MTS Systems FlexTest SE Operating and installation instructions

FlexTest™SE 
100-077-222 C
Service Information

Copyright information © 2002 MTS Systems Corporation. All rights reserved.
Trademark information MTS, Temposonics, and TestWare are registered trademarks of MTS
Systems Corporation.
FlexTest, MPT, MultiPurpose TestWare, Station Builder, Station
Manager, and TestStar 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
100-077-222 C October 2002

Model 493.02 Controller Service
Contents
3
Contents
Preface 9
About Your Manuals 10
Conventions 12
Technical Support 14
Chapter 1 Introduction 19
Stand-Alone Configuration 20
Basic Functions 22
Automated Configuration 23
Chapter 2 Installation 25
Installing the Plug-in Modules 26
VMEbus Modules 27
Chassis Installation Options 30
Connecting Electrical Power 32
Handle Kit Installation 36

Model 493.02 Controller Service
Contents
4
Chapter 3 Cabling 39
CE EMC Compliant Cabling 40
Stand-Alone Cabling Overview 41
Automated Cabling Overview 42
Multiple Controller Connections 43
Cable Part Numbers 45
Model 493.40 I/O Carrier Connections 47
Valve Connections 48
Analog I/O Connections 52
Encoder Connections 54
Accelerometer Connections 55
Workstation Connection 56
Service Connection 57
Model 493.42 System I/O Connections 58
J25 Hydraulic Power Unit Connection 59
J28 Hydraulic Service Manifold Connector 61
J29 Emergency Stop Connections 62
J43 Interlock 64
J49 Auxiliary Power 65
J51 Box In 66
J52 Box Out 67
J54 Digital Inputs 68
J55 Digital Outputs 69
Chapter 4 Servovalve Controls 71
Setting the Servovalve Polarity 73
Getting Things Ready 74
Adjusting Valve Balance 75
Dither 76
Tuning the Inner loop 77
Zero the Spool Position Signal 78
Inner Loop Signals 79

Model 493.02 Controller Service
Contents
5
Chapter 5 Sensors 81
Sensor Signals 82
Transducer Connections 83
Sensor Cables 86
Specifications 86
Sensor Cable Part Numbers 87
Shunt Calibration 89
Shunt Calibration/Bridge Completion 92
I/O Carrier Module 92
Chapter 6 Calibration 95
Before You Begin 97
Calibrating an LVDT 99
Abbreviated Procedure 105
Calibrating a Force Sensor 128
Abbreviated Procedure 129
Calibrating Encoders 161
Abbreviated Procedure 162
Calibrating Temposonics Sensors 167
Abbreviated Procedure 168
Calibrating an Extensometer 174
How To Calibrate an Extensometer 174

Model 493.02 Controller Service
Contents
6
Chapter 7 Tuning 191
About Tuning 192
If You’ve Never Tuned Before 193
When to Tune 194
Control Mode Characteristics 196
How the Tuning Controls Work 199
Creating a Tuning Program 207
Other Considerations 210
Monitoring Waveforms 211
Tuning Displacement 215
Tuning Force 216
Auto tuning 217
How to Auto-Tune Control Modes 218
Tuning a CLC Control Mode 219
Appendix A Hydraulic Configurations 221
Multiple Controller Interconnections 224
Independent HSM (no HPU) 224
Independent HSM (shared HPU) 225
Shared HSM (with HPU) 226
Shared HSM (no HPU) 227
Independent HSM with HPU (FO-LO) 228

Model 493.02 Controller Service
Contents
7
Appendix B Model 493.07 HPU Converter 229
Appendix C Service Tools 231
FlexTest SE Service Tool Application 232
Initializing a FlexTest SE Controller 235
Updating System Options 237
System Options Tab 237
Unit Assignment Set Tab 238
Chassis Attributes Tab 239
Passwords Tab 240
User Files Tab 241
Index 243

