MTS Systems FlexTest IIm User manual

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Models FlexTest IIm, FlexTest GT, and
FlexTest SE Controller Hardware l
100-147-133 E
Service Information:
- Hardware Descriptions
- Specifications
- Installation
- Cabling
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Copyright information © 2008 MTS Systems Corporation. All rights reserved.
Trademark information MTS, Temposonics, and TestWare are registered trademarks of MTS
Systems Corporation.
FlexTest, MPT, Station Builder, and Station Manager are trademarks
of MTS Systems Corporation.
Adobe is a registered trademark of Adobe Systems Inc.
Acrobat is a trademark of Adobe Systems Inc.
PowerPC is a registered trademark of International Business
Machines Corporation
Microsoft and Windows are registered trademarks of Microsoft
Corporation.
Software verification
and validation MTS software is developed using established quality practices in
accordance with the requirements detailed in the ISO 9001
standards. Because MTS authored software is delivered in binary
format, it is not user accessible. This software will not change over
time. Many releases are written to be backwards compatible,
creating another form of verification.
The status and validity of MTS' operating software is also checked
during system verification and routine calibration of MTS hardware.
These controlled calibration processes compare the final test results
after statistical analysis against the predicted response of the
calibration standards. With these established methods, MTS assures
its customers that MTS products meet MTS' exacting quality
standards when initially installed and will continue to perform as
intended over time.
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
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MTS 793 Controller Hardware Contents 3
Contents
Technical Support 11
How to Get Technical Support 11
Before You Contact MTS 12
If You Contact MTS by Phone 13
Problem Submittal Form in MTS Manuals 14
Preface 15
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 25
Model 493.02 Chassis 26
Hydraulic control 27
Interlocks 27
Specifications 28
FlexTest IIm Controllers 29
Model 497.01 Analog Chassis 31
Model 497.05 Hydraulic Control Panel 32
Model 498.22 Chassis with Test Processor (FTIIm) 33
Specifications 34
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MTS 793 Controller Hardware
Contents
4
Chapter 2 Installation 37
Installing the 493.10 Chassis (FTGT) 37
Connecting Electrical Power 38
Installing the Plug-in Modules 41
VMEbus Modules 41
Installing the Transition Panels 46
Installing the 493.02 Chassis (FlexTest SE) 48
Installing the Plug-in Modules 48
VMEbus Modules 49
Chassis Installation Options 50
Connecting Electrical Power 52
Installing the Handle Kit 56
Installing 497/498 Electronics (FTIIm) 59
Connecting the Console and Chassis Power 59
How To Connect the Chassis Power Cables 59
How To Cable the Analog Chassis to the Hydraulic Control Panel 60
Grounding the Console and Chassis 60
Model 497.01 Analog Chassis 61
About Analog Chassis Slots 61
Analog Chassis Plug-in Modules 62
How To Install or Remove a Plug-in Module 63
Analog Chassis Transition Modules 64
How To Install a Transition Module 64
Transition Module Connectors 65
Adding an Analog Chassis to Your Console 66
Model 497.05 Hydraulic Control Panel 68
Test Processor Plug-in Modules 69
Test Processor Transition Modules 71
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MTS 793 Controller Hardware Contents 5
Chapter 3 FlexTest GT Controller Connections 73
CE EMC Compliant Cabling 74
Typical Cabling 75
Cable Part Numbers 76
Model 493.40 I/O Carrier Connections 77
Sensor Connections 78
Model 493.21B (DUC B) Jumpers 82
Digital Universal Conditioner (DUC BC) Switches 84
Full-Range Digital Universal Conditioner (FRDUC) Jumpers 88
Sensor Cables 90
Sensor cable specifications 90
Sensor cable part numbers 91
Shunt Calibration/Bridge Completion Resistor Installation 92
I/O Carrier Module 93
Transducer Identification Modules 95
Valve Connections 97
Multiple Universal Driver Connections 101
Analog I/O Connections 103
Accelerometer Connections 107
Encoder Connections 109
Remote Setpoint Adjust Connections 111
ADDA II Connections 112
Emergency Stop Connections 116
J25 Hydraulic Power Unit Connection 118
Station Connections 120
J28 Hydraulic Service Manifold Connector 120
J29 Load Unit 122
J43 Interlock 123
J44 Run/Stop 124
J49 Auxiliary Power 125
Digital I/O Connections 126
Workstation Connection 131
Remote Station Controller Connection 132
Service Connections 133
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MTS 793 Controller Hardware
Contents
6
Cabling and Programming Model 407 Controllers 135
How to Provide Program to a Model 407 Controller 135
