unique hardware interlock chain. This allows one controller
to run up to eight test stations, each with its own hardware interlock chain.
NoteSome test configurations may only use one station that is assigned to a
single hardware interlock chain.
The controller can generate two type of hardware interlocks, global interlocks,
and station interlocks:
and undervoltage conditions) that can affect any station running on the controller.
A global interlock forces all eight hardware interlock chains to an active state.
hardware interlock chain assigned to that station to an active interlock state.
Series 494 controllers include interlock output contacts (NO/NC) that are
intended to provide hardware interlock status to external systems.
Safety Information
24
NoteIf necessary for critical applications, you can use an external I/O
monitoring device to monitor both NC and NO contacts to detect state
changes and verify relay integrity.
The following table shows E-stop/interlock operation for a typical system that
uses Series 793 Control Software. Interlock and E-stop operation on some test
systems may vary.
E-stop and Hardware Interlock Events/Actions (Series 793 Control Software)
E-S
TOPGLOBAL (CONTROLLER) INTERLOCKSTATION INTERLOCK
Safety Circuits
An E-stop occurs when the
operator presses an electromechanical E-stop switch.
An active E-stop causes the
following actions:
•Physically removes power
from the HPU CRM E-stop
relay.
NoteThe CRM E-stop relay is
located in the HPU.
•Forces a global interlock.
Any of the following events results
in a global interlock:
•Undervoltage conditions on
auxiliary power outputs.
•Controller conditions such as
watchdog timers and
backplane monitoring.
•E-stop button pressed.
A global interlock applies the
following actions to each of the
hardware interlock chains:
•Sets the controller HPU
commands to off.
•Sets each controller HSM
command to off.
•Sets the controller function
generator/program (for all
stations) to off.
•If enabled, the valve driver
current is clamped to a
predefined value/polarity.
Any of the following events results
in a station interlock:
•Software events (such as
limits).
•External interlock input
active.
•Station Stop button pressed.
A station interlock applies the
following actions to the single
hardware interlock chain where
that station is assigned:
•Sets the station HSM
command to off.
•Sets the controller function
generator/program (for that
station only) to off.
•If enabled, the valve driver
current is clamped to a
predefined value/polarity.
E-Stop outputs are intended to be
monitored by external devices.
NoteIf necessary, an external I/O monitoring device can monitor multiple E-stop/Interlock output contacts to
detect state changes and verify relay integrity.
MTS FlexTest® Models 40/60/100/200 Controller HardwareSafety Information
Interlock outputs are intended to be
monitored by external devices.
Interlock outputs are intended to be
monitored by external devices.
About MTS FlexTest Models 40/60/100/200 Controllers
MTS FlexTest Models 40/60/100/200 Controllers are generally used in
servohydraulic test systems. They provide real-time closed-loop control, with
transducer conditioning and function generation to drive various types of servoactuators.
A FlexTest Controller consists of:
•One or more Series 494 Hardware chassis that contain controller hardware.
•A computer workstation that runs MTS controller applications.
Controller capabilities
PARAMETERFLEXTEST40FLEXTEST 60FLEXTEST
Test Stations2Up to 6*Up to 8Up to 8
Control ChannelsUp to 4Up to 8Up to 16Up to 40
100
FLEXTEST
200
FlexTest Controller Configurations
28
Conditioned
Transducer Inputs
Auxiliary Data InputsUp to 16Up to 32Up to 64Up to 96