MTS FlexTest SE User Manual
be certain.
MTS Models FlexTest® IIm/GT/SE Controller Hardware
Service Information for Controllers Using Series 793 Software:
- Hardware Descriptions
- Specifications
- Installation
- Cabling
100-147-133 G
Copyright information © 2006, 2007, 2008, 2009 MTS Systems Corporation. All rights reserved.
Trademark information MTS, FlexTest, Temposonics, and TestWare are registered trademarks of MTS
Systems Corporation; MPT, Station Builder, and Station Manager are trademarks
of MTS Systems Corporation within the United States. These trademarks may be
protected in other countries.
Microsoft and Windows are registered trademarks of Microsoft Corporation. All
other trademarks or service marks are property of their respective owners
Publication information
MANUAL PART NUMBER PUBLICATION DATE MTS 793 SOFTWARE RELEASE
100-147-133 A June 2006 Version 4.0A or later
100-147-133 B October 2006 Version 4.0B or later
100-147-133 C December 2006 Version 4.0B or later
100-147-133 D November 2007 Version 5.0B or later
100-147-133 E January 2008 Version 5.0B or later
100-147-133 F September 2008 Version 5.1A or later
100-147-133 G August 2009 Version 5.2A or later
2
Models FlexTest® IIm/GT/SE Controller Hardware
Contents
Technical Support 9
How to Get Technical Support 9
Before You Contact MTS 10
If You Contact MTS by Phone 11
Problem Submittal Form in MTS Manuals 12
Preface 15
Before You Begin 15
Conventions 16
Documentation Conventions 16
Chapter 1 Introduction 19
FlexTest GT Controllers 20
Model 493.10 Chassis 20
Hydraulic Control 22
Interlocks 22
Specifications 23
FlexTest SE Controllers 24
Model 493.02 Chassis 26
Hydraulic Control 26
Interlocks 26
Specifications 27
FlexTest IIm Controllers 28
Model 497.01 Analog Chassis 30
Model 497.05 Hydraulic Control Panel 31
Model 498.22 Chassis with Test Processor (FTIIm) 32
Specifications 33
Models FlexTest® IIm/GT/SE Controller Hardware Contents
3
Chapter 2 Installation 37
Installing the Model 493.10 Chassis (FTGT) 37
Connecting Electrical Power 38
Installing the Plug-in Modules 42
VMEbus Modules 43
Installing the Transition Panels 47
Installing the 493.02 Chassis (FlexTest SE) 49
Installing the Plug-in Modules 49
VMEbus Modules 50
Chassis Installation Options 51
Connecting Electrical Power 53
Installing the Handle Kit 58
Installing 497/498 Electronics (FTIIm) 61
Connecting the Console and Chassis Power 61
How To Connect the Chassis Power Cables 61
How To Cable the Analog Chassis to the Hydraulic Control Panel 62
Grounding the Console and Chassis 62
Model 497.01 Analog Chassis 63
About Analog Chassis Slots 63
Analog Chassis Plug-in Modules 64
How to Install or Remove a Plug-in Module 65
Analog Chassis Transition Modules 66
How To Install a Transition Module 66
Transition Module Connectors 67
Adding an Analog Chassis to Your Console 69
Model 497.05 Hydraulic Control Panel 71
Test Processor Plug-in Modules 72
Test Processor Transition Modules 74
UPS Systems 76
UPS Systems for FlexTest 60, 100, 200, and GT Controllers 76
UPS Systems for FlexTest 40 and FlexTest SE Servocontrollers 77
Specifications–UPS Systems Used with MTS Controllers 78
UPS Connections for the Model 493.73 HPU Board (FT60, FT100, FT200, FTGT) 79
UPS Connections for the Model 493.42 System board (FlexTest SE ) 80
4
Contents
Models FlexTest® IIm/GT/SE Controller Hardware
Chapter 3 FlexTest GT Controller Connections 81
CE EMC Compliant Cabling 83
Typical Cabling 84
Cable Part Numbers 85
Model 493.40 I/O Carrier Connections 87
Sensor Connections 88
Model 493.21B (DUC B) Jumpers 92
Digital Universal Conditioner (DUC BC) Switches 94
Full-Range Digital Universal Conditioner (FRDUC) Jumpers 97
Sensor Cables 100
Sensor Cable Specifications 100
Sensor Cable Part Numbers 101
Shunt Calibration/Bridge Completion Resistor Installation 103