Connecting Interlock Signals to 407 Controllers 140
Sending and Receiving Signals to a Model 407 Controller 145
Connecting Interlock Signals to 458 Controllers 148
Eurotherm Temperature Controller Connection 148
Miscellaneous Conditioner Output Connections 150
Cabling for External Command Inputs 151
How to Enable and Run External Command Inputs 151
Cabling and Using External Readout Devices 152
How to Send Signals to External Readout Devices 154
Multi-Box I/O Module 155
J8 Interlock IN 155
J9 Interlock OUT 157
J51 Box In 158
J52 Box Out 159
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MTS 793 Controller Hardware Contents 7
Chapter 4 FlexTest IIm Controller Connections 161
Workstation Connection 162
Sensor and Valve Connections 162
ADDA Module Connections 166
ADDA II Connections 167
Hydraulic Connections 172
HPU Connections 173
HSM Connections 174
Interlock Connections 175
Interlock Jumper Plugs 176
Serial Communications 178
Digital I/O Connections 179
Encoder/Temposonics Connections 183
Remote Station Controller (RSC) Connections 186
Cabling and Programming External Controllers 187
How to Program an External Controller 187
Programming Eurotherm Temperature Controllers 191
Cabling for External Command Inputs 193
How to Enable and Run External Command Inputs 193
Cabling and Using External Readout Devices 194
How to Send Signals to External Readout Devices 194
Cable Part Numbers 196
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MTS 793 Controller Hardware
Contents
8
Chapter 5 FlexTest SE Controller Connections 197
Standalone Cabling Overview 198
Automated Cabling Overview 199
Multiple Controller Connections 200
Cable Part Numbers 202
Model 493.40 I/O Carrier Connections 203
Sensor Connections 204
Valve Connections 205
Analog I/O Connections 205
Encoder Connections 206
Workstation Connection 207
Service Connection 207
Model 493.42 System I/O Connections 208
J25 Hydraulic Power Unit Connection 208
J28 Hydraulic Service Manifold Connector 209
J29 Emergency Stop Connections 209
J43 Interlock 210
J49 Auxiliary Power 211
CJ51 Box In 212
J52 Box Out 213
J54 Digital Inputs 214
J55 Digital Outputs 215
Eurotherm Temperature Controller Connection 216
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MTS 793 Controller Hardware Contents 9
Appendix A Hydraulic Configurations 221
Model 493.02 Chassis Multiple Controller Interconnections 223
Independent HSM (no HPU) 224
Independent HSM (shared HPU) 224
Shared HSM (with HPU) 225
Shared HSM (no HPU) 225
Independent HSM with HPU (FO-LO) 226
Appendix B Model 493.07 Converter Box 227
Appendix C Chassis Maintenance 229
Appendix D Optional Station Configurations 231
6-Station Configuration 231
8-Station Configuration 232
Index 233
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MTS 793 Controller Hardware
Contents
10
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Technical Support 11
Technical Support
How to Get Technical Support
Start with your
manuals The manuals supplied by MTS provide most of the information you
need to use and maintain your equipment. If your equipment includes
MTS 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.
Technical support
methods MTS provides a full range of support services after your system is
installed. If you have any questions about a system or product, contact
MTS in one of the following ways.
MTS web site
www.mts.com
The MTS web site gives you access to our technical support staff by
means of a Technical Support link:
www.mts.com > Contact Us > Service & Technical Support
E-mail [email protected]
Telephone MTS Call Center 800-328-2255
Weekdays 7:00 A.M. to 5:00 P.M., Central Time
Fax [phone]
Please include “Technical Support” in the subject line.
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Technical Support
12
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
The site number contains your company number and identifies your
equipment type (material testing, simulation, and so forth). The
number is usually written on a label on your MTS equipment before
the system leaves MTS. If you do not have or do not know your MTS
site number, contact your MTS sales engineer.
Example site number: 571167
When you have more than one MTS system, the system job number
identifies which system you are calling about. You can find your job
number in the papers sent to you when you ordered your system.
Example system number: US1.42460
Know information
from prior technical
assistance
If you have contacted MTS about this problem before, we can recall
your file. You will need to tell us the:
•MTS notification number
•Name of the person who helped you
Identify the problem Describe the problem you are experiencing and know the answers to
the following questions:
•How long and how often has the problem been occurring?
•Can you reproduce the problem?