Model 493.02 Controller Service
Contents
8

Model 493.02 Controller Service
Preface
Preface 9
Preface
Safety first! Before you attempt to use your MTS equipment in your test system,
read and understand the Safety manual. Like an automobile, your test
system is very useful—but if misused, it is capable of deadly force. You
should not be afraid of your test system, but you should always
maintain a healthy respect for it.
Improper installation, operation, or maintenance of MTS equipment in
your test system 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 manual before you
continue. It is very important that you remain aware of hazards that
apply to your test system.
Contents About Your Manuals 10
Conventions 12
Technical Support 14

Model 493.02 Controller Service
About Your Manuals
Preface
Preface
10
About Your Manuals
This manual provides detailed information about the installation,
cabling, and set-up of the MTS FlexTest SE Controller, including all
controller, computer (optional), sensor, I/O, and hydraulic
connections. This manual also provides basic information about
calibrating sensor/conditioner pairs, initial system tuning, and adjusting
servovalves.
Summary This manual includes the following chapters.
Chapter 1, “Introduction”—This chapter introduces a MTS FlexTest SE
Controller, and includes a table of the basic specifications of the
controller and the associated electronic components.
Chapter 2, “Installation”—This chapter covers the installation of the
MTS FlexTest SE Controller, including connections and mounting.
Chapter 3, “Cabling”—This chapter contains detailed cabling
information, including pin-out assignments of all the connectors.
Chapter 4, “Servovalve Controls”—This chapter describes servovalve
adjustments to optimize the interface between the controller and the
servovalve.
Chapter 5, “Sensors”—This chapter describes sensor signals,
connections, and cabling. Shunt calibration for DC sensors is also
described.
Chapter 6, “Calibration”—This chapter describes how to calibrate the
sensors connected to your system.
Chapter 7, “Tuning”—This chapter describes system tuning basics.
Appendix A, “Hydraulic Configurations”—This appendix describes
how to connect the Model 493.02 Chassis to a variety of MTS hydraulic
configurations.
Appendix B, “Model 493.07 HPU Converter”—This appendix describes
the Model 493.07 HPU Converter including connectors and jumper
configurations.
Appendix C, “Service Tools”—This appendix describes the FlexTest SE
Service Tools application.

About Your Manuals
Model 493.02 Controller Service
Preface
Preface 11
Access the
electronic manual
If you have a PC-supervised Controller, you can access an electronic
version of this manual (after you install your MTS software) from the
PC desktop, as follows:
Programs > FlexTest SE > Online Documentation
If you have a stand-alone Controller, an electronic version of this
manual is available on the 793 System Software CD that accompanies
your Controller.
Other MTS manuals If your purchase includes other MTS equipment, you will 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 all of the
MTS manuals that pertain to your test system, including controller
manuals, hydraulic and mechanical component manuals, assembly
drawings and parts lists, and operation and preventive maintenance
manuals.

Model 493.02 Controller Service
Conventions
Preface
Preface
12
Conventions
The following paragraphs describe some of the conventions that are
used in your MTS manuals.
Hazard conventions Hazard notices are embedded in this manual and 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 manual included with
your system.
Danger notices Danger notices indicate the presence of a hazard which will cause
severe personal injury, death, or substantial property damage if the
danger is ignored. For example:
High intensity light and dangerous radiation are emitted by class 3B
lasers.
Viewing a class 3b laser directly or viewing it using optical instruments
will cause immediate and severe injury.
Avoid eye or skin exposure to the laser beam. Ensure that all power to the
laser is off before attempting any maintenance, service, or adjustment
procedure.
Warning notices Warning notices indicate the presence of a hazard which can cause
severe personal injury, death, or substantial property damage if the
warning is ignored. For example:
Hazardous fumes can accumulate in the test chamber as a result of
testing.
Breathing hazardous fumes can cause nausea, fainting, or death.
Ensure the chamber is properly ventilated before you open the chamber door
or put your head or hands into the chamber. To do this, ensure the
temperature controller is off and allow sufficient time for the ventilation
system to completely exchange the atmosphere within the chamber.
DANGER
WARNING