I/O Carrier Module 103
Transducer Identification Modules 106
Valve Connections 108
Multiple Universal Driver Connections 112
Analog I/O Connections 114
Accelerometer Connections 119
Encoder Connections 121
Remote Setpoint Adjust Connections 123
ADDA II Connections 124
Emergency Stop Connections 129
J25 Hydraulic Power Unit Connection 131
Station Connections 134
J28 Hydraulic Service Manifold Connector 134
J29 Load Unit 136
J43 Interlock 137
J44 Run/Stop 138
J49 Auxiliary Power 140
Digital I/O Connections 141
Workstation Connection 145
Remote Station Controller Connection 147
Service Connections 149
Models FlexTest® IIm/GT/SE Controller Hardware Contents
5
Cabling and Programming Series 407 Controllers 151
How to Provide Program to a Series 407 Controller 151
Connecting Interlock Signals to 407 Controllers 156
Sending and Receiving Signals to a Model 407 Controller 162
Connecting Interlock Signals to 458 Controllers 164
Eurotherm Temperature Controller Connection 165
Miscellaneous Conditioner Output Connections 167
Cabling for External Command Inputs 168
How to Enable and Run External Command Inputs 168
Cabling and Using External Readout Devices 169
How to Send Signals to External Readout Devices 171
Multi-Box I/O Module 172
J8 Interlock IN 172
J9 Interlock OUT 173
J51 Box In 174
J52 Box Out 175
Chapter 4 FlexTest IIm Controller Connections 177
6
Workstation Connection 178
Sensor and Valve Connections 179
ADDA Module Connections 183
ADDA II Connections 184
Hydraulic Connections 189
HPU Connections 190
HSM Connections 191
Interlock Connections 192
Interlock Jumper Plugs 193
Serial Communications 195
Digital I/O Connections 196
Encoder/Temposonics Connections 200
Remote Station Controller (RSC) Connections 203
Cabling and Programming External Controllers 204
How to Program an External Controller 204
Programming Eurotherm Temperature Controllers 209
Contents
Models FlexTest® IIm/GT/SE Controller Hardware
Cabling for External Command Inputs 210
How to Enable and Run External Command Inputs 210
Cabling and Using External Readout Devices 213
How to Send Signals to External Readout Devices 213
Cable Part Numbers 216
Chapter 5 FlexTest SE Controller Connections 217
Stand-alone Cabling Overview 218
Automated Cabling Overview 219
Multiple Controller Connections 220
Cable Part Numbers 223
Model 493.40 I/O Carrier Connections 225
Sensor Connections 226
Valve Connections 226
Analog I/O Connections 226
Encoder Connections 228
Workstation Connection 229
Service Connection 229
Model 493.42 System I/O Connections 230
J25 Hydraulic Power Unit Connection 230
J28 Hydraulic Service Manifold Connector 231
J29 Emergency Stop Connections 232
J43 Interlock 233
J49 Auxiliary Power 234
CJ51 Box In 234
J52 Box Out 235
J54 Digital Inputs 236
J55 Digital Outputs 237
Eurotherm Temperature Controller Connection 239
Models FlexTest® IIm/GT/SE Controller Hardware Contents
7
Appendix A Hydraulic Configurations 243
Model 493.02 Chassis Multiple Controller Interconnections 246
Independent HSM (no HPU) 246
Independent HSM (shared HPU) 247
Shared HSM (with HPU) 247
Shared HSM (no HPU) 248
Independent HSM with HPU (First On-Last Off) 249
Appendix B Model 493.07 Converter Box 251
Appendix C Chassis Maintenance 253
Appendix D Optional Station Configurations 255
6-Station Configuration 255
8-Station Configuration 256
8
Contents
Index 257
Models FlexTest® IIm/GT/SE Controller Hardware
Technical Support
How to Get Technical Support
How to Get 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
onlineform:
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)
Models FlexTest® IIm/GT/SE Controller Hardware Technical Support
9
Before You Contact MTS
Before You Contact MTS
MTS can help you more efficiently if you have the following information
available when you contact us for support.