•Were any hardware or software changes made to the system
before the problem started?
•What are the model numbers of the suspect equipment?
•What model controller are you using (if applicable)?
•What test configuration are you using?
Know relevant
computer information If you are experiencing a computer problem, have the following
information available:
•Manufacturer’s name and model number
•Operating software type and service patch information
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Technical Support 13
•Amount of system memory
•Amount of free space on the hard drive in which the application
resides
•Current status of hard-drive fragmentation
•Connection status to a corporate network
Know relevant
software information 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 is
displayed briefly when you launch the application, and can
typically be found in the “About” selection in the “Help” menu.
•It is also helpful if the names of other non-MTS applications that
are running on your computer, such as anti-virus software, screen
savers, keyboard enhancers, print spoolers, and so forth are
known and available.
If You Contact MTS by Phone
Your call will be registered by a Call Center agent if you are calling
within the United States or Canada. Before connecting you with a
technical support specialist, the agent will ask you for your site
number, name, company, company address, and the phone number
where you can normally be reached.
If you are calling about an issue that has already been assigned a
notification number, please provide that number. You will be assigned
a unique notification number about any new issue.
Identify system type To assist the Call Center agent with connecting you to the most
qualified technical support specialist available, identify your system as
one of the following types:
•Electromechanical materials test system
•Hydromechanical materials test system
•Vehicle test system
•Vehicle component test system
•Aero test system
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Technical Support
14
Be prepared to
troubleshoot Prepare yourself for troubleshooting while on the phone:
•Call from a telephone when you are close to the system so that
you can try implementing 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
information Prepare yourself in case we need to call you back:
•Remember to ask for the notification number.
•Record the name of the person who helped you.
•Write down any specific instructions to be followed, such as data
recording or performance monitoring.
After you call MTS logs and tracks all calls to ensure that you receive assistance and
that action is taken regarding your problem or request. If you have
questions about the status of your problem or have additional
information to report, please contact MTS again and provide your
original notification number.
Problem Submittal Form in MTS Manuals
Use the Problem Submittal Form to communicate problems you are
experiencing with your MTS software, hardware, manuals, or service
which have not been resolved to your satisfaction through the
technical support process. This 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.
The Problem Submittal Form can be accessed:
•In the back of many MTS manuals (postage paid form to be
mailed to MTS)
•www.mts.com > Contact Us > Problem Submittal Form (electronic
form to be e-mailed to MTS)
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Preface 15
Preface
Before You Begin
Safety first! Before you attempt to 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 of MTS equipment in your test facility can result in
hazardous conditions that can cause severe personal injury or death
and 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 MTS manuals in
paper or electronic form.
If you have purchased a test system, it may include an MTS System
Documentation CD. This CD contains an electronic copy of the MTS
manuals that pertain to your test system, including hydraulic and
mechanical component manuals, assembly drawings and parts lists,
and operation and preventive maintenance manuals. Controller and
application software manuals are typically included on the software
CD distribution disc(s).
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Conventions
Preface
16
Conventions
Documentation Conventions
The following paragraphs describe some of the conventions that are
used in your MTS manuals.
Hazard conventions As necessary, hazard notices may be embedded in this manual. These
notices contain safety information that is specific to the task 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 the directions that are given. 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,
equipment damage, or 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.
DANGER
WARNING
CAUTION
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Conventions
Preface 17
Special terms The first occurrence of special terms is shown in italics.
Illustrations Illustrations appear in this manual to clarify text. It is important for you
to be aware that these illustrations 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.
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Conventions
Preface
18
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MTS 793 Controller Hardware Introduction 19
Chapter 1
Introduction
This manual contains installation, cabling, jumpering, and hardware
interfacing information for MTS 793 Controllers. It includes setup
information for the Model 493.04 PC Per Station option.
This chapter describes the hardware components and specifications of
FlexTest GT, FlexTest SE, and FlexTest IIm Controllers.
Contents FlexTest GT Controllers 20
Model 493.10 Chassis 20
Hydraulic control 22
Interlocks 22
Specifications 23
FlexTest SE Controllers 25
Model 493.02 Chassis 26
Hydraulic control 27
Interlocks 27
Specifications 28
FlexTest IIm Controllers 29
Model 497.01 Analog Chassis 31
Model 497.05 Hydraulic Control Panel 32
Model 498.22 Chassis with Test Processor (FTIIm) 33
Model 498.12 Chassis with Test Processor (FT II CTC) 26
Specifications 34
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