Conventions
Model 493.02 Controller Service
Preface
Preface 13
Caution notices Caution notices indicate the presence of a hazard which will or can
cause minor personal injury, cause minor equipment damage, or
endanger test integrity if the caution is ignored. For example:
This specimen can develop sharp edges as a result of testing.
Handling the specimen with unprotected hands can result in cuts and
slivers.
Always wear protective gloves when you handle the specimen.
Other conventions Other conventions used in your manuals are described below:
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.
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.
CAUTION

Model 493.02 Controller Service
Technical Support
Preface
Preface
14
Technical Support
Start with your
manuals
The manuals supplied by MTS provide most of the information you
will need to use and maintain your equipment. If your equipment
includes MTS software, you should look for README files for
additional product information.
If you cannot find answers to your technical questions from these
sources, you can use the internet, telephone, or fax to contact MTS for
assistance. You can also fill out the Problem Submittal Form that is
available on the MTS web site and in the back of many MTS manuals
that are distributed in paper form.
Technical support
numbers
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 Problem Submittal Form and a Technical Support link.
•Problem Submittal Form:
www.mts.com > Contact MTS > Problem Submittal Form
•Technical Support:
www.mts.com > Contact MTS > Technical Support
E-mail: [e-mail]
Telephone HELPLine 800-328-2255
Weekdays 7:00 A.M. to 6:00 P.M.,
Central Time
Fax [phone]
Please include an MTS contact name if possible.
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.

Technical Support
Model 493.02 Controller Service
Preface
Preface 15
Example site number: 571167
When you have more than one MTS system, the system 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 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 and serial numbers of the suspect equipment?
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. Examples:
– Windows XP Service Pack 1 (SP1)
– Windows 2000 Service Pack 3 (SP3)
– Windows NT 4.0 Service Pack 7 (SP7)
•Amount of system memory. Example: 640 MB of RAM.
•Amount of free space on the hard drive in which the application
resides. Example: 11.2 GB free space, or 72% free space.
•Current status of hard-drive fragmentation. Example: 3% total
fragmentation.

Model 493.02 Controller Service
Technical Support
Preface
Preface
16
Know relevant software
information
For MTS 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.
Example: Station Manager, Version 3.3A, Build 1190, Patch 4
•The same information for other MTS software included with your
system
•Names of other non-MTS applications that are running on your
computer, such as screen savers, keyboard enhancers, print
spoolers, and so forth
If you contact MTS
by phone
Your call will be registered by a HELPLine agent if you are calling
within the United States or Canada. Before connecting you with a
technical support specialist, your agent will ask you for your site
number, name, company, company address, and the phone number
where you can normally be reached.
Identify system type To assist your HELPLine 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
•Vehicles test system
•Vehicles component test system
•Aero test system
Be prepared to
troubleshoot
Prepare yourself for troubleshooting while on the phone.
•Call from a telephone 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.

Technical Support
Model 493.02 Controller Service
Preface
Preface 17
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.
Problem Submittal
Form in MTS manuals
In addition to the Problem Submittal Form on the MTS web site, there
is also a paper version of this form (postage paid) in the back of many
MTS manuals. Use this form to forward problems you are experiencing
with your MTS equipment, whether it be software, hardware, manuals,
or service. This form includes check boxes that allow you to select
when you expect us to respond to your input. We guarantee a timely
response—your feedback is important to us.

Model 493.02 Controller Service
Technical Support
Preface
Preface
18

Model 493.02 Controller Service
Introduction
Introduction 19
Chapter 1
Introduction
Overview This chapter provides an overview of the MTS Model 493.02 FlexTest
SE Controller. It describes the basic functions and components
included in the Controller’s standard and automated configurations,
and includes a table of specifications.
Contents Stand-Alone Configuration 20
Basic Functions 22
Automated Configuration 23

Model 493.02 Controller Service
Stand-Alone Configuration
Introduction
Introduction
20
Stand-Alone Configuration
The Controller is a fully digital, single-channel, Proportional, Integral,
Derivative, Feedforward (PIDF) servocontroller. It provides complete
control of one servohydraulic channel or station in an MTS test system.
Front Panel 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 knob. The current
settings are saved in a flash disk and are automatically 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.
FlexTest SE Front Panel
FlexTest SE
Emergency Stop
78 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