Know your site
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
10
• What are the equipment model numbers?
• What is the controller model (if applicable)?
• What is the system configuration?
Models FlexTest® IIm/GT/SE Controller Hardware
If You Contact MTS by Phone
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.
Models FlexTest® IIm/GT/SE Controller Hardware Technical Support
11
Problem Submittal Form in MTS Manuals
Identify system type To enable the Call Center agent to connect you with the most qualified technical
support specialist available, identify your system as one of the following types:
• Electromechanical material test system
• Hydromechanical material test system
• Vehicle test system
• Vehicle component test system
• Aero test system
Be prepared to
Prepare to perform troubleshooting while on the phone:
troubleshoot
• 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.
Write down relevant
In case Technical Support must call you:
information
• Verify the notification number.
• Record the name of the person who helped you.
• Write down any specific instructions.
After you call MTS logs and tracks all calls to ensure that you receive assistance for your
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.
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.
Technical Support
12
Models FlexTest® IIm/GT/SE Controller Hardware
Problem Submittal Form in MTS Manuals
Access the Problem Submittal Form:
• In the back of many MTS manuals (postage paid form to be mailed to MTS)
• www.mts.com > Contact Us > Problem Submittal Form button (electronic
form to be e-mailed to MTS)
Models FlexTest® IIm/GT/SE Controller Hardware Technical Support
13
Problem Submittal Form in MTS Manuals
Technical Support
14
Models FlexTest® IIm/GT/SE Controller Hardware
Before You Begin
Preface
Before You Begin
Safety first! Before you use your MTS product or system, read and understand the Safety
manual and any other safety information provided with your system. Improper
installation, operation, or maintenance can result in hazardous conditions that can
cause severe personal injury or death, or damage to your equipment and
specimen. 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).
Models FlexTest® IIm/GT/SE Controller Hardware Preface
15
Documentation 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.
16
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
Models FlexTest® IIm/GT/SE Controller Hardware
Documentation Conventions
Illustrations Illustrations appear in this manual to clarify text. They are examples only and do
not necessarily represent your actual system configuration, test application, or
software.
Electronic manual
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.
Models FlexTest® IIm/GT/SE Controller Hardware Preface
17
Documentation Conventions
18
Preface
Models FlexTest® IIm/GT/SE Controller Hardware
Chapter 1
Introduction
Contents FlexTest GT Controllers 20
This manual contains installation, cabling, jumpering, and hardware interfacing
information for MTS 793 Controllers.
This chapter describes the hardware components and specifications of FlexTest
GT, FlexTest SE, and FlexTest IIm Controllers.
Model 493.10 Chassis 20
Hydraulic Control 22
Interlocks 22
Specifications 23
FlexTest SE Controllers 24
Model 493.02 Chassis 26
Hydraulic Control 26
Interlocks 26
Specifications 27
FlexTest IIm Controllers 28
Model 497.01 Analog Chassis 30
Model 497.05 Hydraulic Control Panel 31
Model 498.22 Chassis with Test Processor (FTIIm) 32
Specifications 33
Models FlexTest® IIm/GT/SE Controller Hardware Introduction
19
Model 493.10 Chassis
BFL
CPU
PMC
ABT
RST
m
498.98-2
Power PC
J6 I/O
J7 I/O
493.40
I/O Carrier
J3 Service
Shunt Cal
J4 I/O
J5 I/O
m
CLOCK OUT
EVENT OUT
J3 IN
J6 STATION
J7 SERIAL
EVENT IN
J4 OUT
J5 DEBUG
+12V
m
498.71B
GRES III
J6 I/O
J7 I/O
493.40
I/O Carrier
J3 Service
Shunt Cal
J4 I/O
J5 I/O
m
J6 I/O
J7 I/O
493.40
I/O Carrier
J3 Service
Shunt Cal
J4 I/O
J5 I/O
m
J6 I/O
J7 I/O
493.40
I/O Carrier
J3 Service
Shunt Cal
J4 I/O
J5 I/O
m
12345678910
MTS Sysrtems Corp
14000 Technologyu Dr.
Eden Prairie, MN 555344-2290 USA
Assy No:
Model: S/N
l
J50D
J7 SERIAL
J50C
J50B
J50A
m
493.71
Serial
Interface
J3 IN
J4 OUT
+12V
m
493.72
Digital I/O
J44BJ44A Run/Stop
J49BJ49A Aux Pwr
J29BJ29A Load Unit
m
J43BJ43A Intlk
J28A HSM
J28B HSM
493.74
HSM
SERVICE
J23
E-STOP OUT
J24
E-STOP IN
J25 HPS
J54
SYS I/O
m
493.73
HPU
Ch 1
Ch 2
Ch 3
Ch 4
Ch 5
Ch 6
m
J11
(Ch 1-4)
J12
(Ch 5-6)
493.75
Analog In
Ch 1
Ch 2
Ch 3
Ch 4
Ch 5
Ch 6
m
J11
(Ch 1-4)
J12
(Ch 5-6)
493.76
Analog Out
J44BJ44A Run/Stop
J49BJ49A Aux Pwr
J29BJ29A Load Unit
m
J43BJ43A Intlk
J28A HSM
J28B HSM
493.74
HSM
PowerOKOver
Temp
J39 Power Monitor
Power
l
12345678910 BA
Front Panel
(with VMEbus Modules)
Rear Panel
(with Transition Modules)
FlexTest GT Controllers
MTS FlexTest GT Controllers are fully digital Proportional, Integral, Derivative,
Feedforward (PIDF) servocontrollers which use an identical chassis
configuration. They provide complete control of up to eight channels distributed
among up to eight stations. Optional station configurations are available (see
“Hydraulic Configurations” on page 243).
Model 493.10 Chassis
FlexTest GT Controllers use the Model 493.10 Chassis. The Model 493.10
Chassis is a multi-station, multi-channel VMEbus chassis which houses up to ten
MTS VMEbus modules in its front panel and up to ten transition modules in its
rear panel.
20
Introduction
Models FlexTest® IIm/GT/SE Controller Hardware
Model 493.10 Chassis
Front panel The Model 493.10 Chassis front panel has twelve slots; ten VMEbus slots and
two slots (A and B) which are reserved.
Rear panel The rear panel of the chassis has twelve transition bus slots. Two of these rear
panel slots (slots A and B) can not be used with powered MTS transition
modules. The chassis can be rack mounted or used in a floor standing
configuration.
VMEbus modules The chassis has ten VMEbus slots that support a variety of MTS VMEbus plug-
in modules.
• The chassis requires at least one processor module. The processor module
provides the processing power to manage the other plug-in modules that
make up the controller.
• The chassis can have up to eight I/O Carrier modules. Each I/O Carrier
module supports up to four mezzanine cards.
• An optional Global Resource (GRES) module provides several connections
to communicate with external devices such as a remote station control
module, temperature controller, and other devices.
Transition bus Transition modules are panels plugged into the transition bus located in the rear
of the chassis. Each transition module allows external devices to interface with
the chassis. Transition modules provide the following:
• Hydraulic control connections
• Station control connections
• Analog input and output connections
• Digital input and output connections
• Serial connections
Cable conduit The chassis has a conduit that allows cables to be routed from the front VMEbus
modules to the rear transition modules and out of the chassis.
Power supply Two power supplies are used. One provides +5 V DC and ±15 V DC for the plug-
in modules; the other provides ±12 V DC for plug-in modules and +24 V DC for
hydraulic power and the chassis fan. The power supplies have universal inputs
and will adapt to any line voltage between 90 and 264 V AC.
The power supply is protected with an external circuit breaker in the On/Off
switch that trips at a 10 amp overload. An internal fuse in the power supply is not
user accessible or repairable.
Models FlexTest® IIm/GT/SE Controller Hardware Introduction
21
Hydraulic Control
Cooling The chassis is cooled with a fan. An overtemperature sensor is part of the
Hydraulic Control
Interlocks
standard power supply assembly. If the internal chassis temperature exceeds
50ºC, this sensor will light an amber indicator located on the rear of the power
supply module.
Hydraulic control is handled with two transition modules:
• The Model 493.73 HPU Transition module has a connection to control a
hydraulic power unit. It includes connections for an emergency stop button
and digital I/O for system communications.
• Typically, up to four Model 493.74 HSM Transition Modules can be used to
support up to eight HSM stations. Each HSM module includes connections
to support two stations. Each station supports an HSM, a load unit, run/stop
outputs, auxiliary outputs, and interlock controlled outputs.
Two types of interlocks are supported, the system wide interlock and station
interlocks. The system wide interlock shuts down the hydraulic power unit and
all stations, and the station interlock shuts down a single station leaving other
stations running. The emergency stop function on the Model 493.74 HSM
transition board contains two separate circuits, the system wide interlock (HPU)
and the station interlock (HSM).
System wide interlock The emergency stop circuit consists of a loop that only runs through the rear
panel transition boards of the chassis. Any board that generates an interlock by
breaking this system wide loop causes the hydraulic power unit to be shut down.
This will also cause all of the stations to shut down.
Note The emergency stop circuit meets the requirements of the Machinery
Safety Directive (EN 60204-1, 1992, section 9.2.5.4). This means the
emergency stop circuit is hard-wired with electromechanical
components.
Station interlocks Each station represents all of the components associated with an interlock chain.
All of the modules plugged into the chassis can be assigned to stations. If one of
the stations generates an interlock, all of the components assigned to the station
are shut down.
Standard configurations support up to four independent stations.
22
Introduction
Models FlexTest® IIm/GT/SE Controller Hardware
Specifications
FlexTest GT Specifications
P
ARAMETER SPECIFICATION
Specifications
Environmental
Tem per atu re
Relative humidity
Altitude
Power input
Input voltage
Input frequency
Input surge
Power
Insulation over
voltage
Pollution degree
Power supply #1
+5 V DC
±15 V DC
For indoor use only
5ºC–40ºC (41ºF–104ºF)
10%–85%, noncondensing
For use at altitudes up to 2000 m
(6500 ft)
power factor corrected universal input
*
100–240 V AC
47–63 Hz
<100 A
<1000 W
Category II
2
maximum draw is 400 W total
40 A
7.5 A
Power supply #2
±12 V DC
+24 V DC
Weight approximately 45 kg (100 lb) in stand
* The specification shown conforms to CE Low Voltage Directive
requirements. The specification allows for 10% of the values stated.
The actual voltage the 493.10 chassis can operate is
90–264 V AC.
Models FlexTest® IIm/GT/SE Controller Hardware Introduction
maximum draw is 400 W total
4 A
10 A
alone configuration
23
Specifications
FlexTest SE
Emergency Stop
7
8 9
65
4
3
2
1
.
0
+/-
enter
cancel
FG
Setup
Status
Scope
Meters
Tuning
Config
Limits
Log
Menu
?
A
B
Recall
Enabled
reset
Rewind Run
Hold Stop
Power
Program
Hydraulic
Interlock
Program
Interlock
HPU
HSM
Off Low High
Off
Low
High
Navigate
Monitor 1
Monitor 2
TS-G436
FlexTest SE Controllers
The MTS Model 493.02 FlexTest SE Controller is a fully digital Proportional,
Integral, Derivative, Feedforward (PIDF) servocontroller. It provides complete
control of one servohydraulic channel or station in an MTS test system.
FlexTest SE Controller The FlexTest SE may be operated in the standalone mode from its front panel
controls, or in the automated mode with MTS Model 793.00 System Software
running on a connected PC.
FlexTest SE front panel
controls
Operations are controlled through the controller’s front panel. An easy-to-read
color display shows the status of the parameter currently being adjusted or
monitored. A simple scroll-through menu provides quick access to any parameter
or function. All parameters are entered through a keypad or adjusted by a single
multi-turn dial. The current settings are saved in a flash disk and are recalled at
start up.
In addition to providing the means to adjust and monitor the test parameters, the
front panel also provides program control, system hydraulic pressure control, and
an Emergency Stop button that shuts down the system hydraulics in an
emergency situation. BNC monitor connectors are also provided to allow you to
connect easily to external readout devices.
24
Introduction
FlexTest SE Front Panel
Models FlexTest® IIm/GT/SE Controller Hardware
Specifications
FlexTest SE stand-alone
function generation
FlexTest SE automated
configuration
A function generator (with a built-in cycle counter) in the controller provides
basic sine, square, triangle, and ramp command waveforms.
For tests requiring complex waveforms, the controller provides an external
command input to receive externally generated commands.
The function generator waveform can be output to another MTS FlexTest SE
Controller (or any external device) for synchronization.
In the automated configuration, the FlexTest SE Controller has added
capabilities—it can acquire data, perform automated testing, apply complex
control compensation techniques to the servoloop, and execute sophisticated test
procedures that include complex triggering mechanisms.
The automated configuration includes the controller, a personal computer, and
the Model 793.00 System Software bundle. It may also include optional MTS
software for additional capability.
Models FlexTest® IIm/GT/SE Controller Hardware Introduction
25
Model 493.02 Chassis
TYPE E PC-MIP
TYPE E PC-MIP
RUN 6TS BFL
ABT RST
DEBUG
PCI MEZZANNE CARD
Power
100–240 VAC
50–60 Hz, 12–6A
TS-G435
Model 493.02 Chassis
FlexTest SE Controllers use the Model 493.02 Chassis. The Model 493.02
Chassis is a single-station, single-channel VMEbus chassis which, in a typical
configuration, houses three plug-in modules:
• A Series 498 Processor
• A Model 493.40 I/O Carrier module
• A Model 493.42 System I/O module
Model 493.02 Chassis
rear panel
Hydraulic Control
Except for two front panel BNC connectors, all cabling is accessed through the
controller’s rear panel. It is not necessary to remove the chassis cover to access
jumpers or switches. The chassis can be rack mounted or used in a table-top
configuration.
FlexTest SE Rear Panel
The controller provides complete control of the test system hydraulics. It can be
used to control a hydraulic power unit and a hydraulic service manifold to apply
low and high hydraulic pressure to the test system. In multiple controller
configurations, the controller provides first-on/last-off control of the hydraulic
power unit in addition to control of a local hydraulic service manifold.
Interlocks
Introduction
26
The controller provides interlocks for adjustable upper/lower limit, underpeak,
error detection for each sensor conditioner installed, and others. These interlocks
can be daisy-chained for multiple controller configurations.
Models FlexTest® IIm/GT/SE Controller Hardware
Specifications
FlexTest SE Specifications
P
ARAMETER SPECIFICATION
Specifications
Environmental
Tem per atu re
Relative humidity
Altitude
Power input
Input voltage
Input frequency
Input surge
Insulation over
voltage
Pollution degree
Weight approximately 8.6 kg (19 lb)
* The specification shown conforms to CE Low Voltage Directive
requirements. The specification allows for 10% of the values stated.
The actual voltage the 493.02 chassis can operate is
90–264 V AC.
*
For indoor use only
5ºC–40ºC (41ºF–104ºF)
10%–85%, noncondensing
For use at altitudes up to 2000 m
(6500 ft)
power factor corrected universal input
100–240 V AC
47–63 Hz
<50 A
Category I
2
Models FlexTest® IIm/GT/SE Controller Hardware Introduction
27
Specifications
FlexTest IIm Controllers
The MTS FlexTest IIm Controller is a fully digital Proportional, Integral,
Derivative, Feedforward (PIDF) servocontroller.
FlexTest IIm
Controllers
The FlexTest IIm configuration provides complete control of up to sixteen
channels distributed among up to four stations in an MTS test system.
The FlexTest IIm Controller is available in five standard configurations. The
FlexTest IIm Controller also supports optional components and custom
configurations that can add features and capability to any standard configuration.
All configurations include the following components:
• Model 497.01 Analog Chassis
The analog chassis includes a complement of valve drivers and
conditioners:
– Model 497.14 AC Conditioner module
– Model 497.22 Dual DC Conditioner module
– Model 497.26 Dual Valve Driver module
– Model 497.34 Multi-Station Interlock module
– Model 497.36 Communications module
• Model 497.05 Hydraulic Control Panel
The hydraulic control panel controls at least one Hydraulic Power Unit
(HPU) or actuator manifold.
28
Introduction
• Model 498.22 Test Processor Chassis
–Model 498.65 ADDA module
– Model 498.71B GRES III module
– Model 498.96-X Processor module
Models FlexTest® IIm/GT/SE Controller Hardware
Specifications
FT IIm standard
configurations
• 4, 6, 8, 12, or 16 channels of control
• 16 inputs and 16 outputs of user DIO
• Per channel resources:
– One valve driver output
– One D/A output
– One A/D input
– One AC Conditioned input
– Two DC conditioned inputs
Console The FlexTest IIm Controller is available in a full-bay (vertical) console, a table-
top console, or a roll-around console.
Note The larger (full-bay) consoles can also accommodate rack-mount
scopes, x-y recorders, and so forth.
Customization A standard FlexTest IIm system can be customized for specific test requirements.
In these cases, the standard hardware and software can be changed to
accommodate a specific customer requirement.
Models FlexTest® IIm/GT/SE Controller Hardware Introduction
29
Model 497.01 Analog Chassis
This chassis shows the maximum complement of modules for a standard
FTIIm system. Customized systems can use all the module locations.
Note This chassis has rear panel transition modules and I/O connectors
to support up to four independent test stations.
Out 1
Gnd
Out 2
Gnd
Ch1Ch
2
497.26
Dual Valve
Out 1
Gnd
Out 2
Gnd
Ch1Ch
2
497.26
Dual Valve
Out 1
Gnd
Out 2
Gnd
Ch1Ch
2
497.26
Dual Valve
Out 1
Gnd
Out 2
Gnd
Ch1Ch
2
497.26
Dual Valve
+15V
-15V
-5V
Station
Interlocks
Power OK
497.34
Station Cntrl
1
2
3
4
Reset
497.35
RS422 Com
Fault
Xmit
Ready
x10
x1
497.22
DC Cond
U Lim
L Lim
Excit
Fail
R-Cal
2
Out1
Out2
Gnd
Ch1Ch
2
R-Cal
1
497.22
DC Cond
U Lim
L Lim
Excit
Fail
R-Cal
2
Out1
Out2
Gnd
Ch1Ch
2
R-Cal
1
497.22
DC Cond
U Lim
L Lim
Excit
Fail
R-Cal
2
Out1
Out2
Gnd
Ch1Ch
2
R-Cal
1
497.22
DC Cond
U Lim
L Lim
Excit
Fail
R-Cal
2
Out1
Out2
Gnd
Ch1Ch
2
R-Cal
1
U Lim
L Lim
Excit
Fail
Out
Gnd
497.14
AC Cond
U Lim
LLim
Excit
Fail
Out
Gnd
497.14
AC Cond
U Lim
L Lim
Excit
Fail
Out
Gnd
497.14
AC Cond
U Lim
L Lim
Excit
Fail
Out
Gnd
497.14
AC Cond
Model 497.01 Analog Chassis
The plug-in modules installed in the 497.01 Analog Chassis provide four main
functions:
• Interlock control—An interlock control plug-in module provides
programmable interlock signal mapping between the test processor and the
modules installed in this analog chassis.
• Processor/Analog Chassis communications—A communications module
provides data conversion between the test processor and the 497 analog
plug-in modules.
• Transducer conditioning—AC and DC conditioners provide transducer
excitation and output signal amplification for both low-level and high-level
transducers.
• Valve drive signals—Valve drivers provide drive current for two- and three-
stage servovalves according to command inputs received for each channel.
Analog Chassis (Front Panel)
30
Introduction
Models FlexTest® IIm/GT/SE Controller Hardware
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